High-Speed Counter
Contents
1. 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 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 set up the module CTRIO Workbench runs under Windows 98 2000 XP and NT 4 0 SP5 or later in real time to incoming signals so there is no delay waiting for the PLC Controller to CTRIO Workbench main configuration screen scan I O el 4 CTRIO Workbench The H2 CTRIO module is designed to eae Camilo Fe ype duct Module work with incremental encoders or other peel Mme oe gias Sean Time Comm Lirik Description tield devices that send pulse outputs an panpe Max Sean Tim Comm Staur Booter vegon OS Version ola j Ea Ln Select PLC Channel 1 Channel Charat Module Configurator kiz Puritan 1 Quad Counter Out Ol F Courter Pule ie E 7 Teed Laurie Pulp AL Fi She aume Courter F gom a Ouz uU __ Resear Config infomation 4 pema Out 3 U 0 Map Input V2000 Ovapaute Piesa Tabes Taint Danni To Pa i m l Pula 5 tapetu Pidie Cw Puks Cach Edy Titi Dus ldg Timer Eal Puks Cachi Edy Tii Dus ldg Ime Use Configure 1 0 dialog to assign the CTRIO input and output fun2. dialog when the module is in Run Mode This allows for a convenient way to test and debug your configuration prior to installation The Monitor O dialog is divided into three functional areas Input Functions Output Functions and System Functions The data displayed under the Input Functions tab includes all input Dword parameters status bits and the current status of each config ured input and output function The fields displayed under the Output Functions tab includes all output Dword parameters and configuration infor mation that can be altered during runtime and the bits that indicate successtul transfers or errors The System Functions can be used to read from or write to the CTRIO s internal registers Monitor I O screen LA titan inpet furcina Dager Fuanceces i priam uretra Pubes fagi Pai Dect Duis on Chl fri n Ferai irda www automationdirect com fieldlO CTRIO Workbench configure I O setup The Configure I O dialog is the location where input and output functions are assigned to the module 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 unsup ported configurations yr Eh woud Le ary aoe eee Rr Le ai T1H CTRIO Configure 1 0 screen CTRIO Workbench on board scaling Scaling raw signals to engineering units is accomplished u
3. 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 achiev able for the CTRIO Master Controller program CTRIO pulse output profile SS RLL Program WU CTRIO high speed input pulse train 7 34 Universial Field I O Multihead drill machine application Proximity switch lt 0 mr lad AAAA Proximity switch A AAAA AAN Proximity switch l Encoder Stepper or servo drive Interface device with CTRIO module i TSS n n lt gt NL 515550 A gt 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 monitors 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 A home sensor is positioned in the middle of the assembly allowin
4. Direction or e User Bus Terminals no internal connection to CTRIO oj jel j l j l j olol oj ololojol O b USER BUS 1 USER BUS 2 1M The same circuitry is present at the corresponding Channel 2 terminal 7 30 Universial Field 1 0 1 800 633 0405 High Speed Counter 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 shios with the CTRIO User Manual You can also download the latest version free at the Host Automation Products L L C Web site www hosteng com CTRIO Workbench main configuration screen HE CTRIO Workbench Maduka Stature Module Mode IRDA Scan Time Meus Max Scan Tm 479un Bote vetom 102 DS Veron 201 Out a Pulse utp Step Direction Chien Ch2 Fri Ou2 Unstsigned Special _ Been Ch2 Fr2 Oud Dama Update Farme Hadar Indo r Conhg Infcoemation Total Blocks 256 VO Map iper va Oupa V Cleat Config Free Blocks 247 Preset Tabler CTRIO Workbench diagnostics and monitoring The Monitor I O dialog is accessible from the main Workbench
5. High Speed Counter I O Module CTRIO features The CTRIO modules offer the following I O features Eight DC sink source inputs 9 30 VDC Four isolated sink source DC outputs 5 30 VDC 1A per point Inputs supported e Two quadrature encoder counters up to 100 kHz or four single channel coun ters up to 100 kHz using module termi nals Ch1A Ch1B Ch2A and Ch2B High speed edge timers dual edge timers pulse catch count reset count inhibit or count capture or home search limits using module terminals Ch1C Ch1D Ch2C or Ch2D Outputs supported e Four independently configurable high speed discrete outputs or two channels pulse output control 20 Hz 25 kHz per channel or 50 kHz if only using one channel e Pulse and direction or cw ccw pulses supported for pulse output control e Raw control of discrete output directly from user control program 518 ree ye Ta 4 2 ei f _ p i i TELL TILL REY gecen aadar pase agoeee va a 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 motor control monitoring alarm or other Software discrete control functions The CTRIO module offers great flexibility for applica configuration tions that call for precise counting or timing based on an input event or for high speed control output applications
