5624 Opto-isolated I/O
Contents
1. This current attempts to power up the card Most inputs are rated at 25 mA maximum When this is exceeded the chip may be damaged Failure on powerup Even when there is not enough current to destroy an input described above the chip may be destroyed when the power to the card is applied This is due to the fact that the input current biases the IC so that it acts as a forward biased diode on powerup This type of failure is typical on serial interface chips but can apply any IC on the card Under rated power supply The board may fail to boot due to an under rated power supply It is important that a quality power supply be used with Octagon Systems cards that has sufficient current capacity line and load regulation hold up time current limiting and minimum ripple It is extremely import to select a supply that ramps up in 10ms or less This assures that all the circuitry on the CPU cards sequences properly and avoids system lockup Excessive signal lead lengths Another source of failure that was identified years ago at Octagon was excessive lead lengths on digital inputs Long leads act as an antenna to pick up noise They can also act as unterminated transmission lines When 5V is switch onto a line it creates a transient waveform Octagon has seen sub microsecond pulses of 8V or more The solution is to place a capacitor for example 0 1 pF across the switch contact This will also eliminate radio frequency and other high frequency2. pickup Table of Contents Copy otea a od O BE SOA SASS e ASD IS 2 Disclaimer A A TO AE NR Se 2 Using CMOS circuitry in industrial control coooconononnnnnnnnnnnnnonnninoninnninnninononoss 3 Table of Contents iaa lll 6 List 0f FISUTES AE E E E EE ET 7 istot Me OE SNC E RS 8 Chapter Li OVEIVIEW sii lesbo UA as BA LEA SS Aca les a aene 9 DESTINA Reeser en en AE eR nn ne ee il 9 Chapter 2 Installations 6 3 ei hese adas 10 Hardware installation vid id cia 10 Using a Micro PC card Cage coocooonononnnnnonmnnnnnonnnnnnnonnnonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnss 10 Component locations oooococcnnccnnnnnnnnnncnnnnnnnocononnnonononnononononononononorononocnsononoconenononos 11 5624 Instalar A IT DAN Laie Mian eA Danresans 12 ASO ACUTE SS la idol diia estates oa 13 Porra A II A LS aba dana 14 HPU edi ds 14 O E eer eee 15 CULPA e o o EE A A O Ue Aa 15 Example O e E IEE BEE 15 APC ID IS AS EN AS O 15 Technical Specifications LL it 17 PUES it 17 OR 17 Power TEQGUITEMENUS iii dl oia aii 17 Environmental specifications ssssssssssesesessseeesssesssesssesssesesesesesseeeseceseecseeesees 17 WATTS A rai 18 Limitations On WalTaO Vinicio dire 18 Service poll iaa e Pee 18 Returning a product for TepalT oooooonononononononononononononononononono nono nono nono nono nono nora nnnnnnnos 19 REUS S andan ter 19 Governingsla Witt IA AAA AD 19 List of Figures Figure 1 5624 component diagram ccccc
3. wrong jumper settings or the customer has problems with the software This causes frustration for the customer and incurs a testing charge from Octagon e Of the remaining 80 of the cards 90 of these cards fail due to customer misuse and accident Customers often cannot pinpoint the cause of the misuse e Therefore 72 of the returned cards are damaged through some type of misuse Of the remaining 8 Octagon is unable to determine the cause of the failure and repairs these cards at no charge if they are under warranty The most common failures on CPU cards are over voltage of the power supply static discharge and damage to the serial and parallel ports On expansion cards the most common failures are static discharge over voltage of inputs over current of outputs and misuse of the CMOS circuitry with regards to power supply sequencing In the case of the video cards the most common failure is to miswire the card to the flat panel display Miswiring can damage both the card and an expensive display Multiple component failures The chance of a random component failure is very rare since the average MTBF of an Octagon card is greater than 11 years In a 7 year study Octagon has never found a single case where multiple IC failures were not caused by misuse or accident It is very probable that multiple component failures indicate that they were user induced Testing dead cards For a card that is completely nonfunctiona
4. 03 426 4521 Telephone 303 430 1500 FAX 303 426 8126 Web site www octagonsystems com IMPORTANT Please read the following section before installing your product Octagon s products are designed to be high in performance while consuming very little power In order to maintain this advantage CMOS circuitry is used CMOS chips have specific needs and some special requirements that the user must be aware of Read the following to help avoid damage to your card from the use of CMOS chips Using CMOS circuitry in industrial control Industrial computers originally used LSTTL circuits Because many PC components are used in laptop computers IC manufacturers are exclusively using CMOS technology Both TTL and CMOS have failure mechanisms but they are different Described below are some of the failures which are common to all manufacturers of CMOS equipment However much of the information has been put in the context of the Micro PC Octagon has developed a reliable database of customer induced field failures The average MTBF of Micro PC cards exceeds 11 years yet there are failures Most failures have been identified as customer induced but there is a small percentage that cannot be identified As expected virtually all the failures occur when bringing up the first system On subsequent systems the failure rate drops dramatically e Approximately 20 of the returned cards are problem free These cards typically have the
