Nematron OptiLogic User Manual

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Page 1

OptiLogic Series

Opti

Logic

Optimal Automation for Industry

Input/Output Modules

Optimation, Inc.

(256)883-3050 1

www.optimate.com

Page 2

OptiLogic Series

WARNING

Thank you for purchasing industrial control products from Optimation, Inc. We want your new system to operate safely. Anyone who installs or uses this equipment should read this manual (and any other relevant publication) before installing or operating the system.

To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regulate the installation and operation of your system. These include the National Fire Code, National Electric Code, and other codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or governmental offices that can help determine which codes and standards apply to your situation. It is your responsibility to determine which codes and should be followed, and to verify that the equipment, installation, and operation is in compliance with the latest revision of these codes. If you have any questions concerning the installation and operation of Optimation products, please call us at (256)883-3050.

All Optimation products are warranted against defects in materials and workmanship for a period of one year from the date of shipment. Warranty applies to unmodified product under normal and proper use and service. Optimation’s sole obligation under this warranty shall be limited to either, at Optimation’s option, repairing or replacing defective product. The cost of freight to and from Optimation will be borne by the customer. No other warranty is given or implied.

This publication is based on information that was available at the time it was printed. We constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or publications at any time without notice and without any obligation. This publication may also discuss features that may not be available in certain revisions of the product.

Trademarks

This publication may contain references to products produced and/or offered by other companies. These products and company names may be trademarked and are the sole property of the respective owners. Optimation disclaims any proprietary interest in the marks and names of others.

No part of this document shall be copied, reproduced or transmitted in any way without the prior, written consent of Optimation, Inc. Optimation retains the exclusive rights to all information included in this document.

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Page 3

OptiLogic Series

Table of Contents

Introduction . . . . . . . . 6

Digital Inputs . . . . . . . . 7

Input Isolation . . . . . . . 7

DC Inputs . . . . . . . . 7

AC Inputs . . . . . . . . 8

Digital Input Voltage . . . . . . 8

I/O “Common” Terminals . . . . . 8

Digital Outputs . . . . . . . 9

Relay Outputs . . . . . . . 9

Transistor Outputs . . . . . . . 10

NPN Transistor Sinking Outputs . . . . 10

Solid State Relay Outputs . . . . . . 10

Analog Inputs . . . . . . . . 11

Isolation . . . . . . . . 11

Resolution . . . . . . . . 12

Accuracy . . . . . . . . 12

Range . . . . . . . . . 12

Multiplexing . . . . . . . . 12

Single Ended Inputs . . . . . . 13

Differential Inputs . . . . . . . 13

OL2104 Isolated Relay Output Module . . . 14

OL2108 Relay Output Module . . . . . 15

OL2109 DC Sinking Output Module . . . 16 OL2111 AC Solid State Relay Module . . . 17 OL2201 Digital Input Simulator Module . . . 18 OL2205 Isolated AC/DC Input Module . . . 19

OL2208 DC Digital Input Module . . . . 20

OL2211 AC Digital Input Module . . . . 21

OL2252 Dual High Speed Pulse Counter . . . 22

OL2258 High Speed Pulse Counter . . . . 25

OL2304 4 Channel Analog Voltage Output . . 28 OL2408 Analog Voltage Input Module . . . 29 OL2418 Analog Current Input Module . . . 30

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OptiLogic Series

OL2602 Dual RS232 Module . . . . . 31

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evision History

Issue

Date

Pages

Description

Original 8/99

1.1

1.2

1.3

1.4

1.5

Optimation, Inc. (256)883-3050 5

1-24 1/00 9/00 04/01 09/02

13, 18, 25

25-28

various

15 10/2012 14, 15

Original release Added OL2104, OL2205, OL2418 Added OL2258, OL2304 Added specs requested by UL Changed wording of OL2108 voltage rating spec Changed voltage ratings of OL2104 and OL2108

to match UL ratings

Page 6

OptiLogic Series

OptiLogic Input/Output Modules

Introduction

Optimation’s OptiLogic series is a flexible, modular system, designed to allow you the ability to configure an optimal solution for your exact needs. To accomplish this goal, Optimation has developed a series of I/O modules, communications modules, specialty modules and operator panels that can be plugged together in nearly any combination. This manual covers the currently available modules that plug into the card cage.

Additional I/O modules are under development. Please check our web site at optimate.com for a complete list of available modules.

Most OptiLogic modules can be installed in any card cage slot and used in any combination and quantity that will fit in the card cage. This applies to all general purpose digital and analog I/O. If you need all digital inputs plug in digital input modules only. If you need a mixture of analog and digital inputs and output select the mixture that fits your needs. Snap together modularity gives you the ability to optimize your system for your needs.

OptiLogic I/O modules are designed to meet your needs in real world application. They are all small circuit boards with a few available points to minimize your system cost. Most module connectors are pluggable terminal strips for easy connection, and easy maintainability. The snap-together design means low labor costs

- or costs on your time. Visual status indicators on digital I/O and communications modules provide a convenient means for monitoring operation. All together, the result is a cost effective, easy to use and maintain set of industrial control hardware.