6. Ldit Pulse Profile 4 x r Finita Iria Hame pooo Pesk Freg ff o TH Hz P mh Profile Ippe Total Tias i TLS sec f S prenien Curve Acca Time Depnanet Pophioring TOU pres Denanec Velowaly d Hrom Search Decel Tine i TUUU roe i p Fie Stans Fi Fis Humber 1 TasErmes m Deca Time frond ms Blnedcs Lart 15 Total Pulser eer Arcee Time 1000 het Fist au Hz Pat Frag TUG Hz End Frege fu Hz Min Feeg Change E ki Min Ent Trae 10 mi 7 33 Universial Field I O iN A Direct v 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 Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Enclosures Appendix Part Index 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 dedes 7000 en Dia Tm O Siar Frees E Heo Patey 100 oat Et Foy D ie Tea Pde Co 1m High Speed inputs and pulse output combinations The flexible design of the CTRIO module allows for combining high speed inputs and delivering high speed pulse outputs signals simultaneously There are limitations to this type of configuration
7. and to the clutch and or braking device When the count from the encoder is equal to a pre programmed setpoint within the module the high speed outputs are activated to stop and cut the material to a repeat able 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 Interface device with CTRIO module Motor rs Interface in Gearbox clutch and brake interface CTRIO high C speed output Encoder _ interlace Mh C Cutter assembly Material to be cut to length Using Configure 1 0 screen to configure CTRIO for high speed counting Contequre 1 Chaneli Charee Dutguis inputs Fedez 1 EJ Courier Ue Counter 7 Pulse bitap T E usd Courter Puke Pw E Cori mru Dace on Chh Fal E j Ay m E Function 2 E Rep Fr 1 Pulia 5 Sane E Pli a CWE Dieses ori hil Frl E inhibi Fr 1 1 800 633 0405 High Speed Counter Pulse output operations Using Edit Pulse Profile screen to select Trapezoid pulse output profile Edit Pulse Profile gt x File Number 1 Name Trapezoid S Curve Symmetrical S Curve Dynamic Positioning foo joo Hz Positioning Freg 1000 Hz End Freq feo Hz 1000 ms 1000 ms Total Pulses Peak Freq Start Freq 1000 Hz Total Time 10 98 sec Accel Time Accel T
8. ce current The module has four optically isolated output points points YO Y3 on isolated commons CO C3 respectively The outputs must be wired so that positive current flows into the Cn terminal and then out of the Yn terminal see the diagram below and the schematic on the following page The module is contigured 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 further details about power source considerations circuit polarities and field devices Input Output Channels ore rf a gt C Terminator I O V _ T1H CTRIO Le 6O OK ERR CH1 CH2 OO O amp O O 2 O O O 0 Channel Commons 1A 1B 1C 1D YO Y1 gt i W N O we iw ox lt oo S SO OS SES SS S SeS SSe O Notes 1 Inputs 1A 1B 1C 1D an
9. ctions www automationdirect com fieldIO Typical applications High speed cut to length operations using encoder input e Pick and place or indexing functions controlling a stepper drive e Dynamic registration for web material control Accurate frequency counting for speed control with onboard scaling PLS Programmable Limit Switch functions for high speed packaging gluing or labeling e Sub 10 Usec pulse catch capability for high speed product detection e Functions for level or flow Supported systems Multiple T1H CTRIO modules can reside in the same O system provided that the base power budget is adequate PC based Ethernet I O control systems The T1H CTRIO module can be used in PC based control systems using the T1H EBC 100 interface module Profibus systems The TIH CTRIO module can be used in Profibus systems using the T1H PBC slave interface module ERM to EBC systems The T1H CTRIO module is supported in TIH EBC 100 slaves in H ERM systems Notes 1 The T1H CTRIO module is not supported in T1K RSSS serial remote I O bases 2 System functions are not available when CTRIO is used in ERM EBC expansion 1 0 7 27 Universial Field I O pu PLC Overview DLO5 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 L
