Dutec I/O Plexer Instructions for use
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I/O PLEXER Nov. 23, 2004
-ii-
Copyright
Copyright 2004-duTec inc. All rights reserved. However, any part of
this document may be reproduced, provided that duTec inc. is cited as
the source. The contents of this manual and the specifications herein
may change without notice.
Trademarks
The duTec logo and I/O PLEXER are trademarks of duTec inc.
WINDOWS™ and WINDOWS 95 are trademarks of MicroSoft.
Notice to the User
The information contained in this manual is believed to be correct.
However duTec inc. assumes no responsibility for any of the circuits
described herein, conveys no license under any patent or other right
and makes no representations that the circuits are free from patent
infringement. duTec inc. makes no representation or warranty that such
applications will be suitable the use specified without further testing or
modification.
DuTec inc. general policy does not recommend the use of its products
in life support applications where failure or malfunction of a
component may directly threaten life or injury. It is a condition of sale
that the user of duTec inc. products in life support applications assumes
all risk of such use and indemnifies duTec inc. against all damage.
Warranty
duTec inc. warrants its products to be free of defects in materials and
workmanship for a period of two (2) years from the shipment date.
DuTec inc., at its option, will repair or replace all material found to be
defective. All repair or replacement must be performed by duTec inc.
personnel. Any parts determined by duTec inc. to be defective as a
result of abuse, misuse or attempts to repair will be repaired at the
expense of the customer. DuTec inc. will not be held liable for any
consequential, incidental, or special damages.
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Table of Contents
-iii-
Overview ....................................................1-1
Capacity: ............................................1-1
I/O Signal Compatibility ................................1-2
Built-in Diagnostics: ....................................1-2
EasySetup:...........................................1-3
Protocol Compatibility ..................................1-3
Available I/O Functionality: ......................................1-4
Analog Inputs .........................................1-4
AnalogOutputs........................................1-4
Digital Inputs .........................................1-5
DigitalOutputs ........................................1-5
Extended capabilities: ...................................1-6
Communications watchdogs ..............................1-6
Specifications .................................................1-7
Communications.......................................1-7
Power ...............................................1-8
Environment ..........................................1-8
Package..............................................1-8
OrderingInformation ...........................................1-8
Options ..............................................1-8
Available I/O Modules ..........................................1-9
Installation ...................................................1-1
Mounting: ............................................2-1
PowerWiring: ........................................2-1
DigitalExpander.......................................2-2
Designingthenetwork ..........................................2-3
Multidrop ............................................2-5
Repeat...............................................2-5
NetworkTypeSwitches .........................................2-6
Repeat ..............................................2-7
Multidrop ............................................2-7
LastUnit.............................................2-7
CommunicationsWiring ........................................2-8
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Table of Contents
-iv-
RS-232 Host to I/O Plexer wiring .........................2-8
ModemtoI/OPlexer -RS-232 ...........................2-9
RS-422 Host to I/O Plexer wiring ........................2-10
HosttoI/OPlexer-RS-485 .............................2-11
RS-422 I/O Plexer to I/O Plexer Wiring ....................2-12
RS-485 I/O Plexer to I/O Plexer wiring ....................2-13
AddingDigitalExpanders: ..............................2-14
Module Wiring ...............................................2-15
Analog Inputs: .......................................2-15
Analogoutputs: ......................................2-17
Digital Inputs: ........................................2-18
ChassisSetup .................................................2-1
Baudrate ....................................... 3-1,3-3
Setuppushbutton ......................................3-1
Sequentialdisplay......................................3-1
Protocolhandshaketypes ................................3-3
ModemJumpers .......................................3-3
Changingsetupparameters ......................................3-4
Equivalent RS-232/ 422 Communications circuit ..................... A-1
I/OPerformance ............................................... A-1
InstructionFormat ............................................. B-1
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Introduction 1
1 - 1
Overview
I/OPLEXERs are a family of small, completely self-contained, industrial grade,
remote data acquisition and control systems which exchange data with a Host
computer via a serial communication link. Controlled by a Host, I/OPlexers are
located near the sensors and actuators. The serial link eliminates the need for
expensive and noise prone field wiring between sensors and actuators, and a
central control room.
In applications such as remote process monitoring, factory automation, and
energy management, a variety of signals must be transmitted over long distances.