This manual covers general I/O characteristics and applications first. Specific I/O boards are covered in the latter pages. The general pages should serve as a guide to selecting and installing I/O boards in your application.

Communications and specialty modules are covered in the latter pages of this manual.

It is Optimation’s desire for this manual to serve as a guide in your selection of the modules appropriate for your application, as well as to provide complete information for their use.

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OptiLogic Series

processor

Sourcing DC input

Digital Inputs

Digital I/O modules are used to either monitor (input) or control (output) the “state” of something. “State” being on or off, active or inactive, open or closed - etc. In the “real world” digital I/O requirements come in a variety of shapes and sizes. Therefore, there are a variety of available modules designed to meet the variety of needs.

Typical digital inputs are connected to switches, buttons, digital outputs from other equipment, discrete level sensors, thermostats and other on/off sensing devices.

Digital status is sensed by a controller, such as an OptiLogic system, by passing current through an input sensor. When the current is on, the input state is active. When it is not there, the input state is inactive.

Input Isolation

In most cases, it is important to “isolate” the real world inputs from the internal electronics of the controller. You want to prevent some external situation from “zapping” the controller’s electronics.

figure shown, when the digital input contact closes, the circuit path is complete and current will flow. On the input module this circuit path passes through a device which emits light when current flows through it. The light emitter is in very close physical proximity to (actually in the same chip) a photo sensor, which will turn on when it senses light. In this way, a digital input module can sense whether the input device is closed (current flow) or open (no current flow) without a direct electrical connection between the external sensor and the internal electronics.

DC Inputs

DC digital inputs are typically supplied by a DC power supply. The most common DC supplies used in industry are 12VDC and 24VDC.

Typical DC digital input circuits are shown below. As shown, the physical optical emitter on the input module is an LED (light emitting diode). OptiLogic DC inputs use bidirectional LEDs - i.e. Your inputs may either source or sink current. The top figure shows a sourcing input. The figure below it shows a sinking input. When inputs are connected to a

“common” (most instances), inputs must be

either all sourcing or all sinking.

electrical isolation is optical isolation. The figure below illustrates the basic concepts of optical isolation of a digital input circuit. In the

Power source

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An effective means of providing such

sensor

optical isolation

OptiLogic

Input module

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sensor

common

Sinking DC input

common

optical isolation

OptiLogic processor

Input module

optical isolation

OptiLogic processor

Input module

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OptiLogic Series

Sourcing

10-30VDC

processor

AC Inputs

AC digital inputs are typically supplied either directly from line voltage or transformed down from line voltage. The most common AC inputs are 120VAC and 24VAC, although any voltage range is possible.

A typical AC input circuit is shown below. As shown, the physical optical emitter on the input module consists of two LEDs of opposite polarity. An AC (alternating current) connection flows current one way, then the other. Light is emitted in both cases.

sensor

optical isolation

OptiLogic

maximum voltage corresponds to the maximum current the optocoupler can handle without being damaged.

I/O “Common” Terminals

For a digital input circuit, one input terminal and one output terminal is necessary for operation. For practical application, one of these two terminals may be “common” to several circuits.

In most systems, the power source for all digital inputs is from the same supply. In such cases, connecting all of the circuit return lines together results in reduced equipment costs as well as simpler system wiring.

The example below illustrates a digital input board that has eight inputs and two commons. This can be accomplished with a 10 terminal connector block.

Input module

There is a short period when voltage, and therefore current flow, switches from one direction to the other when no current flows. This is called zero crossover. During zero crossover, the digital input circuit must

“debounce” the signal to ensure that the system

does not provide a false indication that the input contact is not closed when it is, in fact, closed. OptiLogic AC digital inputs handle such zero crossover conditions.

Digital Input Voltage

Any digital input module, AC or DC, is designed to operate within an input voltage range. The input voltage directly controls the amount of current flowing through the circuit. The minimum voltage corresponds to a voltage that creates enough current to produce LED light sufficient to be sensed by the optical sensor. The

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

10-30VDC

Sinking

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

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OptiLogic Series

Digital Outputs

Digital outputs are used to turn “loads” on and off. “Loads” may be lights, motors, solenoids, or any type of on/off device found in the “real world”.

Digital outputs in the OptiLogic series come in three types - relay, transistor and solid state relay. Each type has applications it is best suited for. The following is a general list of application characteristics for each output type.

Relay

•

Low contact loss

•

AC or DC

•

Moderate to high current rating

•

Low cost

Should not be used for

•

Ultra low current switching (less than 10mA)

•

Switching loads at high frequency

Transistor

•

DC application only

•

Low current rating High frequency switching

•

Low cost

Relay Loads

Relays are affected by the type of load that is switched. Inductive loads (solenoids, motors, etc.) tend to wear the relay much more than resistive loads (lights, heaters, etc.).

Inductive load wear is due to the fact that inductive loads will continue to conduct current for a period, even after the circuit is broken. This current flow builds up opposing polarity charges between the contact segments that just separated. This makes the two segments attract each other - making opening the contact more difficult. It also can result in arcing while the contact is being opened. Arcing, in turn, builds up carbon deposits, i.e. wear.