5. 624 will accept signals from 2 7 14V DC Plug in resistor packs allows the user to accommodate ranges from 3V to 84V The 5624 is protected from accidental reverse polarity Noise filtering is provided and the system is not damaged by 200V noise pulses All inputs are isolated from each other and the system ground The card measures 4 5 x 4 9 inches and operates on 5V It is compatible with all Micro PC Control cards and Microcontrollers and can be installed in an ISA slot in a desktop PC Chapter 2 Installation The 5624 Isolated Digital I O card uses one slot of the Micro PC card cage and can plug directly into any slot in the backplane Hardware installation WARNING The 5624 card contains static sensitive CMOS components The card is most susceptible to damage when it is plugged into a backplane The 5624 card becomes charged by the user and the static discharges to the system To avoid damaging your card and its components Ground yourself before handling the card Disconnect power before removing or inserting the card Using a Micro PC card cage To install the 5624 card in a Micro PC card cage you will need the following equipment or equivalent 5624 Isolated Digital I O card Micro PC card cage 5xxx Card Cage Power module 510x or 71xx Power Module Octagon Micro PC CPU or Microcontroller card 10 Component locations Figure 1 shows the 5624 Isolated Digital I O card component diagram Refer to th
6. C maximum Output load current 200 mA maximum Switch resistance 3 0 ohm maximum Isolation to system 500 VDC isolation between channels 100 Vpk reverse polarity protection Power requirements 5V 100 mA maximum Environmental specifications 40 to 70 C operating 50 to 85 C nonoperating RH 5 to 95 noncondensing 17 Warranty Octagon Systems Corporation Octagon warrants that its standard hardware products will be free from defects in materials and workmanship under normal use and service for the current established warranty period Octagon s obligation under this warranty shall not arise until Buyer returns the defective product freight prepaid to Octagon s facility or another specified location Octagon s only responsibility under this warranty is at its option to replace or repair free of charge any defective component part of such products Limitations on warranty The warranty set forth above does not extend to and shall not apply to Products including software which have been repaired or altered by other than Octagon personnel unless Buyer has properly altered or repaired the products in accordance with procedures previously approved in writing by Octagon Products which have been subject to power supply reversal misuse neglect accident or improper installation The design capability capacity or suitability for use of the Software Software is licensed on an AS IS basis with
7. O C T A GON S YSTEMS Embedded PCs For Extreme Environments 5624 Isolated Digital I O Card User s Manual 3702 0903 Copyright Micro PC PC SmartLINK CAMBASIC Octagon Systems Corporation the Octagon logo and the Micro PC logo are trademarks of Octagon Systems Corporation Disclaimer Copyright 2003 Octagon Systems Corporation All rights reserved However any part of this document may be reproduced provided that Octagon Systems Corporation is cited as the source The contents of this manual and the specifications herein may change without notice The information contained in this manual is believed to be correct However Octagon 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 Octagon makes no representation or warranty that such applications will be suitable for the use specified without further testing or modification Octagon Systems Corporation general policy does not recommend the use of its products in life support applications where the failure or malfunction of a component may directly threaten life or injury Itis a Condition of Sale that the user of Octagon products in life support applications assumes all the risk of such use and indemnifies Octagon against all damage O OCTAGON SYSTEMS 6510 W 91 Ave Westminster CO 80031 Technical support 3
