2CH HSC+2 CH PTO User Manual

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Messung Systems NEXGEN PLC Plug In Modules

NEXGEN Series of PLCs


2 Channel HSC + 2 Channel PTO User Manual

Document No.:ED-2002-053

Version: 1.0

Published Sept 2002

MESSUNG SYSTEMS
EL-2, J- Block MIDC Bhosari,
Pune – 411026.(INDIA)

Tel: (+91)-020-7120807, 7122807.


Email : marketing@ms.messung.com
WEB: www.messung.com

2CH HSC+2 CH PTO User Manual Published Sept 2002


Document No.: ED-2002-053 /V1.0 Page 1 of 26
NEXGEN PLC Plug In Modules Messung Systems

Revision

Version Date Description

2 Channel HSC + 2 Channel PTO User


1.0 3 September 2002
Manual

Published Sept 2002 2CH HSC+2 CH PTO User Manual


Page 2 of 26 Document No.: ED-2002-053/V1.0
Messung Systems NEXGEN PLC Plug In Modules

INDEX
1. INTRODUCTION ............................................................................................................... 5
2. ORDERING INFORMATION ............................................................................................. 6
3. GENERAL SPECIFICATIONS .......................................................................................... 7
4. HIGH SPEED COUNTER.................................................................................................. 8
4.1 MODES OF OPERATION OF HIGH SPEED COUNTER ......................................................... 9
4.1.1 Mode 0................................................................................................................. 9
4.1.2 Mode 1............................................................................................................... 10
4.1.3 Mode 2.............................................................................................................. 11
5. PULSE TRAIN OUTPUT ................................................................................................. 12
5.1 MODE 0...................................................................................................................... 12
5.2 MODE 1...................................................................................................................... 13
6. WIRING............................................................................................................................ 14
6.1 HIGH SPEED INPUT CONNECTIONS............................................................................... 16
6.1.1 Differential High Speed Input Connections ....................................................... 16
6.1.2 Open Collector (NPN) High Speed Input Connections ..................................... 17
6.1.3 Open Collector (PNP) High Speed Input Connections ..................................... 18
6.2 PULSE TRAIN OUTPUT CONNECTIONS .......................................................................... 19
6.2.1 Differential Pulse Train Output Connections ..................................................... 19
6.2.2 Open Collector (PNP) Pulse Train Output Connections ................................... 20
7. LIBRARY HSC_PTO ....................................................................................................... 21
7.1 HSC_DRV1, HSC_DRV2 (FB) ................................................................................. 22
7.2 PTO_DRV1, PTO_DRV2 (FB).................................................................................. 24

INDEX OF FIGURES
FIGURE 1 : BOTTOM SIDE OF PROCESSOR MODULE WITH 2 HSC+ 2 PTO PLUG IN MODULE ......... 5
FIGURE 2 : HSC MODE 0 ............................................................................................................ 9
FIGURE 3 : HSC MODE 1 ........................................................................................................ 10
FIGURE 4 : HSC MODE 2 .......................................................................................................... 11
FIGURE 5 : PTO MODE 0......................................................................................................... 12
FIGURE 6 : PTO OPERATION MODE 1 ....................................................................................... 13
FIGURE 7 : PATCH PANEL 2 HSC & 2 RS 422 TYPE PTO (4962)............................................... 14
FIGURE 8 : PATCH PANEL 2 HSC & 2 PNP TYPE PTO (4960) ................................................... 15
FIGURE 9 : INTERFACE CABLE .................................................................................................... 15
FIGURE 10 : DIFFERENTIAL INPUT CONNECTIONS ........................................................................ 16
FIGURE 11 : OPEN COLLECTOR (NPN) INPUT CONNECTIONS ...................................................... 17
FIGURE 12 : OPEN COLLECTOR (PNP) INPUT CONNECTIONS ...................................................... 18
FIGURE 13 : DIFFERENTIAL OUTPUT CONNECTIONS WITH PATCH PANEL 4962 .............................. 19
FIGURE 14 : OPEN COLLECTOR (PNP) OUTPUT CONNECTIONS WITH PATCH PANEL 4960 ............ 20