This situation can be improved for DC inductive circuit loads by the addition of external diode protection of the circuit. The figure below illustrates diode protection. When the contact is closed, the diode is reverse biased and no current flows through it. When the contact opens, current will continue to flow through the inductive load. The diode provides a path for current flow. The result that is the energy is dissipated in the inductive coil and not the relay contact.

Inductive load

Solid State Relay

•

AC application

•

Any switching frequency

•

Moderate current

•

Moderate cost

Relay Outputs

Relays are basically electrically controlled mechanical switches. All current OptiLogic Relay output boards utilize form A relays - i.e. the contact is either open or closed.

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Diode protection

isolation

From OptiLogic processor

Output module

Note : Do not use this circuit for AC loads.

Page 10

OptiLogic Series

processor

Transistor Outputs NPN Transistor Sinking Outputs

An NPN transistor sinking output provides a path to ground. A typical circuit is shown below.

Inductive load

optical

Diode protection

There is a small voltage drop across the transistor in such a circuit. The voltage drop will generate heat in the transistor. Therefore NPN transistor outputs are generally limited to lower current applications.

isolation

From

OptiLogic

Output module

Solid State Relay Outputs

Solid state relays are semiconductor switches that operate very much like mechanical relays. They have an advantage over mechanical relays by virtue of the fact that they are semiconductors. Solid state relays can be switched at relatively high frequencies and they do not wear out. However they are more expensive and there is a small voltage drop across the contact.

The figure below illustrates a typical solid state relay output. OptiLogic Solid state relays are designed for AC load operation.

load

optical isolation

From

OptiLogic

Transistor outputs can be operated at high frequency. There is no effective wear on a transistor output from switching, as there is in a mechanical relay.

Diode protection applied to inductive loads is recommended in cases where the load current approaches the rated current limit of the output. In most cases OptiLogic outputs are designed to withstand voltages of at least twice the rated output voltage. However, diode protection like that shown above will ensure that turn off voltage spikes will never get to that level.

Output module

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OptiLogic Series

Analog Inputs

Analog inputs are used to monitor the value of some continuously variable measurement. Typical analog inputs are measurements of temperature, pressure, weight, liquid level, pH, flow rate and many other “real world” parameters.

The purpose of an analog input module is to convert the measurement into a format that is usable by the data acquisition or control system. To be usable by an computer-based system, the analog measurement must be converted to digital format. Doing so accurately and, in some cases, quickly, is the goal of the analog to digital converter module.

also use the main power supply and isolated power via a switching power converter and a transformer. There are OptiLogic analog input modules in both categories. Neither is functionally superior to the other. The on-board power generation may save the cost of an additional external power supply.

Analog inputs

A/D

Converter

Bus

Interface

A good understanding of analog input modules includes an understanding of isolation, accuracy, single and differential inputs, multiplexing, resolution and range. The following paragraphs provide an overview of these subjects.

Isolation

In many applications there is a good deal of benefit to be derived from isolating the analog measurement source from the RTU’s power supply. In some cases, signal inputs may contain voltages or noise signals which could adversely affect the main processor’s operation. Likewise, noise on the main power bus can degrade the accuracy of the analog value measurement. Both potential problems can be solved by isolating the analog inputs from the main power supply.

Converter Module

The other aspect of isolation is the fact that the measured value must be transmitted from the analog to digital converter, operating on one power supply, to the main system, which is operating on another power supply. This is commonly accomplished through optical isolators.

Isolation involves totally isolating the analog to digital (A/D) converter from the main power bus. This can be accomplished in two ways. The A/D input module can use a separate power source input, which is isolated from the power input to the base. The A/D module can

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OptiLogic Series

Resolution

Resolution is the number of significant bits of information the A/D converter uses to express the value of the measured input. A 12-bit A/D converter uses 12 bits of information, meaning the entire range is covered by a number between 0 and (2 A/D expresses the same range as a number between 0 and 16,383. In other words, the more bits used, the finer the increment. In general terms, the higher the resolution, the better.

(12)

-1) or 0 to 4095. A 14-bit

Range

The analog input range is the minimum and maximum voltage, or current level, measured by the A/C converter. Typical ranges are 0 to 5 volts, 0 to 10 volts, +/- 5 volts, +/- 10 volts, and 4 to 20 mA.

You should try to match the input range to the range of the signal that you are measuring.

Multiplexing

Analog to digital converter devices are typically quite expensive. In order to keep the cost per channel of analog inputs down, a multiplexer is commonly used.

2 3 4 5 6

Bits of Resolution

Accuracy

Accuracy is expressed as the worst case deviation from the “ideal value” across the entire input range. For example, for a 0 to 5V input range and a 12-bit A/D module, a 2.0 volt input should yield a value equal to 1638 (0.4 x 4096). If it returns a value of 1636, and this is the worst case error across the entire range of 0 to 5V, the accuracy is 12 bits +/- 2 counts.