10. d 2A 2B 2C 2D require user provided 9 30 VDC power sources Terminals 1M and 2M are the commons for Channel 1 and Channel 2 inputs Maximum current consumption is 12 mA per input point 2 Polarity of the input 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 damaged if power wiring is reversed 3 Outputs have one polarity only and are powered by user provided 5 36 VDC power sources The maximum allowable current per output circuit is 1A 4 User Bus 1 and User Bus 2 are independent 8 wire terminal buses They can be used for additional power rail connections www automationdirect com field IO Universial Field I O 7 29 A Direct v 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 Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Enclosures Appendix Part Index High Speed Counter Solid state input Pulse output schematic wiring device DC types of field devices are contigured to ea ee n where n 0 1 2 either sink or source current This affects eats the wiring of the device to the CTRIO Output modu
11. el output design the CTRIO can satisfy both high speed counting timing pulse catch operations along with high speed discrete output or several profile choices of pulse output operations Not all combina tions 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 contigured for timing functions based on both count or rate Using a common configu ration 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 its counts This value can be scaled within the module to the engineering units required for the application High speed timing application Interface device with CTRIO module m0 Proximity switch Using Configure 1 0 screen to configure CTRIO for high speed timing 7 32 Universial Field 1 0 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 and inhibit signals In a simple cut to length application as shown the encoder provides an input position reference for the mote rial to the module The module s high speed outputs are wired to the cutting device
12. g the PLC to reset the count Note Closed loop control for the CTRIO module requires control program interaction to close the loop This makes the application subject to the master controller scan 1 800 633 0405
13. gle Inhibit Capture reset count functions assigned to respond to Timer Counter input functions Raw mode Direct access to discrete output from user application program Timer Range Resolution 4 2 billion 32 bits 1 usec Target Position Range 2 1 billion 32 bits or 31 bits sign bit 2 1 billion Counter Range 31 bits sign bit 7 28 Universial Field O 1 800 633 0405 High Speed Counter Status indicators T1H CTRIO LED Descriptions Module OK T1H CTRIO LED Diagnostic Definitions LED ER Description User Program Error ON OFF All is well RUN Mode ChiA Ch1D Input Status ON ON Hardware Failure Ch2A Ch2D Input Status Blinking Blinking Boot Mode Used for Field OS Upgrades Channel 1 Status Blinking OFF Program Mode Channel 2 Status OFF Blinking Module Self diagnostic Failure Output Status OFF ON Module Error Due to Watchdog Timeout OFF OFF No Power to Module T1H CTRIO LED Diagnostic Definition Blinks when Channel 1 Function 1 is counting or timing Blinks when Channel 2 Function 1 is counting or timing Follow actual output state ON output is passing current Installation and wiring The TIH CTRIO module has two independent input channels each consisting of four optically isolated input points points 1A 1D on common 1M and points 2A 2D on common 2M The inputs can be wired to either sink or sour
14. ime 1000 ms Decel Time Decel Time 1001 ms Calculate Profile Cancel 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 on two channels with support for pulse and direction or CW CCW pulses The available profile choices include Trapezoid S Curve Symmetrical S Curve Dynamic Positioning and Pulse to Limit 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 s
15. imit Switches Encoders Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Enclosures Appendix Part Index High Speed Counter I O Specifications General Module Type Intelligent Modules Per Base Limited only by power consumption 10 Points Used None I O map directly in PLC V memory or PC control access Field Wiring Connector Standard removable terminal block 400 mA Max at 5V from Base Power Supply Maximum of 6 Watts Internal Power Consumption 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 2500 V 1 0 to Logic 1000 V among Input Channels and All Outputs T1H CTRIO Input Specifications T1H CTRIO Output Specifications are NE 4 pts independently isolated current sourcing or sinking p p Outputs FET Outputs open drain and source with floating gate drive Minimum Pulse 5 usec Voltage Range 5 VDC 36 VDC Width Maximum Voltage 36 VDC Input Voltage Range 9 30 VDC Output Clamp Voltage 60 VDC Maximum Voltage 30 VDC Maximum Load Current 1 0A Input Voltage Zener Clamped at 33 VDC Maximum Load Voltage 36 VDC PLOreGNQH Maximum Leakage 400 uA Rated Input Current 8 mA typical 12 mA maximum Current p Minimum ON 90 VDC Inrush Current 5 A for 20 ms Voltage l OFF to ON Response Less than 3 psec Maximum OFF 20 VDC ON to OFF Re
