DL05/06 High-Speed Counter
Contents
1. Sensing ce O A www automationdirect com dlO5and06 O Pulse output schematic 5 to 36VDC __ CE Yc CTRIO Output O Yn where n 0 1 Set the module jumpers to Hi Common position when switching the high side of a DC load Load 5 to 36VDC __ Load EO oloofo o ofoofo o eefe eojeelo O Common gt Yn where n 0 1 CTRIO O utput yc Set the module jumpers to LO Common position when switching the low side of a DC load Stepper servo drive wiring example Pulse Direction Step Amplifier For this wiring example the module jumpers should be set to the LO Common position 4lgl glaz lololw w Z OUT eefe eofeelo LO Common gt PLC Produds 2 63 PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field I O Software C more HMIs Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index DLO5 06 High Speed Counter CTRIO Workbench configure I O setup The Configure I O dialog is the location where input and output functions are assigned to the mod2. activated to stop and cut the material to a repeatable fixed length Additionally the clutch brake signal can be used for an inhibit signal to not accumulate counts while the material is being cut High speed cut to length application PLC with CTRIO module Motor Interface LS aR POR CTRIO high speed output Cutter interface Encoder _ Using Configure 1 0 screen to configure CTRIO for high speed counting te V A Cutter assembly f Material to be cut to length PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field I O Software C more HMls Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index DLO5 06 High Speed Counter Pulse output operations ee Desi A Ta Papag D ve pre E by Pulse output for stepper servo control The CTRIO module is capable of multiple configurations for pulse output control most often when connected to a stepper or servo drive system The module can deliver a pulse output signal up to a maximum of 25 kHz with support for pulse and direction or CW CCW pulses The available profile choices include Trapezoid S Curve Symmetrical S Curve Dynamic Pos
3. kHz e Pulse and direction or cw ccw pulses supported for pulse output control e Raw control of discrete output directly from user control program Software configuration All scaling and configuration is done via CTRIO Workbench a Windows software utility program This eliminates the need for PLC ladder programming or other interface device programming to contigure the module CTRIO Workbench runs under Windows 98 2000 XP and NT 4 0 SP5 or later CTRIO Workbench main configuration screen CPU Firmware Required DirectSOFT Required DLOS5 Version 4 60 or later Version 3 0c or later DLO6 Version 1 40 or later 2 60 PLC Products Version 4 0 Build 16 or later Typical applications e High speed cut to length operations using encoder input Pick and place or indexing functions controlling a stepper servo drive e Dynamic registration for web material control e Accurate frequency counting for speed control with onboard scaling PLS Programmable Limit Switch func tions for high speed packaging gluing or labeling e Sub 10 usec pulse catch capability for high speed product detection Functions for level or flow Supported systems Multiple CTRIO modules can reside in the same PLC provided the base power budget is adequate DirectLOGIC DLO5 and DLO6 PLCs You can use the HO CTRIO module with any of the DLOS and DLO6 PLCs Configure 1 0 screen 1 800 633 0405 DLO5 06
4. A home sensor is positioned in the middle of the assembly which allows the PLC to reset the count Closed loop control for the CTRIO module requires PLC CPU program interaction to close the loop This makes the application subject to the PLC CPU scan PLC Products 2 67 PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field I O Software C more HMls Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index
5. DLO5 06 High Speed Counter I O Module High Speed Counter 1 O Module Overview The High Speed Counter I O CTRIO module is designed to accept high speed pulse type input signals for counting or timing applications and to provide high speed pulse type output signals for stepper servo motor control monitoring alarm or other discrete control functions The CTRIO module offers great flexibility for applications that call for precise counting or timing based on an input event or for high speed control output applications The CTRIO module has its own micro processor and operates asynchronously with respect to the PLC controller This means that the on board outputs respond in real time to incoming signals so there is no delay waiting for the PLC controller to scan I O The HO CTRIO module is designed to work with incremental encoders or other field devices that send pulse outputs CTRIO features The CTRIO modules offer the following I O features 4 DC sink source inputs 9 30VDC e2 isolated sink source DC outputs 5 36 VDC 1A per point Inputs supported i ee encoder counter up to 100 KHz or 2 single channel counters up to 100 KHz using module terminals A B C and D Ma edge timers dual edge timers pulse catch count reset count inhibit count capture or home search limits using module terminals C or D Outputs supported 2 independently au ee discrete outputs or 1 channel pulse output control 20 Hz 25