Analog inputs

A/D

Converter

Bus

Interface

Converter Module

A multiplexer switches one analog input at a time into the A/D converter. Each input is converted in sequence. The trade off is reduced sampling rate for a particular channel versus reduced cost per channel measured. In most industrial applications, the conversion rate is so fast in relation to the rate of change in the measured value, that sampling rate is not a factor.

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OptiLogic Series

Single Ended Inputs

Single ended inputs are all referenced to the same ground point. In many applications, single ended inputs produce significant advantages. Single ended inputs require only one ground connection and one signal input per measured value. The result is reduced wiring costs along with the reduced cost per channel on the analog input module.

In order to use single ended inputs, the ground connection must be very good. The measurement devices must also be capable of being referenced to a common ground.

Differential Inputs

There are cases when the individual analog inputs cannot be connected to a common ground. In those cases, a differential input A/D converter should be used.

With a differential analog input, both a positive and negative signal line must be connected for each signal. The analog input module then measures the difference between the positive and negative. The effect of one channel’s signal on another channel’s signal should be as little as possible. That relationship of the effect on the measured value of one channel to the value input on a second channel is called “common mode”. The higher the

“common mode rejection ratio (CMRR)” the

better.

Analog inputs

Common ground

A/D

Converter

Bus

Interface

Converter Module

Analog inputs

A/D

Converter

Bus

Interface

Converter Module

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1A (resistive)/point

Outputs

Output Type

Contact voltage rating

Contact rating

Contact type

Minimum load

Contact arrangement

Mechanical life

OL2104 Relay Output Module

Mechanical relay 0 - 24 VDC

0 - 120 VAC

@24 VDC, 1A/point @120 VAC, 1A/point

Form A (SPST)

10 mA

4 isolated normally open contact relays

10,000,000 operations per relay (at no load)

Card Cage Power Required

Contact resistance

Status Indicators

Terminal Strip

Terminal Screws

Maximum terminal wire gauge

Terminal block torque

Required Temperature rating of field installed conductors

215 mA

0.1 ohm (initial)

Logic Side LED

Plug In (removable)

Slotted max)

18 AWG (use copper conductors)

2.2 lb-in

60°C/75°C

(0.1î blade

Electrical life

Type

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2 3

8 7 6 5 4

3 2 1

0 1

2104

100,000 operations per relay (at full load)

Weight

Subtype

Inductive load

isolation

Diode protectio

Output module

From

ptiLog

processo

1.6 oz (58 g)

5 4

3 2 1

Terminal

Out0 NO 5

Out0 C 6

Terminal

Out2 NO

Out2 C

5-30VDC 5-132VAC

Page 15

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Outputs

Output type

Contact voltage rating

Contact rating

Contact type

Minimum load

Contact arrangement

Mechanical life

OL2108 Relay Output Module

Mechanical relay 0 - 24 VDC

0 - 120 VAC

1A (resistive)/point @24 VDC, 1A/point

@120 VAC, 1A/point

Form A (SPST)

10 mA

4 relays per common

10,000,000 operations per relay (at no load)

Card Cage Power required

Contact resistance

Status Indicators

Terminal Strip

Terminal Screws

Maximum Terminal Wire Gauge

Terminal block torque

Required Temperature rating of field installed conductors

375 mA

0.1 ohm (initial)

Logic Side LED

Plug In (removable)

Slotted max.)

18 AWG (use copper conductors)

2.2 lb-in

60°C/75°C

(0.1î blade

Electrical life Type

Optimation, Inc. (256)883-3050 15

0 1 2 3 4 5

6 7

2108

10 9 8

7 6 5 4 3 2

100,000 operations per

Weight Subtype

To LED

Fro

O processor

ptiLog

Terminal

Out 3

Out 4

isolation

U T

module internal circuit

Terminal

Common

Out 0-3

Common

Out 4-7

2.1 oz (58g) 1

L7 L6 L5 L4

L3 L2

L1 L0

10 9

8 7 6

5 4

2 1

Out 0

Out 5

Out 1

Out 2 10 Out 7

Out 6

5-30VDC 5-132VAC

Connection diagram

Page 16

OptiLogic Series

circuit

optical

5-40VDC

OL2109 DC Sinking Output Module

Outputs 8

Output Type

NPN open collector transistor

Card Cage Power required

140 mA

Status indicators Logic side LED

Voltage Rating 0 - 40VDC Peak Voltage 80VDC

.75V @ 100mA

On voltage drop

Terminal strip Plug In (removable)

.95V @ 300mA

Commons 2 (connected internally) Terminal screw

Maximum continuous load current

Maximum surge current

300 mA

1.0A for 5 seconds

Maximum terminal wire gauge

Required Temperature rating of field installed conductors

Slotted (0.1” blade max)

18 AWG (use copper conductors)

60C/75C

Weight 1.1 oz (30 g) Terminal block torque 2.2 lb-in Type 9 Subtype 2

The OL2109 Transistor Output module provides eight optically isolated transistor outputs which can be used for switching small DC loads. Individual LED indicators provide visual feedback of output state.