16. le Refer to the sinking sourcing ee N ex section of the appendix in this catalog for a complete explanation of sinking and sourcing concepts Or Load NPN Field Device sink ey E a 2 1C and 1D The same circuitry is also present at the corresponding Channel 2 terminals 5 to 36 VDC __ O Cn where n 0 1 2 3 M 1 A AN CTRIO Sensing Circuit O Output O Yn Load O N The same circuitry is present at the corresponding Channel 2 terminal Stepper servo drive PNP Field Device source gs wiring example Q This drawing illustrates wiring that is typical for Channel 1 terminals 1A 1B 1C and 1D The same circuitry is also present at the corresponding D Channel 2 terminals wy ae T a N Input Output Channels lolololololololololololololo lo 1A 1B 1c 1D Yo Yo Y1 Y1 24 2B 2c 2D Y2 Y2 Y3 Y3 Step Amplifier O Fa O O70 lt s Step Amplifier i 5 36 VDC l 5 36 VDC al OPTO Power OPTO Power Sql Channel Commons Pulse or CW Pulse or CW Direction or CCW A
17. peed 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 from the PLC CPU is the Enable Output signal to begin a movement www automationdirect com fieldlO Stepper or servo drive Interface device with CTRIO module TEAS LSS Terminator I O OA mmnm Ud mma FERERERE CTRIO pulse output signals Circular turn table Stepper motor inside housing Rotary indexing liquid fill application Other common pulse output applications e S Curve accel decel profile for signaling a stepper or servo drive that needs a curved acceleration and deceleration pro file i 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 requirement 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 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
18. sing the Scaling Wizard The Scaling Wizard options are different tor the Counter functions as compared with the Timer functions Position and Rate scaling are avail able when you select a Counter function Interval scaling is available when you select a Timing tunction Scaling Wizard screen Scaling Wizard Rate Settings x m Unit Definition 1000 Rate Scaling Calculator Counts unit Enter a count value and sample Scale Offset fo time in ms to confirm scaling configuration m Unit Time Base milliseconds Counts in sample 5000 3 seconds minutes Sample Time fi 000 H ms Ch si Scaled Yalue 300 ee m Data Smoothing Calc Interval fio J ms fLdncososan min D max Cancel lt Back Finish 7 31 Universial Field I O iN a Direct v 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 Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Enclosures Appendix Part Index 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 flexible 2 channel input and separate 2 chann
19. sponse Less than 3 usec Voltage ON State V Drop lt 0 3 V Minimum ON 5 0 mA 9 VDC required to External Power Supply For loop power only not required for internal module function Cen A Overcurrent Protection 15 A max pen OFF 2 0 mA Thermal Shutdown Tjunction 150 C OFF to ON Response Less than 3 psec Overtemperature Reset Tjunction 130 C Duty Cycle Range 1 to 99 in 1 increments default 50 ON to OFF Response Less than 3 usec Configurable Presets a Each output can be assigned one preset or a single b Each output can be assigned one table of presets one table can contain max 128 b multiple presets max predefined tables 255 User supplied power source required for stepper drive configuration T1H CTRIO Input Resources T1H CTRIO Output Resources 4 2 per 4 input channel grou Pulse output Discrete outputs Pulse outputs 2 channels 2 outputs each channel Discrete outputs 4 pts Counter Timer 5 ut group put p p 2 outp puts 4 p Pulse outputs pulse direction or cw ccw Profiles Trapezoid S Curve 1X 2X or 4X Quadrature Up or symmetrical S Curve Dynamic Position Dynamic Velocity Home Search Resource Down Counter Edge Timer Dual Velocity Mode Run to Limit Mode and Run to Position Mode Options Edge Timer Input Pulse Catch Reset Resource Options Discrete outputs 4 configurable for set reset pulse on pulse off tog
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