8. UT amp H100 8 amp HO1 Output 00000001 to address 108H Access LED The amber LED will light briefly whenever the card is accessed input or output 15 Port pinouts J1 and J2 are 26 position headers Of the 16 input lines the first 12 INO to IN11 are connected to J1 The remaining 4 input lines IN12 to IN15 are connected to J2 All 8 output lines are connected to J2 Refer to Tables 5 and 6 Table 5 J1 connector input lines Pin Description Pin Description 1 INO 14 IN6 2 INO 15 IN7 3 IN1 16 IN7 4 IN1 17 IN8 5 IN2 18 IN8 6 IN2 19 IN9 7 IN3 20 IN9 8 IN3 21 IN10 9 IN4 22 IN10 10 IN4 23 IN11 11 IN5 24 IN11 12 IN5 25 nc 13 IN6 26 nc Table 6 J2 connector input output lines Pin Description Pin Description 1 IN12 14 OUTI 2 IN12 15 OUT2 3 IN13 16 OUT2 4 IN13 17 OUT3 5 IN14 18 OUT3 6 IN14 19 OUT4 7 IN15 20 OUT4 8 IN15 21 OUT5 9 Ne 22 OUT5 10 Ne 23 OUT6 11 OUTO 24 OUT6 12 OUTO 25 OUT7 13 OUT1 26 OUTT 16 Technical specifications Inputs 2 7 14 VDC as shipped 2 8 27 VDC resistor pack option 8 8 58 VDC resistor pack option 17 84 VDC resistor pack option Input current 1 5 mA Programmable threshold 2 8V 8 8V 17V Isolation to system 500 VDC Isolation between channels 100 VDC reverse polarity protection reverse voltage may not exceed range Frequency range 0 4KHz Outputs 50 VDC or 50 VA
9. ators 5624 resistor designators Reference designators Input channels RN6 0 1 2 3 RN7 4 5 6 7 RNY 8 9 10 11 RN10 12 13 14 15 If your application requires a different input threshold than the factory default Table 4 lists the resistor packs recommended for replacement at locations RN6 RN7 RN9 or RN10 14 Table 4 Suggested resistor networks Bourns www bourns com Part number Resistor value 4116R 001 511 510 ohms 4116R 001 102 1K ohms 4116R 001 472 4 7K ohms 4116R 001 103 10K ohms The inputs also use a 01 uF capacitor and a 2 2K ohm resistor across the LED in order to debounce switch and relay contacts The inputs are designed for input frequencies from 0 to 4KHz Example The following statement is an example of how to read an input on the 5624 A INP amp H100 Read 1st 8 bit port from address 100H B INP amp H104 Read 2nd 8 bit port from address 104H Outputs The 5624 provides eight isolated solid state relays for outputs The outputs may switch both AC and DC loads The loads may be connected to either the OUT or the OUT terminal The DC load voltage may be connected in either polarity The rated load for an output is 200 mA at 50V This applies to both AC and DC loads Example Writing a logic one to the output causes the output switch to close Writing a logic zero to the output causes the switch to open The following statement is an example of how to write an output for the 5624 O
10. cccscccssccesccesccsccceccceeccescceeceeeceseceeeceseeeeeeens Figure 2 Edge connector orientation cccccccccecccsssesssneeeeeecesssessnneeeeeeeessesseeseaeeeeess Figure 3 Populated Micro PC card Cag8 oooooooccconccnnnononononnnnnnnnnnnnnnnnnnnnnncnnnnnnnnnnnnnnnnnnnn List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 W1 jumper base address Select oooonononnnonnonononnnanonn nono nnnonnnnn nono nao nononnnos 13 Resistor NetWorkS id Ve senna act or MIN ane eased 14 Resistor network and channel designators ooococommmmmmmmmmasoam9a9 m oo 14 Suggested resistor networks ccccccceccceccceeccescccecccecccecceecceseceeeceeeceeeeeeeees 15 J1 connector input liMeS oooononononanonononnononononono nono no nono non nnnnnnnr nar naar ano n noo 16 J2 connector input output linesS ooonoonnonnnononononanannono nono no non nnnn nono nono nono noo 16 Chapter 1 Overview Description The 5624 Isolated Digital I O card accepts switch closures PLC and 12V logic inputs and other voltages that can not be used with standard TTL logic The card supports 16 input channels and 8 output channels The inputs have 500V of isolation to ground and 100V between channels The eight output channels will drive relays lamps small motors and solenoids Each channel can switch loads up to 200 mA and 50V Signals may be AC or DC Each output is isolated from each other and the system As shipped the 5
11. ion of W1 As shipped the base address is 100H which is jumper configuration W1 1 2 3 4 5 6 If there is another card in your system with a base address of 100H you must use a different base address for the 5624 or the other expansion card To change the base address change the jumper configuration according to Table 1 W1 jumper base address select Pins Jumpered Base Address 1 2 3 4 5 6 100H 3 4 5 6 110H 1 2 5 6 120H 5 6 130H 1 2 3 4 140H 3 4 150H 1 2 160H Not jumpered 170H default 13 Table 2 Table 3 Ports Inputs The 5624 inputs are optically isolated and are capable of receiving high voltage level inputs If the input voltage level is below the threshold level a logic zero is read If the input voltage is above the threshold voltage a logic one is read The inputs require a minimum of 1 mA at the threshold voltage in order to turn on The input thresholds are programmed by using DIP resistor packs The resistor value and the associated threshold are listed in Table 2 Resistor networks 5624 resistors RN6 RN7 RN9 and RN10 Resistor network Typical Maximum value ohms threshold allowed volts volts 510 ohms 2 7 14 1K ohms 2 8 27 4 7K ohms 8 8 58 10K ohms 17 84 default Each DIP resistor pack affects four adjacent inputs The DIP resistors reference designators and the associated input channels are listed in Table 3 Resistor network and channel design