6 2109

isolation

module internal

From OptiLogic processor

Terminal Terminal

1 Common 6 Out 3 2 Common 7 Out 4 3 Out 0 8 Out 5 4 Out 1 9 Out 6

5 Out 2 10 Out 7

Connection diagram

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OptiLogic Series

15-132VAC

circuit

optical

OL2111 AC Solid State Relay Module

Outputs 8

Card Cage Power required

120 mA

Output Type SSR (Trice) Commons 2 (connected internally) Voltage Rating 12 - 132 VAC Status indicators Logic side LED Max. load current .5A/point @ 120VAC Min. load current 10mA Terminal Strip Plug In (removable)

On state voltage drop 1V (typical) Terminal screws

Peak one cycle surge current

15A

Maximum terminal wire gauge

Slotted (0.1” blade max.)

18 AWG (use copper conductors)

Required Temperature

AC frequency 47 - 63 Hz

rating of field installed

60C/75C

conductors

Weight 1.3oz (38g) Terminal block torque 2.2 lb-in Type 9 Subtype 3

The OL2111 Solid State Relay module provides eight (8) solid state relay outputs. This module is ideally suited for switching small AC loads. As a solid state device, switch wear will not be a factor. Each output is optocoupled for system isolation. Individual LED indicators provide visual feedback indicating the state that each relay is being driven.

2 3

isolation

From OptiLogic processor

2111

4 3

module internal

Terminal Terminal

1 Common 6 Out 3 2 Common 7 Out 4 3 Out 0 8 Out 5 4 Out 1 9 Out 6

5 Out 2 10 Out 7

Connection diagram

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Page 18

OptiLogic Series

OL2201 Digital Input Simulator Module

Inputs 8

Card Cage Power Required

60mA

Input Type Toggle Switch Status Indicators Logic side LED

Weight 1.1 oz (30 g)

Type 1 Subtype 3

The OL2201 Digital Input Simulator Module is designed to be an aid to program development. Use the OL2201 to simulate real world inputs during your design and debug process. The OL2201 enables the program developer to cause a change in input status at will to simulate a system action. In doing so, you are able to see the program’s response. Use of the OL2201 is an aid in the process of thoroughly testing and debugging a system prior to “going live” with real hardware.

When it becomes time to move to real hardware, replace the OL2201 with the appropriate digital input module. The logic of your program will remain the same.

2201

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Page 19

OptiLogic Series

circuit

optical

10-30V AC or DC

IN3

OL2205 AC/DC Input Module

Inputs 4

Card Cage Power Required

60mA

Input Type AC Optocoupled Status Indicators Logic Side LED Voltage Range 10-30 V AC or DC Input Impedence 2.7K Min. On Current (per

point) Max. On Current (per

point)

Max. Terminal wire gauge

3.3 mA Inputs

11 mA Terminal Strip Plug In (removable)

Terminal Screws

18 AWG (use copper conductors)

Required Temperature rating of field installed conductors

DC sinking or sourcing / or AC

Slotted (0.1” blade max.)

60C/75C

Weight 1.2 oz (34g) Terminal block torque 2.2 lb-in Type 5 Subtype 1

The OL2205 Digital Input module senses up to four (4) AC or DC input signals. All inputs are individually optocoupled for isolation. Inputs are also individually isolated from each other by separate terminal connections. Filtering is provided for zero crossover. Individual LED indicators provide visual feedback of current status.

2205

4 3

Optimation, Inc.

isolation

module internal

OptiLogic processor

Terminal Terminal

1 In 0 5 In 2 2 In 0 6 In 2 3 In 1 7 In 3

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IN2

IN1

IN0

Page 20

OptiLogic Series

Sourcing

10-30VDC

circuit

optical

OL2208 DC Digital Input Module

Inputs 8

Card Cage Power required

60mA

Input Type DC Optocoupled Status Indicators Logic side LED Voltage Range 10 - 30 VDC Input Impedance 2.7K Min. On Current (per

point)

3.3 mA

Max. On Current (per point)

11 mA

Commons 2 Terminal Strip Plug In (removable) Max. Terminal wire

gauge

18 AWG (use copper conductors)

Terminal screw

Slotted (0.1” blade max.)

Required Temperature rating of field installed

60C/75C

conductors

Weight 1.2 oz (34g) Terminal block torque 2.2 lb-oz Type 1 Subtype 1

The OL2208 DC Digital Input module can be used in either sourcing or sinking application (all 8 inputs must be used in the same manner). Each input is optocoupled to provide system isolation. Individual LED indicators provide a visual feedback of current status.

isolation

To OptiLogic processor

2208

9 8

4 3

module internal

Terminal Terminal

1 Common 6 In 3 2 Common 7 In 4 3 In 0 8 In 5 4 In 1 9 In 6

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

10-30VDC

Sinking

IN7

IN6

IN5

IN4

IN3

IN2

IN1

IN0

5 In 2 10 In 7

Connection diagram

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Page 21

OptiLogic Series

80-132VAC

IN7

circuit

optical

OL2211 AC Digital Input Module

Inputs 8

Card Cage Power Required

60 mA

Input Type AC Optocoupled Status Indicators Logic side LED Voltage Range 80 - 132 VAC Input Impedance 47K Min. On Current (per

point) Max. On Current (per

point)

Max terminal wire gauge

1.7 mA Commons 2 (connected internally)

2.8 mA Terminal Strip Plug In (removable)

Slotted (0.1” blade max.)