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Guidelines for the safety of the user and protection of I/O modules

This manual provides information for the use of I/O Module. The manual has
been written to be used by trained and competent personnel. The definition of
such a person or persons is as follows:
a) DESIGN ENGINEER Any engineer who is responsible for the planning,
design, and construction of automatic equipment using the product
associated with this manual should be of a competent nature, trained
and qualified to the local and national standards required to fulfill the
role.. These engineers should be fully aware of all the aspects of safety
with regards to automated equipment.

b) COMMISSIONING/SERVICE ENGINEER. Any engineer who is


responsible for the commissioning, use and maintenance of automatic
equipment using the product associated with this manual should be of a
competent nature, trained and qualified to the local and national
standards required to fulfill the role .This includes being completely
familiar with all the associated documentation** for the said system.
Maintenance to be carried out in accordance to the established safety
practices.

c) OPERATORS. The personnel using the completed equipment* should


be trained to use the product in a safe and co-ordinated manner in
compliance to established safety practices. They should be also familiar
with documentation, which is relevant to the actual operation of the
equipment.

Note: The term-completed equipment refers to a third party constructed


device, which contains or uses the product associated with this manual.

Warning !

This product can only function correctly and safely if it is


installed correctly and operated and maintained as
recommended.

Warning !

The specifications of product and contents of manual


are subject to change without notice.

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Messung Systems NEXGEN PLC Plug In Modules

1. Introduction
In Processor 5214, 2 Channel HSC + 2 Channel PTO functionality is
provided with plug in module fixed at bottom side of Processor Module. It
provides two independent channels for high-speed counter inputs and two
independent channels for pulse train outputs.

The Processor 5214 module is available with patch panel along with
interface cable to connect field I/Os. The figure shows the bottom view of
Processor module (5214) with plug in module. Plug in module has 25 pin
female D connector fixed on it.

Figure 1 : Bottom Side of Processor Module with 2 HSC+ 2 PTO Plug In Module

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2. Ordering Information

The table below gives the items related to 2 Channel HSC + 2 Channel PTO.

Item Ordering Code


Processor Module with 2 Channel HSC + 2 Channel PTO 5214

Patch Panel 2 HSC & 2 PNP type PTO 4960

Patch Panel 2 HSC & 2 RS422 type PTO 4962

Interface Cable ( 0.5 meter length) 4944

Interface Cable ( 1 meter length) 4945

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3. General Specifications

General specifications are given in the table below.

High Speed Counter Input


Channels 2 nos.
Inputs A, B and Z
Frequency 100 KHz Maximum
Counting Range -2147483648 to 2147483647
Type
Open Collector (18-30 VDC inclusive of ripple)
(Selectable by input
connections at Patch
Differential ( RS-422 )
Panel)
7 mA for open collector type of Input.
Current
15 mA for differential type of Input.
Min. ON time duration 10 µs
Min. OFF time
10 µs
duration
Pulse input , Counts at rising edge of
Mode 0 Direction input input depending upon
and Reset input Direction.
Pulse input , Counts at rising and falling
Mode of Operation Mode 1 Direction input edge of input depending
(Software Selectable) and Reset input upon Direction.
Phase A input,
Counts at rising and falling
Phase B input
Mode 2 edge of phase A input and
and Zero
phase B input.
Marker input
Pulse Train Output
Channels 2 nos.
Outputs FP+ and FP-
100 KHz, ±1% maximum for differential output with patch
panel 4962.
Frequency
5 KHz, ±1% maximum for open collector (PNP) output
with patch panel 4960.
Duty Cycle 50 %
Pulse output range 0 to 4294967296 with Direction
Open collector With patch panel
(18 – 30 VDC 2 HSC & 2 PNP type PTO
Type
including ripple) (Ordering Code – 4960)
(Selectable by type of
patch panel) With patch panel
Differential
2 HSC & 2 RS 422 type PTO
( RS-422 )
(Ordering Code – 4962
60 mA maximum for differential output with patch panel
4962.
Current
1.5 Amp maximum for open collector (PNP) output with
patch panel 4960.
Mode of Operation Mode 0 Pulses and Direction
(Software selectable) Mode 1 Forward Pulses and Reverse Pulses
For pulse output driving circuit.
External Power Supply
24 VDC ( 18 – 30 VDC including ripple), 100 mA

