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.