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Dutec Basic I/O Product Hardware Manual

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  • Page 2 Basic I/O Product Family NOTICE: This document contains two separate users manuals. The first section should be used for the BIO4, BIO8, and BIO16 products. The second section should be used for the BIO4AD, BIO8AD, and the BIO16AD products. If you find that you have any questions with the setup or installation of any duTec...

  • Page 4: Table Of Contents

    Vol.1 The Basic I/O ............1 - 1 ANALOG INPUTS .
  • Page 5 Vol. 1 Communication verification ..........2 - 18 Hardware error codes .

  • Page 6: Vol.1

    The Basic I/O 1 THE BASIC I/O: BASIC I/Os are a family of small, industrial grade, remote data acquisition and control systems which exchange data with a Host computer via a serial communications link. Controlled by a wide range of software running on a Host computer, Basic I/Os are located near the sensors and actuators.

  • Page 7: Analog Inputs

    A notable feature of the BASIC I/O is its ability to gather data and perform ranging and statistical operations on raw data before it is sent to the Host. The Host can thus spend less time manipulating data and more time gathering it. The following sections discuss the different signals the BASIC I/O can handle.

  • Page 8: Analog Outputs

    ANALOG OUTPUTS: Analog output modules are 100% isolated. These self-sourcing modules provide the voltage or current necessary to drive standard instrumentation loads. All are updated every 10 Ms, or 100 times per second. Analog output instruction types are: Level Value Waveforms Can set output levels, as a fraction of the module’s full scale range, and are specified with 12 bit (1 part in 4096) resolution.

  • Page 9: Digital Inputs

    DIGITAL INPUTS: Digital input modules detect the presence or absence of a field signal. Module types vary from AC to dry contact sense. Because the industry standard modules are optically isolated, the response time performance of digital input instructions can be limited by the delay in the input modules themselves.

  • Page 10: Digital Outputs

    DIGITAL OUTPUTS: Digital output modules, commonly referred to as solid state relays, control external AC or DC power sources. A dry-contact (mechanical relay) with very low contact resistance is also available. Digital output instruction types are: Set outputs Pulse Generator Modifiers: One Shot Delayed...

  • Page 11: System Throughput

    SYSTEM THROUGHPUT: Input data throughput is the time from beginning of the first character of an input instruction to the end of the last character of the response. The processing time of the Host computer will affect the effective throughput. Output Execution throughput is the time from the beginning of the first character of an instruction until the actual output changes.
  • Page 12 It should be noted that the values in the preceding throughput tables and the following equations reflect only the communications overhead and inherent processing delay of the BASIC I/O equipment. In practice, a significant amount of overhead will be devoted to other processing tasks such as screen updates, Data logging, etc...

  • Page 13: Communication Protocol

    The Basic I/O 1 COMMUNICATION PROTOCOL: The BASIC I/O Communication Protocol is 100% compatible with the Opto-22 Optomux™ protocol. This ASCII printable serial protocol uses a “speak-only-when-spoken-to” format where only the host can initiate an information exchange. Each BASIC I/O unit installed in a network has a unique address.

  • Page 14: Available I/O Modules

    ANALOG INPUTS, 12 BIT Frequency IIF10K-B Input 300Hz -10KHz IF2.5K-L Input 0-2.5KHz IF5K-l Input 0-5KHz IF10K-L Input 0-10KHz Voltage IV25M Input 0-25mV IV50M Input 0-50mV IV100M Input 0-100mV Input 0-1V Input 0-5V IV5B Input Bipolar +/-5V IV10 Input 0-10V IV10B Input Bipolar +/-10V IVAC Input 28-140Vac...

  • Page 15: Diagnostics

    DIAGNOSTICS: To confirm internal operations and communications link integrity, a set of built-in diagnostics test key system functions each time power is applied. Diagnostics reduce both installation debugging and operation troubleshooting. A hardware watchdog timer insures safe shutdown in the event of processor or software failures by turning all outputs OFF.