Instead of requiring expensive, multi-conductor, sensor wiring for each signal,
cabling costs can be reduced significantly by using I/O PLEXERs and a single
communications circuit. One of the most useful features of the I/O PLEXER is
that in addition to gathering “raw” data, it can be instructed to perform many
ranging and statistical operations on the data before it is given to the Host; thus
allowing the Host to spend less time manipulating numbers and more time
gathering them. Also the I/O PLEXER is able to spend more time exposed to the
data which in turn allows it to base its responses to the Host on more samples of
data. The I/O PLEXER may also be directed to manipulate the outputs in specific
ways to produce delayed or repetitive effects.
Capacity:
Each I/O PLEXER Master unit will hold any mix of 16 analog or digital,
electrically isolated input or output modules which can interface to a wide
variety of sensors and actuators.
The I/O PLEXER Digital Expander, in an identical enclosure, provides an
additional 16 digital I/O module positions for each master unit. Up to three
Digital Expanders can be attached to each master chassis. See Page 1-8 For
ordering information.
I/O PLEXER networks can service over 4000 analog and or digital I/O Lines in
various Combinations.
Product Test
Every I/O PLEXER is burned-in while operating in a a network of a period of 24
hours at 70° C, prior to shipment.
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Introduction 1
1 - 2
Every I/O module is tested while its operating environment temperature is cycled
over the specified operating range of 0° C to 60° C for a period of 24 hours. A
computer record is maintained for every analog I/O module.
Throughput:
System response or throughput for the I/O PLEXER can be calculated using
appendix B.
I/O Signal Compatibility
I/O PLEXERs use duTec I/O modules to match signal requirements exactly.
With a direct interface to sensors, no external signal conditioning is required.
Furthermore, all duTec modules feature total electrical isolation, both module-to-
logic, and module-to-module.
Analog modules are available to measure:
Millivolts DC to hundreds of volts AC
Milliamps DC to amps AC
Frequency to tens of KHz
Temperature with all popular thermocouples and resistive temperature
devices
A full range of industry standard digital modules is available for AC, DC and dry
contact inputs and outputs to hundreds of volts.
Thermocouple modules provide a cold reference junction compensation. I/O
PLEXER instructions provide linearized thermocouple and RTD sensor data.
Engineering unit conversions are handled at the Host level.
Built-in Diagnostics:
On power-up, the unit self-tests for system faults and reports via a sequential
display. Should hardware or firmware fail, an on board hardware watchdog
provides safe shutdown by turning off all outputs. Normally ON modules are
available for those loads that must remain ON.
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Introduction 1
1 - 3
Easy Setup:
The I/O PLEXER has its own power supply, no need to purchase or reserve
space for an external supply. A push-button and an on board LED indicator
configure unit address and baud rate. Removable terminal strips allow
attachment/ removal of multiple cable sets in one step. This modularity greatly
reduces troubleshooting and upgrade delays.
Protocol Compatibility
The I/O PLEXER instruction set core complies 100% with the OPTO-22
OPTOMUX serial communications protocol for remote data acquisition and
control. With speak-only when spoken to protocol, which only uses ASCII
printing characters, a Host transmits inquiry requests to the I/O PLEXER to
determine the status of its various process inputs. Based on the reported status,
the Host makes control decisions and transmits this data, as instruction messages,
to the I/O PLEXER which uses the new decisions to make the proper changes to
its various actuators. Both the Host and the communications link are essential
elements in this data acquisition and process control scheme.
Originally, the protocol only allowed for all analog or all digital I/O chassis.
Depending on application requirements, each I/O PLEXER can respond to up to
five different function addresses. With their abbreviations they are:
MC Master Unit Control function address
MD Master Unit Control digital I/O function address
MA Master Unit Analog I/O function address
E1 1st Expander Digital I/O function address
E2 2nd Expander Digital I/O function address
E3 3rd Expander Digital I/O functions address
It is the multiple function addressing capability of the I/O PLEXERs that allow s
them to utilize, without modification, software developed for competitive
products. Similarly I/O PLEXERs can operate simultaneously on the same
network with these products.
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Introduction 1
1 - 4
Available I/O Functionality:
Analog Inputs
Input Value Determines signal levels, with 12 bits resolution*
Offsets Input values can be software offset, with 12 bits resolution,
over the module’s specified range.
Gain/ Slope The amplitude of input values can be software multiplied by
factors ranging from 0.25 to 4.0.
Range Limits The occurrence of input values falling out of user defined
upper or lower limits can be flagged.
Minimums The minimum level input values can be captured.
Maximums The maximum level input values can be captured.
Averages Can calculate average input amplitude for 1-65,535 samples.
Temperature Can linearize in °C, inputs from thermocouples and RTD’s.
Will also return temperature probe data.