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4. High Speed Counter

Processor 5214 provides two independent channels for HSC (High Speed
Counter) inputs. Each channel provides three input interfaces as A, B and Z.
Channel provides hardware interface for open collector ( PNP and NPN )
inputs of 24 VDC or differential ( RS-422 ) inputs. This depends on type of
connection.

To configure and handle high speed input channels, Processor 5214


provides driver FB (function block) for each channel as HSC_DRV1 and
HSC_DRV2. These are provided in library HSC_PTO.lib. Driver FB sets
mode of operation and provides accumulated count and status of Z input.
Counter provides pulse count in double integer format. Pulse counting is as
shown below.

Up Direction

Down Direction
-2147483648 0 2147483647

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4.1 Modes of Operation of High Speed Counter

For HSC, three modes of counting are provided as explained below.

4.1.1 Mode 0

In this mode, high speed input is interfaced to A input. Direction input is


interfaced to B Input. Counter increments its count by 1 at rising edge of
pulse input if direction input is FALSE. Counter decrements its count by 1 at
rising edge of pulse input if direction input is TRUE. The following figures
show the counter behavior in x 1 mode.

Count

Figure 2 : HSC Mode 0

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4.1.2 Mode 1

In this mode, high speed input is interfaced to A input. Direction input is


interfaced to B Input. Counter increments its count by 1 at rising and falling
edge of pulse input if direction input is FALSE. Counter decrements its count
by 1 at rising edge and falling edge of pulse input if direction input is TRUE.
The following figures show the counter behavior in x 2 mode.

Count

Figure 3 : HSC Mode 1

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4.1.3 Mode 2

In this mode, encoder phase A input is interfaced to A input, phase B is


interfaced to B input and zero marker input is interfaced to Z input. If A phase
is leading to B phase, counter increments. Counter increments its count by 1
at rising and falling edge of both A phase pulse input and B phase pulse
input. If A phase is lagging to B phase, counter decrements. Counter
decrements its count by 1 at rising and falling edge of both A phase pulse
input and B phase pulse input. The following figures show the counter
behavior in x 4 mode.

Count

Figure 4 : HSC Mode 2

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NEXGEN PLC Plug In Modules Messung Systems

5. Pulse Train Output

Processor 5214 provides two independent channels for PTO (Pulse Train
Output). Channel provides two output interfaces. The outputs functionality
depends on the mode of operation selected.

To configure and handle PTO, Processor 5214 provides driver FBs


PTO_DRV1 and PTO_DRV2. These are provided in library HSC_PTO.lib.

Driver FB selects the mode of operation, number of pulses, output frequency


and direction. The modes of operation are explained below

5.1 Mode 0

This mode provides two outputs, one as pulse output (FP) and another as
direction (RP) as shown below.
Pulse
Output
FP

Direction
RP
Forward Reverse Forward

Figure 5 : PTO Mode 0

In mode 0, driver FB generates number of pulses with frequency defined by


user. Depending on direction, status of direction output is FALSE or TRUE.

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5.2 Mode 1

This mode provides two outputs, one as forward pulse output (FP) and
another as reverse pulse output (RP) as shown below.
Forward
Pulse
Output
FP
Reverse
Pulse
Output
RP

Figure 6 : PTO Operation Mode 1

In mode 1, driver FB generates number of pulses with frequency defined by


user. Depending on direction, pulses are generated at forward pulse output
or reverse pulse output.

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6. Wiring

In Processor 5214, plug in module is fixed at bottom side of Processor


Module. It provides two high-speed counter inputs and two pulse train
outputs. For external interface, patch panel (DIN rail mountable) is provided.
Interface cable ( 0.5 / 1 meter length ) with 25-pin D male connectors at both
ends connects Processor module and patch panel. Patch panel provides 25
pin female D connector where interface cable from Processor module can be
connected. It provides terminals to interface field inputs and outputs. Patch
panel should be mounted on a DIN rail.

