Dutec I/O Plexer Repeater User manual

Repeater
MANUAL

I/O Plexer Repeater January 2005
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 and I/O Plexer Repeater are trademarks of duTec
inc.
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.

I/O Plexer Repeater January 2005
Overview .............................................................. 1-1
Capacity .......................................................1-1
Compatibility ...................................................1-1
Communications.................................................1-2
Response Time ..................................................1-2
EasySetup .....................................................1-2
Built in Diagnostics ..............................................1-3
Communications Watchdogs .......................................1-3
Ungradable ..................................................... 1-3
Available I/O Modules ............................................1-4
PhysicalCharacteristics ................................................... 1-4
Power .........................................................1-5
Environment .................................................... 1-5
Package........................................................ 1-5
OrderingInformation ..................................................... 1-5
Options ........................................................ 1-5
Installation ............................................................. 2-1
Mounting ...................................................... 2-1
PowerWiring ................................................... 2-1
DigitalExpander................................................. 2-2
LinkingthetwoI/OPlexerRepeaters ........................................ 2-3
LinkviaRS-485 ................................................. 2-4
LinkviaRS-422 ................................................. 2-5
Linkviamodem ................................................. 2-6
AddingDigitalExpanders ......................................... 2-7
Installing the I/O Modules .................................................2-8
Analogoutputs .................................................2-15
Digital Inputs ..................................................2-16
Digitaloutputs ................................................. 2-17
ChassisSetup ........................................................... 3-1
Baudrate ...................................................... 3-1
Setuppushbutton ................................................3-1
Sequentialdisplay................................................3-1
Input/outputseparators ........................................... 3-2
BaudRates ..................................................... 3-3
Networktypeswitch.............................................. 3-3
ModemJumpers ................................................. 3-3
Changingsetupparameters ................................................ 3-3
Unitnumber .................................................... 3-3
Pushbutton ..................................................... 3-3

Table of Contents
Sequentialdisplay ............................................... 3-4
CommunicationVerification ............................................... 3-5
Hardwareerrorcodes ..................................................... 3-5

Introduction 1
1 - 1
Overview:
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 a pair of I/O Plexer Repeaters and a single communications circuit.
Often called “wire savers” or “Cable concentrators” I/O Plexer Repeaters replace expensive
and noise prone long distance wire runs.
One I/O Plexer repeater concentrates sensor signals into serial data. The other recreates the
individual signals at a second location. Special firmware eliminates the need for a host
computer. Data flow is bi-directional, meaning that signals can be passes in either direction.
Data checksumming is automatically employed to ensure data integrity.
Capacity:
One pair of I/O Plexer Repeaters can interface 16 analog and digital signals in any
combination. With optional digital expanders, up to 48 more digital signals can be added for a
total of 64 I/O channels.
Compatibility:
I/O Plexer Repeaters 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 resistance 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.

Introduction 1
1 - 2
I/O Plexer Repeaters can be used to convert signals from one type to another. For example, a
thermocouple at the remote site can be converted to a standard process current (4-20mA)
signal at the local site.
Communications:
DuTec supports several standards for transmitting serialized I/O data between I/O Plexer
repeaters. In addition to hard wiring, built in modem control lines allow the use of telephone,
fiber optic, and radio modems at baud rates 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
Response Time:
Under full load (sixteen analog and 48 digital signals), the average response time between an
input event and resulting output is less than 250mS @9600 Baud.
Easy Setup:
The I/O Plexer Repeater has its own power supply, no need to purchase or reserve space for
an external supply. A push-button and on board LED indicator configure the baud rate and
Input/ Output separators. Removable terminal strips allow the attachment/ removal of
multiple cable sets in one step. This modularity greatly reduces troubleshooting and upgrade
delays.

Introduction 1
1 - 3
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 onboard hardware watchdog provides safe shutdown by turning
off all outputs.
Communications Watchdogs:
The I/O Plexer Repeater can be instructed to implement alarm and failsafe states in the event
of a communication failure.
Ungradable:
If the application evolves to a centralized or distributed control network, I/O Plexer Repeaters
can be returned to the factory to be converted into standard I/O Plexers for a fraction of the
cost of a new unit. This means that the I/O Plexer Repeater hardware can be “recycled” into a
fully compatible I/O system for use with a standard MMI or SCADA package.

Introduction 1
1 - 4
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 IDC5Z Module 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
Physical Characteristics:

Introduction 1
1 - 5
Power Standard 85-132 VAC @30W
(47-440 Hz)
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 3.5 in. (8.9cm)
Weight 4 lbs. (1.8kg)
Ordering Information:
Specify duTec products by model number e.g.,
IOP-RAD I/O Plexer repeater for analog and digital signals
IOP-RD I/O Plexer repeater for digital signals only
Options are specified by a series of suffixes to the model number, preceded by a slash. Power
supply options are noted above. To expand signal capacity beyond 16, the following options
allow the use of the I/O Plexer repeater with digital expanders. For example,
IOP-RAD/3+ Allows the use of one to three digital expanders on an analog capable I/O
Plexer repeater.
IOP-RD/B Specifies a digital only I/O Plexer Repeater with a 12 VDC compatible power
supply.