6. High Speed Counter I O Specifications Module Type General Intelligent Modules Per Base Limited only by power consumption 10 Points Used None 1 0 map directly in PLC V memory or PC control access Field Wiring Connector Standard removable terminal block Internal Power Consumption 250mA Max at 5V from base power supply All 1 0 in ON state at max voltage current Operating Environment 32 F to 140 F 0 C to 60 C humidity non condensing 5 to 95 Manufacturer Host Automation Products LLC Isolation HO CTRIO Input Specifications Inputs 4 pts sink source 100K Hz Max Minimum Pulse Width 5 usec 2500V 1 0 to Logic 1000V among input channels and all outputs Outputs HO CTRIO Output Specifications 2 pts independently isolated current sourcing or sinking FET outputs open drain and source with floating gate drive Voltage Range 5VDC 36VDC Input Voltage Range 9 30VDC Maximum Voltage 36VDC Maximum Voltage 30VDC Output clamp Voltage 60VDC Input Voltage Protection Zener Clamped at 33VDC Maximum Load Current 1 0A Maximum Load Voltage 36VDC Rated Input Current 8mA typical 12mA maximum Maximum Leakage Current 100A Minimum ON Voltage 9 0VDC Inrush Current 5A for 20ms OFF to ON Response less than 3usec Maximum OFF Voltage 2 0VDC ON to OFF Respon
7. LED Diagnostic Definitions Blinks when Channel 1 Function 1 is counting or timing Blinks when Channel 1 Function 2 is counting or timing Installation and wiring Follow actual output state ON output is passing current The HO CTRIO module has one input channel consisting of four optically isolated input points pts A D on common M The inputs can be wired to either sink or source current The module has two optically isolated output points pts YO Y1 on common YC The outputs must be wired so positive current flows into the YC terminal and then out of the Yn terminal The module s internal jumpers must be set to the High Side Common position for high side switching sourcing outputs or to the Low Side Common position for low side switching sinking outputs Source operation is the factory default setting See the schematic on the next page for sample jumper settings The module is configured using CTRIO Workbench to accommodate the user s application The function of each input counting timing reset etc and output pulse output discrete output etc is defined in the configuration of the module See the notes below for turther details about power source considerations circuit polarities and field devices Notes 1 Inputs A B C D require user provided 9 30 VDC power sources Terminal M is the common for Channel 1 inputs Maximum current consumption is 12 mA per input point 2 Polarity of the in
8. e flexible design of the CTRIO module allows for combining high speed inputs and delivering high speed pulse output signals simultaneously There are limitations to this type of configuration in that the module does not internally support closed loop control Providing closed loop control with the CTRIO involves additional PLC code to coordinate this control making the application subject to the PLC CPU program scan Simple position speed monitoring via a high speed counting input for non critical response while providing pulse outputs to a drive is easily achievable for the CTRIO PLC CPU program CTRIO pulse output profile RLL lt eee rogram lt c CTRIO high speed input pulse train www automationdirect com d O05and06 Multihead drill machine application Proximity switch Encoder PLC with CTRIO module Stepper or servo drive Example application In the simple drill head application shown above the CTRIO pulse outputs are wired to a stepper and or servo drive The inputs are wired to an encoder attached to the lead screw on the movable portion of the drill head assembly The CTRIO module output pulse train to the drive allows the motor to spin the lead screw making the drill move forward into the passing material The encoder moni tors the speed and position of the drill head Prox switches at each end act as limit switches ensuring the drill head will not over travel