  • Page 16: Product Test

    PRODUCT TEST Every BASIC I/O is burned-in at 70 °C while operating in a network for a period of 24 hours prior to shipment. Every analog I/O module is operated and tested while it’s ambient operating temperature is cycled over the specified operating range of 0°C to 60°C for a period of 24 hours. BASIC I/O Models: BIO4 4 Position BASIC I/O Unit Includes SLB Logic Board and SMB4 Module board...
  • Page 17 The Basic I/O 1 NOTES 1-12(Vol.1)

  • Page 18: Mounting

    Setup & Installation 2 MOUNTING: BASIC I/Os come in 4, 8, and 16 channel versions. Figure 2-1 below shows the footprint of each BASIC I/O. Using corner holes, the unit can be mounted with 4- #6 or #8 round head or pan head screws.

  • Page 19: Power Wiring

    POWER WIRING: Power connections are made at the 2 position terminal block located on the module board marked +5V and GND No. 8 captive wire clamps accept 10-16 AWG wire or spade lugs. +5V GND Power wiring conventions: + of the power source to the +5V terminal - of the power source to the terminal marked GND Power requirements Voltage: 5.0- 5.4Vdc...

  • Page 20: Communicating With The Basic I/O

    Setup & Installation 2 COMMUNICATING WITH THE BASIC I/O: The BASIC I/O is designed to serve as an intelligent I/O front end for a Host computer (Typically a P.C.). The host and BASIC I/O communicate over a serial link. This interchange is half-duplex in nature;...

  • Page 21: Multidrop

    BASIC I/Os can be networked together to obtain up to 4096 I/O points of data. These serial networks can be either multidrop or repeat. Figure 2-3 Multidrop V.S. Repeat networks Multidrop: Multidrop networks can be up to 5000 ft long end-to-end. Each station is passively located on the network and represents one “Drop”...

  • Page 22: Rs-422

    The serial communications link between a Host computer and a network of BASIC I/Os is made up of either a single (RS-485 half-duplex) or Dual (RS-422 full duplex) shielded twisted pair (s) of wires whose shields are connected to a signal common conductor. This communications link should in turn have an overall shield which is isolated from the signals (including signal ground) and connected to earth or chassis ground at one location.

  • Page 23: Rs-485 Programming

    RS-485 Programming: The BASIC I/O will work equally well when connected to either RS-422 or RS-485. However special host programming considerations may be necessary when implementing an RS-485 network. Unlike RS-422 where both the transmit and Receive signals have their own differential pair of conductors, RS-485 utilizes only one differential pair.

  • Page 24: Communication Wiring

    Setup & Installation 2 approximate time necessary to transmit the entire instruction before the RS-485 driver is disabled. Since the BASIC I/O can respond very quickly to the instruction, the Host must disable the driver as soon as possible in order to receive the BASIC I/Os response. RS-485 communications can be tricky at best and should be seriously considered before being adopted.

  • Page 25: Network Load V.s. Noise Suppression

    Setup & Installation 2 Network load V.S. Noise suppression: In order to improve RS-485 Bus noise immunity, particularly under tri-state conditions, a pair of “Network Bias Resistors” have been installed in each BASIC I/O unit. This design feature has been implemented in order to satisfy the majority of our customers. If it is necessary to multidrop more than eight BASIC I/O units(but ultimately less than thirty-two devices), It will be necessary to remove these network bias resistors so as to not exceed the maximum bus loading.

  • Page 26: Rs-422 Host To Basic I/O

    Setup & Installation 2 RS-422 HOST TO BASIC I/O: Figure 2-5 RS-422 Host to BASIC I/O wiring Figure 2-5 shows two individually shielded twisted pairs of AWG 24. Each pair has a ground wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 27: Basic I/O To Basic I/O Rs-422

    Setup & Installation 2 BASIC I/O TO BASIC I/O RS-422 MULTIDROP OR REPEATER Figure 2-6 RS-422 BASIC I/O-To-BASIC I/O multidrop Figure 2-6 shows two individually shielded twisted pairs of AWG24. Each pair has a drain wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 28: Rs-485 Host To Basic I/O

