Akytec MK210-312 User manual

MK210-312_3-EN-38929-1.10
© All rights reserved
Subject to technical changes and misprints
akytec GmbH - Vahrenwalder Str. 269 A - 30179 Hannover - Germany Tel.: [phone] - www.akytec.de
MK210-312
Digital I/O module
User guide

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akytec GmbH - Vahrenwalder Str. 269 A - 30179 Hannover - Germany Tel.: [phone] - www.akytec.de
Contents
Warning notice system ............................................................................................................3
Safety.......................................................................................................................................4
Introduction .............................................................................................................................5
Abbreviations ..........................................................................................................................6
1 Overview.............................................................................................................................7
2 Specifications.....................................................................................................................8
2.1 Specifications .............................................................................................................8
2.2 Isolation of the Device Components..............................................................................9
2.3 Environmental conditions...........................................................................................10
3 Installation........................................................................................................................ 11
4 Connection .......................................................................................................................13
4.1 Connection recommendations....................................................................................13
4.2 Terminal block layout .................................................................................................13
4.3 Connectors...............................................................................................................14
4.4 Power supply ............................................................................................................15
4.5 Connection sensors to discrete inputs.........................................................................15
4.6 Connection of p-n-p and n-p-n transistors....................................................................16
4.7 Connection of p-n-p and n-p-n encoders .....................................................................16
4.8 Connection to the outputs ..........................................................................................16
4.9 Ethernet connection ..................................................................................................17
5 Construction and operation..............................................................................................18
5.1 Operation principle ....................................................................................................18
5.2 Indication and control ................................................................................................18
5.3 Real time clock..........................................................................................................19
5.4 Log file .....................................................................................................................19
5.5 Data exchange modes...............................................................................................21
5.5.1 Modbus TCP communication ..............................................................................21
5.5.2 Error codes for Modbus protocol..........................................................................28
5.6 Operation modes of the digital inputs ..........................................................................30
5.6.1 Logic level detection ...........................................................................................30
5.6.2 Сounting of high-frequency pulses.......................................................................31
5.6.3 Frequency measurement ....................................................................................31
5.6.4 Encoder signal processing ..................................................................................31
5.7 Digital outputs operation modes .................................................................................31
5.8 Safe output status .....................................................................................................31
5.9 Load interruption monitoring.......................................................................................32
6 Configuration....................................................................................................................33
6.1 Connection to akYtec Tool Pro ...................................................................................33
6.2 Configuring Network Settings.....................................................................................34
6.3 Module access password...........................................................................................35
6.4 Firmware update .......................................................................................................35
6.5 Real-time clock setting...............................................................................................36
6.6 Restore default settings .............................................................................................36
6.7 Сounter reset............................................................................................................36

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7 Maintenance .....................................................................................................................37
7.1 General Instructions ..................................................................................................37
7.2 Battery replacement ..................................................................................................37
8 Transportation and storage ..............................................................................................39
9 Scope of delivery ..............................................................................................................40
Appendix A Encrypting the log file ......................................................................................41

Warning notice system
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Warning notice system
Explanation of the symbols and keywords used:
DANGER
DANGER indicates an imminent dangerous situation that will result in death or serious
injuries if not prevented.
CAUTION
CAUTION indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
NOTICE indicates a potentially dangerous situation that could result in damage to
property.
NOTE
NOTE indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.

Safety
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Safety
Read this manual carefully before installing, operating or servicing the device.
The device has been designed and built solely for the intended use described in this guide, and can
only be used accordingly. The technical specifications contained in this guide must be observed.
Any other use is considered improper.
CAUTION
This device must not be used for medical devices which receive, control or otherwise affect
human life or physical health.
When installing and using this product, all applicable state, federal and local regulations must be
observed.
Based on safety considerations and compliance with the data provided in the documents, the repair
of the components of the products is carried out exclusively by the manufacturer.
There is a dangerous voltage on the terminal block. Any connections to the device and maintenance
operations must be carried out only when the power of the device is turned off.
The device's method of protection against electric shock meets the terms of class II, IEC 61131-2-
2012.
The device installation must be performed in particularized equipment cabinet, the inner access to
which is allowed only to approved specialists.
CAUTION
It is forbidden to use the device in corrosive environments with acids, alkalis, oils, etc. in the
atmosphere.
Obey all the necessary rules and instructions when using programmable logic controllers in areas
where technical safety requirements apply.
Failure to obey these warnings could result in personal injury or equipment damage.
Akytec company shall not be liable for technical or editorial errors or omissions contained in this
document.