Depending on type if pulse output interfaces, two type of patch panels are
provided.

• 2 HSC & 2 PNP type PTO (Ordering Code – 4960)


• 2 HSC & 2 RS422 type PTO (Ordering Code – 4962)

The figures below shows the front view of patch panel 4962 along with
connection details. This patch panel is to be selected if differential (RS 422)
type of pulse output is needed.

Figure 7 : Patch Panel 2 HSC & 2 RS 422 type PTO (4962)

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The figures below shows the front view of patch panel 4960 along with
connection details. This patch panel is to be selected if open collector (PNP)
type of pulse output is needed.

Figure 8 : Patch Panel 2 HSC & 2 PNP type PTO (4960)

The interface cable with 25 pin male D connector at both ends is required to
connect Processor module and the patch panel. This is one to one
connection cable with shield terminal brought out at both ends. The figure
below shows the interface cable.

Figure 9 : Interface Cable

It is available with length of 0.5 meter (ordering code 4945) and 1 meter
(ordering code 4946).

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6.1 High Speed Input Connections

Differential as well as NPN and PNP type of input interface is provided. The
input connections explained below are applicable for patch panel (4960) as
well as patch panel (4962).

6.1.1 Differential High Speed Input Connections

The figure below shows the input stage of hardware along with connection of
differential input.

Differential ( RS-422) input is connected between terminal numbers 2,3 (HSC


A+ and HSC A-) , between terminal number 5,6 (HSC B+ and HSC B-) and
between terminal numbers 8,9 (HSC Z+ and HSC Z-).

HSC AV
No Connection 3.9KΩ Opto
Isolation
HSC A+ 100Ω

1.5KΩ
100Ω
HSC A-

Figure 10 : Differential Input Connections

Similar connections should be carried out for B and Z inputs.

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6.1.2 Open Collector (NPN) High Speed Input Connections

The figure below shows the input stage of hardware along with connection of
open collector (NPN) type of input.

NPN type of input is connected to terminal numbers 3 (HSC A-) , to terminal


number 6 (HSC B-) and to terminal numbers 9 (HSC Z-). 24 VDC is
connected to terminal number 1 (HSC AV), to terminal number 4 (HSC BV)
and to terminal number 7 (HSC ZV).

HSC AV
+24 V 3.9KΩ Opto
Isolation
HSC A+ 100Ω
No Connection
1.5KΩ
100Ω
HSC A-

Figure 11 : Open Collector (NPN) Input Connections

Similar connections should be carried out for B and Z inputs.

Any wrong connection may damage input section.

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6.1.3 Open Collector (PNP) High Speed Input Connections

The figure below shows the input stage of hardware along with connection of
open collector (PNP) type of input.

PNP type of input is connected to terminal number 1 (HSC AV), to terminal


number 4 (HSC BV) and to terminal number 7 (HSC ZV). Supply ground is
connected to terminal numbers 3 (HSC A-) , to terminal number 6 (HSC B-)
and to terminal numbers 9 (HSC Z-).

+24 V

HSC AV
3.9KΩ Opto
Isolation
HSC A+ 100Ω
No Connection
1.5KΩ
100Ω
HSC A-

Figure 12 : Open Collector (PNP) Input Connections

Similar connections should be carried out for B and Z inputs.

Any wrong connection may damage input section.

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6.2 Pulse Train Output Connections

Patch panel (4962) provides differential outputs and patch panel (4960)
provides open collector (PNP) outputs.

6.2.1 Differential Pulse Train Output Connections

The figure below shows the output stage of hardware for differential output
with patch panel (4962)

Differential ( RS-422) output is connected between terminal numbers 10,11


(PTO FP+ and PTO FP-) and between terminal number 12,13 (PTO RP+
and PTO RP-).