Analog Outputs
Level Value Can set output levels, as a fraction of the module’s full scale
range, and are specified with 12 bits resolution.
Waveforms Analog outputs can provide square, triangular, sawtooth or
ramp waveforms. Maximum and minimum amplitudes, as a
fraction of the output module’s full scale range, are
specified with 12 bits resolution. Waveform periods are
specified from 0.1 to 6,553 Sec. (109 Minutes). All
waveforms are made up of at least 10 segments.
* One part in 4095
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Introduction 1
1 - 5
Digital Inputs
Read Read the ON or OFF state of all inputs.
Pulse widths The duration of a single pulse or total on/ off time of
consecutive pulses can be resolved to the nearest 0.01
seconds for a max total of 10.9 min, or 46.6 Hrs with
multiplied resolution. Positive or negative edges initiate
measurements. The time scale can be multiplied by a factor
of 1-256on a system wide basis.
Pulse Counting Pulses can be counted up to a total of 65,535. To be reliably
counted, pulses must have a minimum On and minimum
OFF times of 1 msec. Thus the maximum counting rate for a
50% duty cycle squarewave with equal ON and OFF times
for a total of 2 msec would be 500HZ.
Edge Detection Off-to-On and On-to-Off transitions can be detected within
1 msec of their occurrence. Action is only reported each 10
msec.
Note: The response time performance of digital input instructions
can be limited by the delay in the input modules themselves
which can have ON plus OFF delays of up to 40 msec.
Digital Outputs
Set outputs Can set individual or multiple outputs ON or OFF.
Modifiers
One Shot Can generate ON or OFF pulse durations of up to 655.35
seconds with a resolution of 0.01 seconds. Resolution can be
further multiplied by a factor of 1-256 on a system wide
basis.
Delayed Can generate delayed ON or OFF outputs of up to 655.35
seconds with a resolution of 0.01 seconds. Resolution can be
further multiplied by a factor of 1-256 on a system wide
basis.
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Introduction 1
1 - 6
Squarewave Can generate squarewaves with programmable ON and OFF
periods. On and OFF periods have a base range from 0.01 to
2.55 seconds. Resolution can be further multiplied by a
factor of 1-256 on a system wide basis. Re-Triggering is
available.
Pulse Generator Can generate 1to 65,535, 50% duty cycle pulses whose
equal ON and OFF periods can range from 0.01 to 2.55 Sec.
Resolution can be further multiplied by a factor of 1-256 on
a system wide basis.
Extended capabilities:
In addition to operating under control of a Host, option /L of the I/O PLEXER
has the ability to perform local control functions without the Host. Local control
functions (LCF’s) can insure the continued safe operation of closed loop control
should the Host or its communication link fail. In addition, the LCF’s can
substantially reduce Host computational load or communications traffic.
Once characterized, local control function blocks enable the I/O PLEXER to
perform control tasks without the constant involvement of a Host computer. After
configuration and activation via Host instructions, LCF’s take data from their
input port and perform computations and send the results to their outputs where
they may drive output modules, or other I/O PLEXER internal functions.
Utilizing the LCF’s to perform simple logic tasks such as analog comparisons,
the summations, differences, sequence generating or multiple state machine
operations eliminates the need for programmable controllers or special purpose
circuitry. This capability allows a more effective use of the Host computer and its
communication link because the LCF’s handle the operation of the designated
control function. In the meantime the Host is only required to monitor over-all
system status and generate the system displays and reports. This is particularly
valuable for systems using modems of communications.
Communications watchdogs
The I/O PLEXER can be instructed to implement alarm and fail-safe states in the
event of a communication failure.
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Introduction 1
1 - 7
Specifications
Network Communications:
duTec supports several standards for transmitting serialized I/O data between the
Host computer and the I/O PLEXERs. In addition to hardwiring, built in modem
control lines allow the use of telephone, fiber optic, and radio modems at baud
rates of up to 38,400.
Maximum Distance
Serial Link Feet Meters
RS-232 50 15
RS-422 5,000 1,524
RS-485 5,000 1,524
Modem Unlimited Unlimited
In addition to network communications, a separate local RS-232 port, with the
same baud rate capabilities, provides the means for Host communications with
local serial devices such as keypads, printers, or displays. Actual interaction with
these devices is controlled via the Host computer in the form of character strings
embedded in standard protocol instructions.
It is not possible to directly access the analog and digital I/O data from the local
RS-232 Port. However this data can be obtained by the Host computer and
relayed to the auxiliary device connected to the local RS-232 port. Device pinout
for this port can be found on the cover plate. Data format is 8 Databits, 1-Stop
and no parity.