Introduction
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Introduction
This document provides detailed information about the operation principle, design, configuration,
installation and maintenance of the digital input/output module MK210-312, hereinafter referred to as
the Device or Module.
Connection, adjustment and maintenance of the device must be carried out only by qualified
personnel after reading this operating manual.
Order code: MK210-312.

Abbreviations
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Abbreviations
–DAC – digital-to-analog converter.
–PC – personal computer.
–PLC – programmable logic controller.
–PWM – pulse width modulation.
–RTC – real time clock.
–USB – an industry standard that establishes specifications for cables, connectors
and protocols for connection, communication and power supply between personal computers and
their peripheral devices.
–UTC – coordinated universal time.

1 Overview
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1 Overview
The Module is designed to collect data and connect executive devices on automation facilities. The
Device is controlled by a PLC, panel controller, PC or other control device.
Module has:
– 12 digital inputs;
– 4 digital outputs (relays).
Digital outputs provide the function of the load interruption monitoring and relay operation
monitoring.
Modules are used in various fields of industry and agriculture.

2 Specifications
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2 Specifications
2.1 Specifications
Table 2.1 Specifications
Characteristic Value
Power supply
Power supply 24 (10 … 48) V DC
Power consumption 5 W
Protection against reverse polarity of supply voltage Yes
Interfaces
Data transfer interface Dual Port Ethernet 10/100 Mbps
Configuration interface USB 2.0 (MicroUSB), Ethernet 10/100
Mbit
Date transfer protocol Modbus TCP
Protocol version IPv4
Digital inputs
Inputs quantity 12
Signal types
– contact sensor (requires 24 V
external power supply);
– npn- and pnp-transistor
Operation modes
– logical level detection;
– counting the number of high-
frequency pulses (only the first 8
inputs);
– frequency measurement (only first 8
inputs);
– encoder signal processing (up to 3
encoders)
Minimum pulse duration perceived by the digital input
(DI9 – DI12 inputs only) 5 µs (up to 100 kHz)
Minimum duration of a single pulse (for inputs DI9 –
DI12) 1 ms (up to 400 Hz)
Current of logical 0 max. 1.2 mA
Current of logical 1 max. 5.5 mA
Voltage range of logical 0 0...6.1 V
Voltage range of logical 1 8.8...30 V
Digital outputs
Outputs quantity 4
Output type Electromagnetic relay
Contact type Normally open contact
Operation mode – logic state switch
– PWM signal generation

2 Specifications
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Characteristic Value
Maximum voltage on relay contacts 250 V AC, 30 V DC
Switching current
– 5 A (max. 250 V AC, 50 Hz and
cosφ>0.4);
– 3 A (max. 30 V DC)
Turn-on time 15 ms
Turn-off time 15 ms
Mechanical life time of the relay min. 5,000,000 switches
Electrical life time of relay at maximum load current min. 200,000 switches
Load interruption monitoring Yes
PWM output parameters
Maximum frequency 1 Hz (at 0.5% duty cycle)
Minimum pulse width 50 ms
Flash-memory (log-file)
Number of write and erase cycles up to 100,000
Maximum log file size 2 KB
Maximum number of log files 1,000
Minimum log writing interval 10 s
Real time clock
Inaccuracy
at +25 °C max. 3 s per day
over the entire temperature
range
max. 10 s per day
Battery type CR2032
Lifetime of one battery 6 years
General specifications
Dimensions 42 × 124 × 83 mm
IP code IP20
Error-free running time 60,000 h
Average service lifetime* 10 years
Weight 0.4 kg
* Excluding electromechanical switches and real-time clock battery
2.2 Isolation of the Device Components
The circuit of galvanic isolated components and the strength of galvanic isolation are shown in
Figure 2.1.