    Setup & Installation 2 RS-485 Host to BASIC I/O: Figure 2-7 RS-485 To-BASIC I/O Figure 2-7 shows one individually shielded twisted pair of AWG 24. Each pair has a drain wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 29: Basic I/O To Basic I/O Rs-485 (Multidrop Only)

    Setup & Installation 2 BASIC I/O to BASIC I/O RS-485 (Multidrop only): Figure 2-8 RS-485 BASIC I/O to BASIC I/O Multidrop Figure 2.8 shows one individually shielded twisted pair of AWG 24. Each pair has a ground wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 30: Basic I/O Setup

    Setup & Installation 2 BASIC I/O setup: BASIC I/O setup is accomplished with a sequential display and pushbutton. Below is a diagram of the location of these components.: Figure 2-9 BASIC I/O Connectors, Switches and Indicators. Unit type (digital or analog), Unit address, baud rate, and 2 or 4 pass protocols are all pushbutton configurable and appear on the sequential display.

  • Page 31: Analog/ Digital

    Setup & Installation 2 Analog/ Digital: The BASIC I/O system must be configured to accept either Analog or Digital I/O modules. The current I/O type is displayed on the sequential display and is indicated by the character following the “U”. The unit will display a”1" if the unit is configured as digital and a”2" if the unit is analog.

  • Page 32: Protocol Handshake Types

    Protocol Handshake Types: Two protocol handshake types are available, 2 pass and 4 pass. 2 Pass: The host transmits an instruction to a BASIC I/O. If the instruction is correctly received (i.e. valid address, instruction type and correct checksum) the BASIC I/O executes the instruction and returns the letter “A”...

  • Page 33: Network Type Switch

    Network Type Switch: Based upon the selected network configuration, each BASIC I/O must be setup before communications can begin. This is done with the network switches shown below. The three basic communication connections for individual BASIC I/Os are: L1 Repeater Used in RS-422 networks to extend range to5000 feet between units L2 Multidrop...
  • Page 34 Setup via Pushbutton: The pushbutton, located on the logic board (see figure 2-9) is used to configure the unit address, baudrate, and network pass type. During the diagnostic test period following the application of power, the sequential display shows “GO GO GO GO GO / “ Pumping the pushbutton once while the / appears, places the unit in the setup mode.

  • Page 35: Communication Verification

    Setup & Installation 2 Communication verification: Network Debugging: Most startup problems are related to the communication link. The installer is urged, after both the communications wiring and configuration have been completed, to test the network before installing I/O modules. To test the serial communications link, the host transmits the abbreviated test instruction: >NNA?? For each BASIC I/O address on the network, where NN is the address of each BASIC I/O.

  • Page 36: Hardware Error Codes

    Setup & Installation 2 Hardware error codes: When the BASIC I/O is initially powered up, it goes through an internal self test. If any of the self-diagnostics fail, the unit will report an appropriate error code on the sequential display and halt.

  • Page 37: Analog Inputs

    Setup & Installation 2 Analog Inputs: Note: analog modules normally run hot to the touch. Correct polarity connections are essential to proper operation of all the analog inputs. Connections to terminals marked with a + must be more positive than the terminals marked with a -.
  • Page 38 Setup & Installation 2 Figure 2-11 Analog Voltage and Current input Wiring Figure 2-12 Temperature Input Wiring 2-21(Vol.1)

  • Page 39: Analog Outputs

    Setup & Installation 2 Analog outputs: Modules should NEVER be installed or removed while power is applied to the BASIC I/O. Following insertion in their respective sockets, modules should b secured with their captive screw. Correct polarity is essential to proper operation. Note: Analog modules run hot to the touch.

  • Page 40: Digital Inputs

    Setup & Installation 2 Digital Inputs: Modules should never be installed while power is applied to the BASIC I/O. With the exception of IDC5S digital input modules, input sensing current comes from a source external to the BASIC I/O. IDC5S input modules provide their own current for sensing contact closures.