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Introduction 1
1 - 8
Physical Characteristics:
Power Standard 85-132Vac@30W (47-440Hz)
Option E, E5 105-256 Vac @23W/ 39W
(47-440Hz)
Option /B 10-16 VDC@35W
Option/C 18-36 Vdc @35W
Environment Temperature 0° -60°C
Humidity 95% non-Condensing
Package Type Stainless Steel
Length 17.25 in. (44 cm)
Width 5.0 in (12.7cm)
Height (w/ modules) 3.5 in. (8.9cm)
Weight 4 Pounds (1.8Kg)
Options /L Local Control Functions
/3+ Expansion ports for 3 digital
expanders
Ordering Information
Specify duTec products by model number:
IOP-AD I/O PLEXER for analog and digital signals
IOP-D I/O PLEXER for digital signals only
IOP-DE Digital expander chassis (Master must have 3+ option)
Options are specified by a series of suffixes to the model number, preceded by a
slash. For example:
IOP-AD/3+ Allows the use of up to three digital expanders on an analog
capable I/O PLEXER.
IOP-D/B Specifies a digital only I/O PLEXER with a 12VDC
Compatible power supply.
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Introduction 1
1 - 9
Available I/O Modules
Analog inputs, 12 Bit Analog Outputs, 12 Bit
Frequency Voltage
IF10K-B Input 300Hz-10Khz OV1 Output 0-1V, self sourcing
IF2.5K-L Input 0-2.5Khz 0v5 Output 0-10V, self sourcing
IF5K-L Input 0-5Khz 0v10 output 0-10V, self sourcing
IF10K-L Input 0-10 KHz
Voltage Current
IV25M Input 0-25mV 01420 Output, 4-20mA Self-Sourcing
IV50M Input 0-50mV into 275 Ohm Load.
IV100M Input, 0-100mV Digital Inputs
IV1 input 0-1V
IV5 Input 0-5 V AC
IV5B Input bi-polar ±5V IAC5 Input 90-140Vac
IV10 Input 0-10V IAC5A Input 180-280Vac
IV10B Input Bi-polar ±10V DC
IVAC Input 28-140 Vac IDC5D Input 3-32 VDC fast>500Hz
IVAC-A Input 56-280 Vac IDC5NP Input 10-32 Vdc, 15-32
Current Nonpolar
II420 Input 4-20 mAdc Digital Outputs
IIAC5 Input 0-5Aac AC
Thermocouple
ITCE Type E 0° to 435°C OAC5 Output 12-140 Vac, 3.5A
ITCJ Type J 0° to 700°C OAC5A Output 24-280Vac, 3.5A
ITCJ-1 Type J -80° to 750°C OAC5A5 Output 24-280Vac 3.5A NC
ITCK Type K -100° to 924°C
ITCK-1 Type K -110° to 1250° C OAC5J Output 20-280Vac, 6.0A
ITCR Type R 0° to 960° C DC
ITCR-1 Type R 0° to 1760° C ODC5 Output 5-60 Vdc, 3.5A
ITCS Type S 0° to 1034° C ODC5A Output 4-200Dc, 1.0A
ITCS-1 Type S 0° to 1760°C ODC5R Electro-Mechanical 0.5A Relay Form
A NO
ITCT Type T -200° to 224° C Special Purpose
ITCT-1 Type T -120° to 400° C IDC5S* Dry input contact sense, built in
ITCT-2 Type T 0° to 150° C isolated source
RTD
ITR100 100 Ohm PT -50° to 350°C IDC5Z* Input±200mV, 0-10Khz
ITR100-1 100 Ohm PT 0° to 100°C (digital)**
Type 590 Temperature Sensor SPS-1* Sensor power supply 18-24Vdc,
30mA
ITP590 -188.4° to 150°C TIO1 Digital Input/output Test Module
ITP590-1 -50.0° to 150°C with field switch and LED
* When Selecting A power supply for the Support Products
system, assume 25mA for standard digital Fuses
modules and 100mA for modules marked FMP-06 Fuse Assy 0.062A
With an * FMP-1 Fuse Assy, 1A
** The IDC5ZModule is used for low-level FMP-3 Fuse Assy, 3A
signals and wil
10Khz The I/O
Communicatio
l pass signals at the rate of
Plexer however is limited by
ns baudrate.