2 Specifications
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Fig. 2.1 Isolation of the Device Components
Table 2.2 Insulation types
Type Description
Basic insulation (BI)
The insulation used for active parts of equipment to provide protection
against electric shock. The electrical strength of the basic insulation is
checked by type tests: by applying a test AC voltage, the value of which
is different for different circuits of the Device
Supplementary
insulation (SI)
Independent insulation used in addition to the basic insulation in order to
guarantee protection against electric shock in the event of a failure of the
main insulation. The electrical strength of the supplementary insulation is
checked by type tests: by applying an alternating test AC voltage of
various levels (RMS value)
Reinforced insulation
(RI)
Separate insulation system used for active parts, which provides a
degree of protection against electric shock, equivalent to double.
NOTICE
The strength of the isolation is indicated for testing under normal climatic conditions
(exposure time is 1 minute).
Digital outputs (relays) are individually isolated from each other. Insulation strength between relay
outputs is 1780 V.
2.3 Environmental conditions
The Module meets the requirements for immunity to interference in accordance with IEC 61000-6-
4:2006. According to the level of emission of radio interference (noise emissions) the Device
complies with the standards established for equipment of class A by CISPR 22-97. The Device is
designed for operation in the following conditions:
– ambient temperature: –40 … +55 °C;
– relative humidity: up to 95% (at +35 °C, non-condensing);
– closed non-hazardous areas, free of corrosive or flammable gases.
– permitted pollution degree 1 according to IEC 61131-2.
The resistance to mechanical influences during operation of the Device is in accordance
with IEC 61131-2-2012.
The resistance to climatic influences during the operation of the Device is in accordance
with IEC 61131-2-2012.

3 Installation
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3 Installation
Module is to install in the electrical cabinet. The design of the
cabinet must protect Module from moisture, dirt and foreign
objects.
To install Module:
1. Make sure that there is enough free space to connect the
wire harness. You need 50 mm above the Module and
below it.
2. Fasten the Device to the DIN rail or to a vertical surface
using screws (see Figure 3.1).
Fig. 3.1 Proper installation
Fig. 3.2 Improper installation
CAUTION
Long-term operation of Module with improper installation can lead to damage (see Figure
3.2).

3 Installation
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Fig. 3.3 Dimension drawing Fig. 3.4 Mounting dimensions

4 Connection
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4 Connection
4.1 Connection recommendations
Mounting of external connections must be carried out by a wire with a cross section of not more than
0.75 mm2.
For stranded wires, use end sleeves.
After mounting, put the wires into the cable channel of Module housing and close the cover.
If necessary, remove the terminal blocks of Module, loosen the two screws at the corners of the
terminal blocks.
The power wires must be mounted using the supplied return terminal block.
CAUTION
Connection and maintenance is performed only when power of Module and devices
connected to it is turned off.
CAUTION
Do not connect wires of different cross-sections to one terminal.
CAUTION
Do not connect more than two wires to one terminal.
4.2 Terminal block layout
Fig. 4.1 Terminal block layout
Table 4.1 Contact assignment
Marking Description
DI1 – DI12 Inputs DI1 – DI12
SS Common input power supply point

4 Connection
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Marking Description
DO1A, DO1B – DO4A, DO4B Outputs DO1 – DO4
NC (Not connected) No connection
CAUTION
It is not allowed to connect wires to NC contacts (Not connected).
4.3 Connectors
The connectors of the interfaces and of the power supply of the Device are shown in Figure 4.2.
Fig. 4.2 Device's connectors

4 Connection
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4.4 Power supply
Fig. 4.3 Power supply contacts
CAUTION
Using power supplies without potential isolation or with basic isolation of low voltage circuits
from AC lines can lead to dangerous voltage in the circuits.
4.5 Connection sensors to discrete inputs
Up to 12 sensors can be connected to the device.
The SS circuits are connected inside the device.
Connection diagram is shown in Figure 4.4.
Fig. 4.4 Connection to inputs DI1-DI12