60C/75C

18 AWG (use copper conductors

Terminal Screws

Required Temperature rating of field installed conductors

Weight 1.3 oz (38g) Terminal block torque 2.2 lb-in Type 1 Subtype 2

The OL2211 AC Digital input module senses up to eight (8) AC input signals. All inputs are individually optocoupled for isolation. Filtering is provided for zero crossover. Individual LED indicators provide visual feedback of current status.

4 5

9 8

4 3

6 2211

isolation

To OptiLogic processor

IN6

IN5

module internal

IN4

IN3

Terminal Terminal

1 Common 6 In 3 2 Common 7 In 4 3 In 0 8 In 5 4 In 1 9 In 6

IN2

IN1

IN0

5 In 2 10 In 7

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Page 22

OptiLogic Series

circuit

optical

10-30VDC

IN7

OL2252 Dual High Speed Pulse Counter

Inputs (all) 8

Card Cage Power Required

100 mA

Pulse Inputs 2 Status Indicators Logic side LED Input Voltage 10 - 30 VDC Input Impedance 2.7K ohms Input frequency (on

pulse inputs) Min. On Current (per

point) Max. On Current (per

point)

Max terminal wire gauge

15 KHz maximum Commons 2

3.3 mA Terminal Strip Plug In (removable)

11 mA Terminal Screws

Slotted (0.1” blade max.)

Required Temperature

18 AWG

rating

of field installed

60C/75C

conductors Weight 1.2 oz (34g) Terminal block torque 2.2 lb-in Type 80 Subtype 1

The OL2252 module provides two independent high speed pulse counter inputs. Each input counter will accurately count pulse inputs up to 15KHz. Inputs may be sourcing or sinking type There are a number of operating options available with the OL2252. The six remaining inputs can be used as predefined control signals or as general purpose inputs. These options are detailed in the following pages.

4 5

9 8

4 3

6 2252

P U L

S E

Optimation, Inc.

isolation

To OptiLogic processor

module internal

Terminal Terminal

1 Common 6 Reset 2 2 Common 7 Enable 1 3 Pulse 1 8 Enable 2 4 Pulse 2 9 In 6 5 Reset 1 10 In 7

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IN6

EN 2

EN 1

RESET 2

RESET 1

Pulse 2

Pulse 1

Page 23

OptiLogic Series

OL2252 Dual Pulse Counter cont’d

The OL2252 Dual Pulse input module is designed to provide two independent pulse counting inputs. Each input is independent of the other. There are also a number of configuration options available.

The following is a list of the input connections.

Terminal Label Description

1 Common 2 Common 3 Pulse 1 4 Pulse 2 5 Reset 1

6 Reset 2

7 Enable 1

8 Enable 2

Sourcing or sinking return line Sourcing or sinking return line Square wave input up to 15KHz Square wave input up to 15KHz If configured as “reset” input ,

will clear the pulse 1 count when activated. If not configured as be used as a general purpose input.

If configured as “reset” input , will clear the pulse 2 count when activated. If not configured as be used as a general purpose input.

If configured as an “enable” input, enables the pulse 1 counter when active. If not configured as an can be used as a general purpose input.

If configured as an “enable” input, enables the pulse 2 counter when active. If not configured as an can be used as a general purpose input.

“reset” input, can

“enable” input,

Theory of Operation

The OL2252 Pulse Counter has two independent pulse counter inputs. These pulse counter inputs will accurately count pulses between 0 and 15KHz.

All counts begin at zero and count up to the maximum number the counter can hold (4,294,967,295). If the count should ever get that high, it will roll over to zero.

In order to count, the count input must be enabled. A message with an enable must come from the host PC. The module can also be set up to use the local hardware input enable (in addition to the enable message). If you are using Think & Do, all of this set up and signaling is part of your Think & Do program. If you are using Visual Basic or C, please refer to the interface software manual.

The count can be reset to 0 at any time. Again there is both a reset message that can be sent from the PC and an optional hardware reset signal.

Whether the hardware “reset” and

“enable” are used is set up from the host PC via a

configuration message. Think & Do will take care of the details. Visual Basic and C users can also easily send this message as part ot their application program.

9 Input 6

10 Input 7

Optimation, Inc.

General purpose input General purpose input

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OptiLogic Series

OL2252 Pulse Input cont’d

Input Signal

The input pulse train is a repetitive square wave input that looks something like the following.

1 count

If you know the maximum frequency of the pulse train, you can configure the pulse counter to count pulse up to that pulse rate. In doing so, the counter will consider anything above the maximum rate that you have defined to be noise and will ignore it.