5 VDC

4.7KΩ
PTO FP+

Differential
Output

PTO FP-

Opto
Isolation
+ 24 VDC
External +
DC to DC 5 VDC
24 VDC _ Converter
Supply GND

Figure 13 : Differential Output Connections with patch panel 4962

Similar connections should be carried out for PTO RP+ and RP-.

For functioning of PTO circuit, external 24 VDC, 100 mA supply is required.


This supply is to be connected between terminal numbers 14, 15 (+24V and
GND). Internal DC to DC converter converts 24 VDC to 5 VDC.

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6.2.2 Open Collector (PNP) Pulse Train Output Connections

The figure below shows the output stage of hardware for PNP type of output
with patch panel (4960).

Open collector output is connected between terminal numbers 10 (PTO FP)


and ground and between terminal number 11 (PTO RP) and ground. The
terminal number 15 is ground terminal. b

5 VDC

4.7KΩ

PTO FP Driver
Circuit

Open
Collector Opto
Output Isolation
+ 24 VDC
External +
DC to DC 5 VDC
24 VDC _ Converter
Supply GND

Figure 14 : Open Collector (PNP) Output Connections with patch panel 4960

Similar connections should be carried out for PTO RP.

For functioning of PTO circuit, external 24 VDC, 100 mA supply is required.


This supply is to be connected between terminal numbers 12, 13 (+24V and
GND). Internal DC to DC converter converts 24 VDC to 5 VDC.

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7. Library HSC_PTO
Nexgen 5000 Processor provides two channels of high speed counter inputs
and two channels of pulse output. This functionality is provided on plug in
module in Processor 5214. Along with this hardware, operating system
provides function blocks (FBs) to control generation of pulse output and to
count input pulses. These FBs are provided in an external library file
HSC_PTO.lib. The subsequent sections describe the working of FBs.

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7.1 HSC_DRV1, HSC_DRV2 (FB)

This FB counts number of pulses as per


mode of operation. FB HSC_DRV1 counts
pulses at channel 1 while FB
HSC_DRV2counts pulses at channel 2.

Description of Parameters-

If BOOLean input Run is TRUE, FB starts counting pulses


Run VAR_IN BOOL
as per mode of operation selected.
This defines mode of operation of counting.
Mode is selected at rising edge of BOOLean input Run.
Any change in mode afterwards is ignored. If Mode=0,
mode 0 is selected. If Mode=1, mode 1 is selected. If
Mode=2, mode 1 is selected. For any other value, FB does
not generate any pulses.
In mode 0, Counter increments its count by 1 at rising
edge of pulse input (A) if direction input (B) is FALSE.
Counter decrements its count by 1 at rising edge of pulse
input (A) if direction input (B) is TRUE.
Mode VAR_IN BYTE In mode 1, Counter increments its count by 1 at rising and
falling edge of pulse input (A) if direction input (B) is
FALSE. Counter decrements its count by 1 at rising edge
and falling edge of pulse input (A) if direction input (B) is
TRUE.
In mode 2, If pulse input A is leading to pulse input B,
counter increments. Counter increments its count by 1 at
rising and falling edge of both A pulse input and B pulse
input. If pulse input A is lagging to pulse input B, counter
decrements. Counter decrements its count by 1 at rising
and falling edge of both A pulse input and B pulse input.
P VAR_IN BOOL Not implemented.
PRV VAR_IN DINT Not implemented.
BOOLean input Z resets count CV to 0. CV remains 0 as
Z VAR_IN BOOL
long as Z input is TRUE.
BOOLean output ZERO becomes TRUE when hardware
input Z to counter is TRUE. When ZERO is TRUE, count
ZERO VAR_OUT BOOL
CV becomes 0. Boolean output ZERO becomes FALSE
when hardware input Z to counter is FALSE.
Output CV holds number counted pulses as per counting
CV VAR_OUT DINT mode selected. The range is -2147483648 to
2147483647.

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Example-

When BOOLian input Run is TRUE, FB starts counting pulses at channel 1.