9. itioning Dynamic Velocity and Home Search All profiles can be easily configured using the CTRIO Workbench software with fill in the blank para meter fields and a graphic representation of the selected profile Three additional profiles are available that are completely controlled by the user program no CTRIO profile is configured They are Velocity Mode Run to Limit Mode and Run to Position Mode Example application In a simple rotary indexing application as shown above a fixed Trapezoid profile is chosen The CTRIO for this application is wired to a stepper drive for pulse and direction The requirement for this application is to provide a smooth movement of the rotary table to allow product to be filled into individual containers equal distance apart The predetermined number of pulses required for each movement is entered into the CTRIO Workbench as Total Pulses along with the Starting Frequency Ending Frequency and Positioning Frequency speed after acceleration The Acceleration and Deceleration parameters are entered in units of time so no ramp distance calculations are required After all parameters are entered a graphical representation of the configured profile is shown automatically Once the configuration has been down loaded to the module all that is needed is from the PLC CPU is the Enable Output signal to begin a movement 2 66 PLC Products Stepper motor PLC with CTRIO module Stepper or servo dr
10. ive Circular turn table Stepper motor inside housing Rotary indexing liquid fill application Other common pulse output applications S Curve accel decel profile for signaling a stepper or servo drive that needs a curved acceleration and deceleration profile e for diminishing any initial jerk upon movement of static products boxes on conveyors liquids in containers on an indexer printing registrations etc e Dynamic Positioning for any run to a specific position require ment either by a pre programmed count of an external high speed discrete input wired to the module This is popular in winding or webcontrol with any dynamic registration mark or variable speed requirement e Home search routines to seek a home position based on CTRIO discrete input limit s Example of S Curve acceleration and deceleration pulse output profile Sm hej IET Fai ae BT dire Tee CED m Diii Tiia HH tadis PO wmi O E p iis jeg 47 Hi Pon Ferg O Win Pom there E iin Dai Pr iE ial CE _ coe 1 800 633 0405 DLO5 06 High Speed Counter Combining high speed input and pulse output operations Using CTRIO Workbench to configure the module for simultaneous high speed input and high speed pulse output operation pmi e Eo om Js Sa Sie fj B e EL E oe he J bil fom e By ee I VE x 3 m z 2 High speed inputs and pulse output combinations Th
11. ns tab includes all inout Dword parameters status bits and the current status of each configured input and output function The fields displayed under the Output Functions tab includes all output parameters and contiguration information that can be altered during runtime and the bits that indi cate successful transfers or errors The System Functions can be used to read from or write to the CTRIO s internal registers CTRIO Workbench on board scaling Scaling raw signals to engineering units is accomplished using the Scaling Wizard The Scaling Wizard options are different for the Counter functions as compared with the Timer functions Position and Rate scaling are available when you select a Counter function Interval scaling is available when you select a Timing function 2 64 Monitor 1 0 screen Se 7 Scaling Wizard screen Fon fo TI li rh 3 1 7 a Cina ante 00 sgiam irge he J O F __ SSheesmneear pee La m sarji won lins f ama fa k e Ae Cie i a aes o ures eran Teo an ma Te 1 PLC Products 1 800 633 0405 DLO5 06 High Speed Counter High speed input operations The CTRIO module is capable of a wide variety of high speed input and output operations all within one module With its single channel input and separate single channel output design the CTRIO can satisty both high speed counting timing pulse catch opera tions along with high speed discrete output or
12. put power sources can be reversed Consideration must be given however to the polarity of the field device Many field devices are designed for only one polarity and can be dam aged if power wiringis reversed 3 Outputs have one polarity only and are powered by user provided 5 36 VDC power sources The maxi mum allowable current per output circuit is 1A Module output jumpers must be set to the High side or Low side common position for Source Sink applications Refer to the diagrams on the next page for sample jumper settings 2 62 E PLC Products n CTR TMR IN 9 30V 5 12mA DC Pulse Out 5 36V 1A IN isl lt lelolololsls A B c D M Yc Yo v4 OUT ere eke He eke eke ee HO CTRIO sy ie ses eas teats eh Nem Need ys ee 1 1 800 633 0405 DLO5 06 High Speed Counter Solid state input wiring device DC types of field devices are configured to either sink or source current This affects the wiring of the device to the CTRIO module Refer to the sinking sourcing section in the appendix tor a complete explanation of sinking and sourcing concepis NPN Field Device sink O This drawing illustrates wiring that is typical for Channel 1 terminals A B C and D PNP Field Device source 9 This drawing illustrates wiring that is typical for Channel 1 terminals A B C and D