  • Page 41: Digital Outputs

    Setup & Installation 2 Digital Outputs: Modules should NEVER be installed or removed while power is applied to the BASIC I/O. The power for ODC5, ODC5A, OAC5, and OAC5A digital output modules comes from a source external to the BASIC I/O. Because they contain a protective reverse diode, the ODC5 and ODC5A output modules are polarity sensitive and operate correctly only when the + terminal is positive with respect to the - terminal.
  • Page 42 Vol.1 Index 2 Pass ............2 - 15, 2 - 17 4 Pass .
  • Page 44 BASIC I/O AD Copyright: Copyright 1995- 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.
  • Page 45 Vol 2 Overview ............. . 1 - 1 Capacity .
  • Page 46 Vol 2 RS-485 Host to BASIC I/O AD ........2 - 11 BASIC I/O AD TO BASIC I/O AD RS-422 .

  • Page 47: Overview

    Introduction 1 Overview BASIC I/O ADs are a family of small, industrial grade, remote data acquisition and control systems which exchange data with a Host computer via a serial communications link. Controlled by a wide range of software running on a Host computer, BASIC I/O ADs are located near the sensors and actuators.

  • Page 48: I/O Signal Compatibility

    I/O signal compatibility: BASIC I/O ADs 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: A full range of industry standard digital modules are available for AC, DC, and dry contact inputs and outputs to hundreds of volts.

  • Page 49: Protocol Compatibility

    Protocol Compatibility: The BASIC I/O AD instruction set core complies 100% with that of the OPTO- 22 Optomux ™ . With this ASCII character, speak-only-when-spoken-to protocol, a Host transmits inquiry requests to the BASIC I/O AD to determine the status of its various process inputs. Similarly, the software in the Host computer makes control decisions and transmits instructions to the BASIC I/O AD, which in turn, makes the proper changes to its various outputs.

  • Page 50: Available I/O Functionality

    Available I/O functionality: Input value Offsets Gain/ Slope Range Limits Minimums Maximums Averages Temperature Level Value Waveforms Analog Input Functions Determines signal levels, with 12 bits resolution Input values can be software offset, with 12 bits resolution, over the module’s specified range. The amplitude of input values can be software multiplied by factors ranging from 0.25 to 4.0.
  • Page 51 Read Pulse widths Pulse counting Edge detection Note: The response time performance of digital input instructions can be limited by the delay in the input modules themselves which can nave on plus off delays of up to 40 mSec. Set Outputs One Shot Delayed Digital inputs...
  • Page 52 Squarewave Pulse Generator Extended capabilities: In addition to operating under the control of a host, Option/L of the BASIC I/O AD has the ability to perform local control functions without the host. Local control functions (LCFs) can insure the continued safe operation of closed loop control should the host of its communication link fail.
  • Page 53 Network Communications: duTec supports two standards for transmitting serialized I/O data between the host computer and the BASIC I/O ADs at baud rates to 38,400. Serial Link RS-422 /485 Physical Characteristics: Power Environment Options Specify duTec products by model number, e.g., BIO4AD BIO8AD BIO16AD...

  • Page 54: Digital Outputs

    ANALOG INPUTS, 12 BIT Frequency I F10K-B Input 300Hz-10KHz IF2.5K-L Input 0-2.5KHz IF5K-l Input 0-5KHz IF10K-L Input 0-10KHz Voltage IV25M Input 0-25mV IV50M Input 0-50mV IV100M Input 0-100mV Input 0-1V Input 0-5V IV5B Input Bipolar +/-5V IV10 Input 0-10V IV10B Input Bipolar +/-10V IVAC Input 28-140Vac...

  • Page 55: Installation 2

    Installation 2 Installation Mounting: BASIC I/O ADs come in 4, 8, and 16 channel versions. Figure 2-1 below shows the footprint of each Basic I/OAD. Using corner holes, the unit can be mounted with 4- #6 or #8 round head or pan head screws. The BIO16 version has two additional mounting holes located near the center of the board as well.