12. is diagram before connecting the 5624 card Figure 1 5624 component diagram DIP Base Address Resistor Access Select Network Indicator e e e U11 U10 U9 U8 E Pin 1 Solid state Relays 11 5624 Installation To install the 5624 card into a card cage 1 Refer to the component diagram Figure 1 for the location of various connectors and jumpers before installing the 5624 card 2 Verify the base address settings are correct for your application Refer to the Base Address section to select the base address 3 Make sure power to the card cage is OFF 4 Correctly orient the card The components on the card should face away from the power supply Refer to Figure 2 for correct orientation of the card into a backplane Figure 2 Edge connector orientation Card edge pins A31 amp B31 Micro PC Passive Back plane Micro PC card Card edge pins Al amp B1 5 Slide the 5624 card into the card cage See Figure 3 for an illustration of a 5624 card in a Micro PC card cage Figure 3 Populated Micro PC card cage 12 Table 1 WARNING Plugging in the card incorrectly will destroy the card 6 Power on the system When removing the 5624 from the backplane make sure to first disable power to your system Base address The 5624 is configured at the factory to operate in most systems without any jumper changes Jumper block W1 defines the base address Refer to Figure 1 for the locat
13. l there is a simple test to determine accidental over voltage reverse voltage or other forced current situations Unplug the card from the bus and remove all cables Using an ordinary digital ohmmeter on the 2 000 ohm scale measure the resistance between power and ground Record this number Reverse the ohmmeter leads and measure the resistance again If the ratio of the resistances is 2 1 or greater fault conditions most likely have occurred A common cause is miswiring the power supply Improper power causes catastrophic failure Ifa card has had reverse polarity or high voltage applied replacing a failed component is not an adequate fix Other components probably have been partially damaged or a failure mechanism has been induced Therefore a failure will probably occur in the future For such cards Octagon highly recommends that these cards be replaced Other over voltage symptoms In over voltage situations the programmable logic devices EPROMs and CPU chips usually fail in this order The failed device may be hot to the touch It is usually the case that only one IC will be overheated at a time Power sequencing The major failure of I O chips is caused by the external application of input voltage while the Micro PC power is off If you apply 5V to the input of a TTL chip with the power off nothing will happen Applying a 5V input to a CMOS card will cause the current to flow through the input and out the 5V power pin
14. out warranty The warranty and remedies set forth above are in lieu of all other warranties expressed or implied oral or written either in fact or by operation of law statutory or otherwise including warranties of merchantability and fitness for a particular purpose which Octagon specifically disclaims Octagon neither assumes nor authorizes any other liability in connection with the sale installation or use of its products Octagon shall have no liability for incidental or consequential damages of any kind arising out of the sale delay in delivery installation or use of its products Service policy If a product should fail during the warranty period it will be repaired free of charge For out of warranty repairs the customer will be invoiced for repair charges at current standard labor and materials rates Customers that return products for repairs within the warranty period and the product is found to be free of defect may be liable for the minimum current repair charge 18 Note Returning a product for repair Upon determining that repair services are required the customer must Obtain an RMA Return Material Authorization number from the RMA Administrator 303 430 1500 If the request is for an out of warranty repair a purchase order number or other acceptable information must be supplied by the customer Include a list of problems encountered along with your name address telephone and RMA number Caref
15. ully package the product in an antistatic bag Failure to package in antistatic material will VOID all warranties Then package in a safe container for shipping Write RMA number on the outside of the box For products under warranty the customer pays for shipping to Octagon Octagon pays for shipping back to customer Other conditions and limitations may apply to international shipments PRODUCTS RETURNED TO OCTAGON FREIGHT COLLECT OR WITHOUT AN RMA NUMBER CANNOT BE ACCEPTED AND WILL BE RETURNED FREIGHT COLLECT Returns There will be a 15 restocking charge on returned product that is unopened and unused if Octagon accepts such a return Returns will not be accepted 30 days after purchase Opened and or used products non standard products software and printed materials are not returnable without prior written agreement Governing law This agreement is made in governed by and shall be construed in accordance with the laws of the State of Colorado The information in this manual is provided for reference only Octagon does not assume any liability arising out of the application or use of the information or products described in this manual This manual may contain or reference information and products protected by copyrights or patents No license is conveyed under the rights of Octagon or others 19
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