FMP-5 Fuse Assy 5A
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Introduction 1
1 - 10
Notes:
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Installation 2
2 - 1
Installation
Mounting:
In a wall mounted enclosure the I/O PLEXER can be mounted horizontally or
vertically. Horizontal installation is good practice as it makes the best use of
natural convection.
Figure 2-1 below shows the outline of the I/O PLEXER. Using the keyhole slots,
the unit can be mounted with 2-#10 screws on 16.5" centers. Using the corner
holes, the unit can be mounted with 4-#6 or #8 round head or pan head screws
located on a 3.5" X 16.5" grid. Hole locations in relation to the overall
dimensions are shown below. Both the I/O PLEXER and the digital expander
have the same mounting dimensions.
Figure 2-1 I/O Plexer footprint
Power Wiring:
Power connections are made at the 3 position terminal block located on the right
end of the I/O PLEXER. No. 8 captive wire clamps accept 10-16 AWG wire or
spade lugs. The terminal block cover need not be removed to install wiring.
2.25
17.25
16.5
3.5
5.0
.5 .375
Corner Mounting
4 #6-32 Screws
Slot Mounting
2 #10-24 Screws
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Installation 2
2 - 2
Figure 2-2 Power wiring
The center terminal block position, adjacent to the letter G on the end of the I/O
module board, is chassis/ earth ground which is connected to the I/O PLEXER
case.
Standard 85-132 VAC, 47-440 Hz and option /E5 105-265 VAC 47-440Hz
Operation.
Following power wiring conventions(AWG)
Black wire to terminal marked H (hot)
White wire to the terminal marked N (neutral)
Green wire to the terminal marked G (chassis/ earth ground)
Option /B or /C 10-30 VDC Operation
+ of the power source to the terminal marked H
- of the power source to the terminal marked N
Earth Ground, where available to the terminal marked G
Digital Expander
The I/O PLEXER Digital Expander (IOP-DE) Receives its power and signals
from the I/O PLEXER via the included 24 pin keyed ribbon cable (duTec part
#CE-24) No other power wiring is required. See page 2-14
I/O Plexer Power supply
terminal block
AC Wiring DC Wiring
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Installation 2
2 - 3
Designing the network
In order for the I/O PLEXER to share its data with the Host computer, it must be
linked via a serial connection. This link can be hard-wired using an RS-232 link
(less than 50 Ft), or an RS-422/ 485 twisted pair connection where the wire run
between devices is less than 5000 Feet. In situations where distances are greater
than 5000 feet or circumstances do not allow additional wire to be installed; RS-
232 Radio or telephone modems may be used. In any event, the appropriate
transmitter of the I/O PLEXER will be connected to a suitable receiver of the
Host computer as shown in figure 2-3
Figure 2-3 Typical installation
Multiple I/O PLEXER Master chassis can be networked together to service large
numbers of I/O Points.
Serial
Link
I/O P
LEXER
Outputs
Inputs
Stri p Ch art
Temper ature
Lamp
Meter
Level Switch
A
larm
Dial
HOST
P. C .
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Installation 2
2 - 4
The serial communications link between a Host computer and a network of I/O
PLEXERs can use various combinations of 3 wire shielded RS-232, dual twisted
pair (plus recommended ground shield) RS-422, or single twisted pair (plus
recommended ground shield) RS-485.
The Host to first I/O PLEXER can be any of the three, but because most Hosts
are equipped with an RS-232 port. This is used most often providing the distance
is less than 50 feet. For greater distances, up to 5000 feet, a choice must be made
to either equip the Host with an RS-422 or RS-485 card, or use an external RS-
232 range extender such as the duTec BaudMaster.
If the Host to first unit link is RS-232, the balance of a network, if any, can be a
mixture of RS-422 and/or RS-485.
If the Host to first link is either RS-422 or RS-485. The balance of the network, if
any, can be a mixture of RS-422 and/or RS-485.
For total wire runs less than 5000 feet, both RS-422 and RS-485 networks can
operate in multidrop mode. In this configuration every unit attached to the Host
computer is passively connected to the network. The benefit to this is that the
loss of power to any unit on the network does not affect the ability of other units
to respond to the Host computer. A drawback to this approach is that the total
length of a multidrop segment can only be 5000 feet.
For ranges greater than 5000 feet, some or all of the I/O PLEXERs can operate in
the repeat mode. In this mode, the unit plays an active roll in broadcasting the
communications signals. The length of each network segment connected to a unit
in the repeat mode can be up to 5000 feet. The limitation of the repeat mode is
that a power failure of any single unit disables communications for all units
further “downstream” from the Host.
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Table of contents