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Page 25

OptiLogic Series

OL2258 High Speed Pulse Counter

Inputs (all) 4

Pulse Inputs 2 Status Indicators Logic side LED

Input signal type

Input frequency (on pulse inputs)

Min. Input On Voltage (or differential)

Max. Input Off Voltage (or differential)

Max. Input voltage 28V

Outputs 2

Sinking, sourcing or differential

80/160 KHz maximum

4.00V Frequency data

3.00V Counting Modes

Card Cage Power Required

Input Impedance 2.0K ohms nominal

Count value 32 bit signed integer

Max terminal wire gauge

100 mA

16 bit signed integer (Configurable for 1

second or 200 mS count) Pulse & Direction

Up/Down Count Quadrature

18 AWG (use copper conductors)

Output Type Open collector Terminal Strip Plug In (removable) Max Output current 300 mA Terminal Screws Slotted (0.1” blade max.)

Required Temperature

Output Voltage range 0 - 40VDC

Weight 1.24 oz (35g) Terminal block torque 2.2 lb-in Type 82 Subtype 1

rating of field installed conductors

60C/75C

The OptiLogic OL2258 High Speed Pulse Counter module provides for direct pulse counting for a variety of high speed pulse interface applications. Typical applications include motion control, metering and velocity measurement. The OL2258 contains on board intelligence necessary for processing and counting pulse information as well as automatically triggering control outputs.

The OL2258 can be configured configured to operate in one of three pulse counting modes. These modes are 1) Pulse & Direction, 2)Up/Down Count and 3) Quadrature . Pulse & Direction and Up/Down count will operate at up to 80KHz input pulse rates. Quadrature inputs count each quadrature state transitions at up to 160 KHz. Additionally, the OL2258 will return frequency information.

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Page 26

OptiLogic Series

Differential Drive Interface

OL2258 Interface

Sinking Encoder Interface

Sourcing Encoder Interface

Differential Drive Interface

OL2258 High Speed Pulse Counter cont’d

Interfacing the OL2258

The OL2258 High Speed Pulse counter is designed to interface to a variety of standard pulse encoder devices. The electrical interface is shown on the right.

Differential, sourcing, or sinking type inputs can be interfaced to the OL2258. The figures across the bottom of this page illustrate connections for each type of encoder.

General Overview

The OL2258 is configurable. It can be used with pulse & direction, up/down count or quadrature type pulse encoders. These signals may come from shaft encoders, flow meters or any other signal source that produces a pulse train output. When operating, the OL2258 maintains a current cummulative count as a 32 bit integer value. It also makes available frequency snapshot data as the most recent count over either 1 second or 200 milliseconds. The Z and LS inputs can be used to automatically reset the count to a user defined value. Each transistor output can be configured to turn on when the count value is within its related count range.

Outs

4 3

Z LS

2258

P U L S E

Term Label Description

1 A1 2 A2 3 B1 4 B2 5 Z1

Pulse input A(quadrature)/ Pulse input (pulse & direction)/ Up pulse (up/down count)

Pulse input B(quadrature)/ Direction (pulse & direction)/ Down pulse (up/down count)

Z input (optional)

6 Z2

Out1

Out2

(Positive differential)

Optimation, Inc.

encoder ground

(Bipolar differential)

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7 LS 8 Com

9 Out1

10 Out2

Limit switch input (optional) Common for limit switch and

two outputs Open collector output 1 Open collector output 2

Page 27

OptiLogic Series

Quadrature Count

Count

17-126-235-34453627180

OL2258 High Speed Pulse Counter cont’d

Pulse and Direction

In this configuration, pulses are input to

“A”. The counter direction is controlled by input “B”. The operation is illustrated below.

Pulse & Direction Count

Pulse (A)

Direction (B)

Count

1 2 3 4 5 4 3

2 1 0

1 2

Quadrature Encoder Input

The counting process for quadrature type encoding is determined by the phase angle between input A and input B. If A leads B, the counter increments. If B leads A, the counter decrements. The count is incremented or decremented on each pulse transition as shown below.

Z and LS Presetting

The count can be preset to a value that you define based on either or both inputs LS and Z. It can also be forced to a preset value on command via a message.

Through the configuration message, the counter can be set up to force a preset value when Z is active, LS is active, both Z and LS are active or on software command.

Output Control

The two open collector outputs can each be progammed to trigger within a programmable (via an ethernet message) count range. This range can be changed at any time via a “Send Output Range” message, effectively providing and unlimited number of ranges, under user program control.

Outputs will trigger within immediately, when the count enters the related range.

Pulse (A)

Pulse (B)

Up/Down Count

For this type of configuration, the count increments on pulses input to “A” and decrements on pulses input to “B”. This is illustrated in the figure below.

Up/Down Count

Up Pulse (A)

Down Pulse (B)

Count

Optimation, Inc.

1 2 3 4 5 4 3

2 1 0

01 1

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Frequency Measurement

Frequency data can be read back as a 16 bit signed integer value. The value will correspond to the most recent 1 second or 200 millisecond (configurable) pulse count.