  • Page 56: Power Wiring

    Power Wiring: Power connections are made at the 2 position terminal block located on the module board marked +5V and GND No. 8 captive wire clamps accept 10-16 AWG wire or spade lugs. Power wiring conventions: + of the power source to the terminal marked +5V - of the power source to the terminal marked GND Power requirements Voltage:...

  • Page 57: Designing The Network

    In order for the BASIC I/O AD 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-422 dual twisted pair or an RS- 485 single twisted pair connection where the wire run between devices is less than 5000 feet. In any event, the appropriate transmitter of the BASIC I/O AD will be connected to a suitable receiver of the host computer.
  • Page 58 RS-422: Advantages: Easier to implement in software since host driver need not be controlled. Can be either Multidrop or Repeat. No turn-around delay required. Disadvantages: Requires five conductor wire instead of three. RS-485: Advantages: Needs only 3 wire conductor. Disadvantages: Host 485 driver control must be implemented requiring tricky serial port manipulations.

  • Page 59: Rs-485 Programming

    RS-485 Programming: The BASIC I/O AD will work equally well when connected as RS-422 or RS-485. However special host programming considerations may be necessary when implementing an RS-485 network. Unlike RS-422 where both the transmit and Receive signals have their own differential pair of conductors, RS-485 utilizes only one differential pair.

  • Page 60: Communication Wiring

    Installation 2 This interaction is heavily dependant on asynchronous timing. Usually, the Host software has no real means of determining that the instruction has been completely sent. This means that the program must calculate the approximate time necessary to transmit the entire instruction before the RS-485 driver is disabled.

  • Page 61: Network Load V.s. Noise Suppression

    Installation 2 Network load V.S. Noise suppression: In order to improve RS-485 Bus noise immunity, particularly under tri-state conditions, a pair of “Network Bias Resistors” have been installed in each BASIC I/O AD unit. This design feature has been implemented in order to satisfy the majority of our customers. If it is necessary to multidrop more than eight BASIC I/O AD units(but ultimately less than thirty- two devices), It will be necessary to remove these network bias resistors so as to not exceed the maximum bus loading.

  • Page 62: Network Type Switches

    Installation 2 Network Type Switches Based upon the selected network configuration, each BASIC I/O AD must be setup before communications can begin. This is done with the network switches shown in figure 2-3. Figure 2-3 BASIC I/O AD Connectors, Switches and Indicators. 2-8(Vol.2)

  • Page 63: Last Unit

    The three basic communication connections for individual BASIC I/O ADs are: Repeat Used in RS-422 networks to extend range to 5000 feet between units. Sequential Display reads L1 Multidrop Used in RS-422 or RS-485 networks. Provides a total network range of 5000 feet. Display reads L2 Last Unit Must be used in RS-422 and RS-485...

  • Page 64: Communications Wiring

    Installation 2 Communications Wiring Host to BASIC I/O AD-RS-422: Figure 2-7 RS-422 Host to BASIC I/O AD Figure 2-7 shows two individually shielded twisted pairs of AWG 24. Each pair has a ground wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 65: Rs-485 Host To Basic I/O Ad

    Installation 2 RS-485 Host to BASIC I/O AD: Figure 2-8 RS-485 To-BASIC I/O AD Figure 2-8 shows two individually shielded twisted pairs of AWG24. Each pair has a drain wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 66: Basic I/O Ad To Basic I/O Ad Rs-422

    Installation 2 BASIC I/O AD TO BASIC I/O AD RS-422 Figure 2-6 RS-422 BASIC I/O AD-To-BASIC I/O AD Figure 2-6 shows one individually shielded twisted pair of AWG 24. Each pair has a drain wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 67: Basic I/O Ad To Basic I/O Ad Rs-485

    Installation 2 BASIC I/O AD to BASIC I/O AD RS-485 Figure 2-8 RS-485 BASIC I/O AD to BASIC I/O AD Figure 2.8 shows one individually shielded twisted pair of AWG 24. Each pair has a ground wire connected to its shield. These drain wires are then connected to the signal grounds at each unit.