13. se less than 3usec Minimum ON Current 5 0mA 9VDC required to guarantee ON state ON State V Drop m 0 3V External Power Supply For loop power only not required for internal module function Maximum OFF Current 2 0mA Overcurrent Protection 15A max Thermal Shutdown Tjunction 150 C OFF to ON Response Less than 3 usec Overtemperature Reset Tjunction 130 C ON to OFF Response Less than 3 usec HO CTRIO Input Resources Counter Timer 2 Duty Cycle Range 1 to 99 in 1 increments default 50 Configurable Presets a Single b Multiple a each output can be assigned one preset or b each output can be assigned one table of presets one table can contain max 128 presets max predefined tables 255 User supplied power source required for stepper drive configuration HO CTRIO Output Resources Pulse output Discrete outputs Pulse outputs 1 channel 20Hz 25KHz Discrete outputs 2 pts Resource Options 1X 2X or 4X Quadrature Up or Down Counter Edge Timer Dual Edge Timer Input Pulse Catch Reset Inhibit Capture Timer Range Resolution 4 2 billion 32 bits 1 usec Counter Range 2 1 billion 32 bits or 31 bits sign bit Resource Options Pulse outputs pulse direction or cw ccw Profiles Trapezoid S Curve Velocity Mode Run to Limit Mode and Run to Position Mode Discrete outp
14. several protile choices of pulse output operations Not all combinations of input functions and output functions are possible within the resources of the module but the following examples are some of the most common applications for the CTRIO Check out these examples and see how they relate to your high speed application needs High speed timing The CTRIO can be configured for timing functions based on count or rate Using a common configuration of a proximity switch sensing the teeth on a gear the module is able to calculate the velocity of the gear based on the rate it receives counts This value can be scaled within the module to the engineering units required for the application High speed timing application PLC with CTRIO module miimo Proximity switch _ r em www automationdirect com dlO5and06 Gearbox clutch and brake interface High speed counting The CTRIO can be configured for counting functions for the use of an encoder input up to two quadrature encoders per module with available connections for external reset capture and inhibit signals In a simple cut to length application as shown the encoder provides an input position reference for the material to the module The module s high speed outputs are wired to the cutting device and to the clutch and or braking device When the count trom the encoder is equal to a pre programmed setpoint within the module the high speed outputs are
15. ule The choice of input and output functions determines which options are available The input function boxes prompt you with selections for supported functions The Workbench software automatically disallows any unsupported configurations Fill in the blank configuration software The CTRIO Workbench is the software utility used to configure the CTRIO module and to scale signals to desired engineering units Workbench also allows you to perform various other functions such as switching between the CTRIO s Program mode and Run mode monitoring O status and functions and diagnostic control of module functions The CTRIO Workbench utility ships with the CTRIO User Manual You can also download the latest version free at the Host Engineering s Web site www hosteng com CTRIO Workbench main configuration screen HO CTRIO Configure 1 0 screen F Dizni E a Thi al i E H 7 n n JCC CTRIO Workbench diagnostics and monitoring E 1e eune ain ts a i The Monitor I O dialog is accessible from the main Workbench aeaa pani Tamer 7 m dialog when the module is in Run Mode This allows for a conve tomes nient way to test and debug your configuration prior to installation ea tha C The Monitor I O dialog is divided into three functional areas Input i an Qe Functions Output Functions and System Functions The data displayed under the Input Functio
16. uts configurable for set reset pulse on pulse off toggle o unctions assigned to respond to Timer Counter input func ions Raw mode Direct access to discrete output from user application program Symmetrical S Curve Dynamic Position Dynamic Velocity Home Search Target Position Range www automationdirect com dlO5and06 2 1 billion 32 bits or 31 bits sign bit PLC Products 2 61 Direct v PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field I O Software C more HMls Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index DLO5 06 High Speed Counter Status indicators HO CTRIO LED Descriptions Module OK OK HO CTRIO LED Diagnostic Definitions ERR Description User Program Error ON OFF All is well RUN Mode Channel 1 Fn1 Status ON ON Hardware Failure Channel 1 Fn2 Status Blinking Blinking Boot Mode Used for Field OS Upgrades Output Status Blinking OFF Program Mode OFF Blinking Module Self diagnostic Failure OFF ON Module Error Due to Watchdog Timeout OFF OFF No Power to Module HO CTRIO
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