Page 28

OptiLogic Series

OL2304 Four Channel Voltage Output

Outputs 4

0-5V, 0-10V, +/-5V, +/-10V

Output Ranges

Resolution 12 bit (1 in 4096) Output current +/-5mA

Output type

Offset calibration error

Nonlinearity +/- 1 count Terminal strip Plug In (removable)

Load impedence 2Kohm mimimum Terminal screws

Terminal block torque 2.2 lb-in

Type 25 Subtype 1

(individual channel configurable)

Single ended, 1 common

+/-8 counts @ +/-10V +/-16 counts @ +/-5V +/-16 counts @ 0-10V +/- 32 counts @ 0-5V

Card Cage Power required

External Power required

Short circuit current +/-15mA

Max terminal wire gauge

Required Temperature rating of field installed conductors

700mA

none

18 AWG (use copper conductors)

Slotted (0.1” blade max)

60C/75C

The OL2304 analog output module is range configurable, on a channel by channel basis, to any of four common output ranges. Each channel can be configured, via software for either 0-5V, 0-10V, +/-5V or +/-10V ranges. The module generates its own isolated output power supply, eliminating any need for an outside source.

Terminal Terminal 1 Common 5 Common 2 Out 1 6 Out 3 3 Common 7 Common 4 Out 2 8 Out 4

Channel 4

Channel 3

Channel 2

Channel 1

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Page 29

OptiLogic Series

OL2408 Analog Voltage Input Module

Inputs 8 Power required 700mA

Input Type

Resolution 14 bit (1 in 16384)

Input Impedance 10 MOhm Maximum Voltage

Input

0-5 VDC or 0-10VDC

+/- 15VDC

Conversion Type Successive approximation

Full Scale Calibration Error

Offset Calibration error

Max. Terminal wire gauge

+/- 15 counts max. +/- 5 counts typical

+/- 2 counts max. 18 AWG (use copper

conductors)

Linearity error +/- 1.25 count max Terminal Strip Plug In (removable) Input stability +/- 2 counts Terminal Screws Slotted (0.1” blade max.)

Terminal block torque

2.2 lb-in

Required Temperature rating of field installed conductors

60C/75C

Type 17 Subtype 1

The OL2408 comes set up for 0-5VDC input range. If you need 0-10VDC input range, you must remove the plastic module cover by lifting the board latches over the retainer hooks on the PC board. Then, place the jumper on both pins of J2 and replace the plastic module cover. To change back to 0-5VDC range, repeat the process and remove the jumper. Having the cover over the range selector jumper ensures that it will not be inadvertantly changed.

Analog Voltage

Input

2408

4 3

Optimation, Inc.

Terminal Terminal

1 Common 6 Channel 4 2 Common 7 Channel 5 3 Channel 1 8 Channel 6 4 Channel 2 9 Channel 7 5 Channel 3 10 Channel 8

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0-5 VDC or 0-10 VDC

Page 30

OptiLogic Series

OL2418 Analog Current Input Module

Inputs 8

Input Type 4 - 20 mA Conversion Type

Resolution 14 bit (1 in 16384)

Input Impedence 250 ohm +/- 0.05%

Card Cage Power Required

Full Scale Calibration Error

Offset Calibration Error

700mA

Successive approximation

+/- 15 counts max. +/- 5 counts typical

+/- 2 counts max.

Power Isolation Transformer Signal Isolation Optical

Max. Terminal Wire Gauge

18 AWG (use copper conductors)

Linearity error +/- 1.25 counts Terminal Strip Plug In (removable) Input Stability +/- 2 counts Terminal Screws Slotted (0.1” blade max.)

Terminal block torque

2.2 lb-in

Required Temperature rating of field installed conductors

60C/75C

Type 18 Subtype 2

2418

8 channel

analog

current in

4 3

Optimation, Inc.

optical isolation

4-20 mA

analog current input module

OptiLogic processor

Terminal Terminal

1 Common 6 Channel 4 2 Common 7 Channel 5 3 Channel 1 8 Channel 6 4 Channel 2 9 Channel 7

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4-20 mA

Page 31

OptiLogic Series

OL2602 Dual RS232 Module

Communication Ports 2

Card Cage Power Required

110 mA

Type RS232C Status Indicators LEDs for TX and RX

1200, 2400, 4800,

Baud Rates

9600, 19,200

System limitations *See below

(selectable)

Parity Even, odd or none

Max. Terminal Wire gauge

18 AWG (use copper conductors)

Data bits 7 or 8 Terminal Strip Plug In (removable)

Transmit buffer 48 bytes Terminal Screws

Required Temperature

Receive buffer 48 bytes

rating of field installed conductors

Slotted (0.1” blade maximum)

60C/75C

Weight 1 oz (29g) Terminal block torque 2.2 lb-in Type 112 Subtype 1

* For OL4058 ethernet base a maximum of one OL2602 modules may be used. It must be placed in slot 0. For the OL4054 ethernet base, a maximum of two OL2602 may be used. They must be placed in slots 0 and 1.

OL2602

Opti

OptiOptiOptiOptiOpti

Logic

Terminal (each port)

1 Signal

ground 2 Transmit 3 Receive

Signal Gnd

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Page 32

OptiLogic Series

Optimation, Inc.

(256)883-3050

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