4 Connection
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4.6 Connection of p-n-p and n-p-n transistors
Fig. 4.5 Connection of p-n-p transistors Fig. 4.6 Connection of n-p-n transistors
4.7 Connection of p-n-p and n-p-n encoders
Connection diagrams are shown in the figures.
Fig. 4.7 Connection of p-n-p encoders Fig. 4.8 Connection of n-p-n encoders
4.8 Connection to the outputs
Figure 4.9 shows the connection diagram to the outputs of the relay type.
Fig. 4.9 External connections to digital outputs of the relay type

4 Connection
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4.9 Ethernet connection
To connect modules to an Ethernet network, you can use the following schemes:
– Wye (Figure 4.10),
– Daisy-chain (Figure 4.11).
Fig. 4.10 Wye connection
NOTICE
1. Maximum length of communication lines: 100 m.
2. Connection is possible to any Ethernet port of the module.
3. The unused Ethernet port must be closed with a blanking plug.
To connect to the Daisy-chain scheme, you must use both Ethernet ports of Module. If Module fails
or the power is turned off, the data will be transferred from port 1 to port 2 without disconnecting.
Fig. 4.11 Daisy-chain connection
NOTICE
1. The maximum length of the communication line between two adjacent active devices
when connected with the “Daisy-Chain” must be not more than 100 m.
2. An adjacent connection scheme is allowed.
3. The unused Ethernet port should be closed with a blanking plug.

5 Construction and operation
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5 Construction and operation
5.1 Operation principle
The Module receives commands to control outputs from the Network Master.
As a Network Master you can use:
– PC;
– PLC;
– Operator panel.
5.2 Indication and control
On the front panel there are indication LEDs. The decoding of the LED indications is given in Table
5.1.
Fig. 5.1 Device faceplate
NOTICE
The IP field is located at the bottom of the front panel.
The IP field is intended for applying the IP address of the Module with a thin marker or on a
paper sticker.
Table 5.1 LED States
LED LED Status Function
Power (green) ON Device operating voltage is applied
Eth 1 (green) Flashing Data transfer via Ethernet port 1
Eth 2 (green) Flashing Data transfer via Ethernet port 2
Fault (red) OFF Normal operation
ON Main application and / or
configuration failure
Lights 200 ms once every
3 seconds
RTC battery must be replaced

5 Construction and operation
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LED LED Status Function
Lights 100 ms twice a
second (after a pause of
400 ms)
Module is in a safe state
900 ms on, 100 ms off Hardware peripheral failure (Flash,
RTC, Ethernet Switch)
Output status indicators (red-
green)
Green Output is closed
OFF Output is open
Red A load break or an output fault is
detected
Under the module faceplate there are terminal blocks and a service button (Figure 4.1).
The service button performs the following functions:
– Factory settings restore (Section 6.6);
– IP-address assignment (Section 6.2);
– Firmware update (Section 6.4)
5.3 Real time clock
The Module has a built-in real time clock (RTC). Its source of power is a battery.
The timing is in seconds, starting with January 1, 2000 at midnight UTC. RTC indication is used for
writing entries into the log file.
5.4 Log file
The module has built-in encrypted flash memory. The encryption algorithm is Data Encryption
Standard (DES) in cipher block chaining (CBC) mode. The key is the string superkey. An
initialization vector is generated using a hash function. The function argument is the password
specified in akYtecToolPro. A checksum is calculated by the CRC32 algorithm and saved in the file
end. The checksum is also encrypted.
Log file of Module will be saved as a few files. The log interval, the restriction on the size of one file
and their number is set by the user in akYtecToolPro. If the log file is full, then the data is overwritten,
starting with the oldest data in the oldest file.
A log file is a collection of records. Entries are separated by line break characters (0x0A0D). Each
entry corresponds to one parameter and consists of fields separated by the “;” character (without
quotes). Entry format is shown in table.
Table 5.2 Entry format
Parameter Type Size Comment
Time stamp binary
data
4 bytes In seconds from 00:00 01.01.2000 (UTC+0)
Separator string 1 byte Character ";" (without quotes)
Unique identifier of
the parameter
(UID)
string 8 byte As a string of HEX characters with leading
zeros
Separator string 1 byte Character ";" (without quotes)
Parameter value string depending on
the parameter
As a string of HEX characters with leading
zeros
Separator string 1 byte Character ";" (without quotes)