Introduction 1
1 - 6

Installation 2
2 - 1
Installation:
In a wall mounted enclosure the I/O Plexer Repeater 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 Repeater. 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
repeater 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 Repeater. 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

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 Repeater 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 Repeater Digital Expander (IOP-DE) Receives its power and signals from the
I/O Plexer Repeater via the included 24 pin keyed ribbon cable (duTec part #CE-24) No other
power wiring is required.
I/O Plexer Repeater Power supply
terminal block
AC Wiring DC Wiring

Installation 2
2 - 3
Linking the two I/O Plexer Repeaters:
In order for two I/O Plexer Repeaters to share their data, they must be linked via a serial
connection. This link can be hard-wired using either an RS-422 or RS-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 Repeater will be connected to a suitable receiver of the other I/O
Plexer Repeater as shown in figure 2-3.
Figure 2-3 Communications link
Serial
Link
IOP-RAD
IOP-RAD
Outputs
Inputs
Inputs
Outputs
Stri p Chart
Temperature
Lamp
Meter
Level Switch
Alarm
Dial
Tx
Tx Rx
Rx

Installation 2
2 - 4
Link via RS-485
Figure 2-4 Link via RS-485
Figure 2-4 shows one individually shielded twisted pairs of AWG 24 (such as Belden 8162)
with the shields connected between unit grounds. The overall isolated shield should be
connected to ground in one place only. In a perfect world with no electrical noise and equal
ground potentials everywhere the ground connection is not required. Not using the ground
connection can lead to costly debugging.
These connections, which require the cover to be removed, are made by placing a 1/4 inch
stripped wire into the openings of the wire clamp terminal block and tightening the screw.
This block is socketed for easy removal.
An alternative means for network connection is to use the 10 pin male connector located
behind the clamp terminal block. This connector mates with Molex shell, number 50-57-9005,
and used pins, 16-02-0103
In addition to the Host to I/O Plexer Repeater wiring the installer should confirm that the 8
switches are set in the correct positions (all on or up). In all cases, the switches marked “pull-
up” in the diagram in page 3-1 should be left in the “on” position.

Installation 2
2 - 5
Link via RS-422
Figure 2-5 Link via RS-422
Figure 2-5 shows two individually shielded twisted pairs of AWG 24 with an overall isolated
shield (such as Belded 8162) with the internal shield connected between unit grounds. The
overall isolated shield should be connected to earth ground in one place only. In a perfect
wold with no electrical noise and equal ground potentials, the signal ground connection would
not be required. Not connecting signal ground however, frequently leads to costly debugging.
These connections, which require the cover to be removed, are made by placing a 1/4 inch
stripped wire into the openings of the wire clamp terminal block and tightening the screw.
This block is socketed for easy removal.
An alternative means for network connection is to use the 10 pin male connector located
behind the clamp terminal block. This connector mates with Molex shell, number 50-57-9005,
and used pins, 16-02-0103
In addition to the serial link wiring the installer should confirm that the 8 switches are set in
the correct positions (on or up). The switches marked”pull-up” in the diagram on page 3-1
should be left in the “on” position.

Installation 2
2 - 6
Link via modem:
Figure 2-6 Link via Modem
Two handshake control lines are provided on the I/O Plexer Repeater for interfacing to
modems. They are request to send (RTS) and Clear to send (CTS).
An active high RTS signal from the I/O Plexer Repeater advises the modem that data is
available. When the modem is ready to accept data, it places its CTS line active high to the
I/O Plexer Repeater thus initiating the data exchange.
In addition to the modem to I/O Plexer Repeater wiring the installer should confirm that JP3
(RTS/CTS Jumper) is positioned as shown in figure 2-10. Jumper JP5 (RTS/CTS for the local
RS-232 port), should remain in the horizontal position unless the RTS/CTS pair is needed in
the device connected to the local RS-232 port. A cable for most modem applications, the IOP-
RT cable, is available from duTec.
The switches marked “Pull up” in figure 3-1 should be left in the “on” position.

Installation 2
2 - 7
Adding Digital Expanders:
Figure 2-15 Digital Expanders
Up to three Digital expanders may be connected to each side of an I/O Plexer Repeater
system. These chassis are attached to the main unit via a ribbon cable supplied with the
Digital Expander. Normally, power is supplied through this cable. In some circumstances,
however, the Digital Expander is purchased with an optional power supply. If so equipped,
the installer must provide the necessary power connections as well (see page 2-2).
Digital expanders are configured during the main chassis’ normal setup procedure.

Installation 2
2 - 8
Installing the I/O Modules:
The I/O Plexer Repeater system is made up of a communications link with an I/O system
located at each end. At one end of this link is a main I/O chassis designated UNIT O at the
other end there is a similar I/O chassis designated UNIT1. Installed on these chassis are
individual I/O Modules designed to handle analog or digital, input or output signals. For every
analog input located on UNIT O, there is a corresponding analog output on UNIT 1 and vise
versa. Naturally this is true for digital modules as well.
In addition to the main I/O chassis, an I/O Plexer Repeater system may include additional I/O
chassis called digital expanders. These chassis allow up to 48 additional digital only I/O
signals to be transmitted over the serial link.
When installing the system, place the chassis designated UNIT O in the location having
the most output signals.
Certain guidelines must be followed when installing I/O modules on the I/O Plexer repeater
chassis. In particular the inputs must be grouped separately from the outputs on each I/O
chassis. Using the worksheets found in the next four pages, place the desired I/O modules in
the indicated positions.
The following worksheets will be used when setting the necessary input/ output separator for
UNIT O.

Installation 2
2 - 9
UNIT O Main Chassis UNIT 1 Main Chassis
Mod # Input/
Output
Module PN Mod # Output/
Input
Module PN
00
11
22
33
44
55
66
77
88
99
10 10
11 11
12 12
13 13
14 14
15 15
1) Install all analog input modules for UNIT O beginning with module #0 then #1
and so on. If none were used, skip this step.
2) Install all digital input modules for UNIT O beginning with the next available
module position. If none are used, skip this step.
3) Repeat step 2 for the analog output and digital output modules.
4) Install the modules in UNIT 1 which are to be matched with those in UNIT O. Be
sure that each input in UNIT O is paired with a corresponding output in UNIT 1.
Likewise for the outputs.