  • Page 68: Modules

    Installing the I/O modules: Certain guidelines must be followed when installing I/O modules on the BASIC I/O AD Chassis. In particular the analog modules must be grouped separately from the digital modules on each I/O chassis. Using the worksheets found on the next page, place the desired I/O modules in the indicated positions.

  • Page 69: Module Wiring

    Installation 2 Module Wiring Analog Inputs: Modules should NEVER Be installed or removed while power is applied to the BASIC I/O AD. Following insertion in their respective sockets, modules should be secured with the captive screw. Note: Analog Modules Normally Run hot to the touch Correct polarity connections are essential to proper operation of all the analog inputs.
  • Page 70 Installation 2 Figure 2-12 Analog Voltage, frequency and Current input Wiring Figure 2-13 Temperature Input Wiring 2-16(Vol.2)

  • Page 71: Analog Outputs

    Installation 2 Analog outputs: Modules should NEVER be installed or removed while power is applied to the BASIC I/O Note: Analog modules run hot to the touch. Both voltage and current output modules provide their own isolated power output. This eliminates the need for external power supplies and insures electrical isolation between each output.

  • Page 72: Digital Inputs

    Installation 2 Digital Inputs: Modules should never be installed while power is applied to the BASIC I/O AD. With the exception of IDC5S digital input modules, input sensing current fomes from a source external to the BASIC I/O AD. IDC5S input modules provide their own current for sensing contact closures.

  • Page 73: Digital Outputs

    Installation 2 Digital Outputs: Modules should NEVER be installed or removed while power is applied to the BASIC I/O The power for ODC5, ODC5A, OAC5, and OAC5A digital output modules comes from a source external to the BASIC I/O AD. Because they contain a protective reverse diode, the ODC5 and ODC5A output modules are polarity sensitive and operate correctly only when the + terminal is positive with respect to the - terminal.

  • Page 74: Chassis Setup

    Setup 3 Chassis Setup Figure 3-17 Connectors, Switches, and Indicators During the setup phase of a BASIC I/O AD system, the chassis is given specific values for unit address, analog/ digital separator, network baud rate, and protocol pass type. A momentary pushbutton and seven segment display provide access to these parameters.

  • Page 75: Sequential Display

    Function Master Unit Control Master Unit Digital I/O Master Unit Analog I/O The OFFSET addressing mode is more convenient to use as only one address setup is required for each network connection. For example changing the master unit control MC, from 00h to 03h will automatically cause MD=43h;...

  • Page 76: Baud Rate

    Baud Rates: Any One of the standard baud rates of 300, 600, 1200, 2400, 4800, 9600, 19200, or 38400 can be used for the serial network communications. The sequential display indicates the letter H followed by the baud rate divided by 100. Basic I/Os are shipped at 9600 baud; the sequential display indicates H096.

  • Page 77: Changing Setup Parameters

    Setup 3 Changing Setup Parameters Via Pushbutton: During setup the user may need to change the unit address, serial link, baud rate, and protocol pass type. The pushbutton located under the removable cover is used to change these parameters. The pushbuton causes the ajacent red LED to flash each time it is pushed. Any changed values are automatically saved in non-volatile EEPROM.

  • Page 78: Communication Verification

    Setup 3 The display continues to cycle through this sequence until there is a full cycle with no changes. The BASIC I/O AD then stores all values in EEPROM for automatic use following the next power cycle. The unit is now in the operational mode and the sequential display cycle becomes*: U0=00 U1=40 U2=80...
  • Page 79 Setup 3 Hardware error codes: When the BASIC I/O AD is initially turned on it goes through internal self testing. If anything is not correct, the appropriate error code will flash on the sequential display. Try cycling power, if that does not resolve the error condition please call duTec technical support at 800-248-1632.

  • Page 80: Mounting

    Vol.2 Index Analog Inputs ........... . . 1 - 8, 2 - 15 Analog outputs .
  • Page 81 Vol.2 Index...

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