As mode 2 is selected, If pulse input A is leading to pulse input B, counter
increments. Counter increments its count by 1 at rising and falling edge of
both A pulse input and B pulse input. If pulse input A is lagging to pulse input
B, counter decrements. Counter decrements its count by 1 at rising and
falling edge of both A pulse input and B pulse input.

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7.2 PTO_DRV1, PTO_DRV2 (FB)

This FB generates number of pulses


specifiedby PV with frequency specified by
Freq. FB PTO_DRV1 generates pulses at
channel 1 while FB PTO_DRV2 generates
pulses at channel 2.

Description of Parameters-

If BOOLean input Run is TRUE, FB starts generating


pulses. If Run is FALSE, pulses are stopped. Output CV
Run VAR_IN BOOL
becomes zero and BOOLean outputs DN and OV are
reset.
This defines mode of pulse output.
Mode is selected at rising edge of BOOLean input Run.
Any change in mode afterwards is ignored. If Mode=0,
mode 0 is selected. If Mode=1, mode 1 is selected. For
Mode VAR_IN BYTE any other value, FB does not generate any pulses.
Mode 0 provides two outputs, one as pulse output (FP)
and another as direction (RP).
Mode 1 provides two outputs, one as forward pulse output
(FP) and another as reverse pulse output (RP).
FB generates pulses with frequency defined by Freq. The
range is from 3 Hz to 100000 Hz. For values less than 3,
pulses with frequency 3 Hz are generated. For values
Freq VAR_IN DWORD greater than 100000, pulses with frequency 100000 Hz
are generated.
The duty cycle of pulse output is fixed to 50 %.
During Run time, the change in frequency is effective.
FB generates total number of pulses defined by PV. The
range is from 0 to 4294967296. After generating pulses
equal to PV, FB sets BOOLean output DN to TRUE and
PV VAR_IN DWORD stops generating pulses further. During Run time, the
change in PV is effective. If PV<CV, then pulse generation
is immediately stopped and BOOLean output DN becomes
TRUE.
Boolean input Dir decides direction of pulses at rising
edge of BOOLean input Run. Any change in Dir
afterwards is ignored. If Dir is FALSE, pulses are
Dir VAR_IN BOOL
generated in forward direction. If Dir is TRUE, pulses are
generated in reverse direction. FB generates pulses as
per mode of operation.
Boolean input decides operation type at rising edge of
BOOLean input Run. Any change in OP afterwards is
OP VAR_IN BOOL ignored. If OP is TRUE, it is continuous operation. Pulses
are generated continuously as long as Run is TRUE. If OP
is FALSE, it is preset operation.

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Output CV displays the number of pulses generated by


FB. When Run is TRUE, CV starts incrementing. When
CV VAR_OUT DWORD
CV=PV, BOOLean output DN becomes TRUE and FB
stops any pulse generation further.
Boolean output DN is TRUE when CV=PV. It is reset when
DN VAR_OUT BOOL
Run is FALSE.
If CV crosses DWORD limit i.e. 4294967296, then
BOOLean output OV becomes TRUE and remains true
OV VAR_OUT BOOL
from one call to next call of FB. When CV crosses
4294967296, it starts incrementing from 0 again.

Example-

When BOOLEan input EN is TRUE, FB is executed. The status of BOOLean output


OUT changes as IN changes as shown below.

When BOOLean input Start is TRUE, FB instance PTO2 start generating


pulses with frequency 2000 Hz at channel 2. The mode of operation is 0 so
that pulses are generated at output FP and output RP is FALSE as Direction
selected is Forward. When Start input is TRUE, CV starts incrementing
towards 50000. When CV=PV, BOOLean output InPosition becomes TRUE.

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NEXGEN PLC Plug In Modules Messung Systems

MESSUNG SYSTEMS
EL – 2, J - Block, MIDC, Bhosari,
PUNE – 411 026. INDIA
Tel. – (+91) –020 – 712 0807, 712 2807
Fax. – (+91) –020 –712 0391

NEXGEN PLC I/O Modules


2 Channel HSC + 2 Channel PTO User Manual

Document No.:ED-2002-053

Published Sept 2002 2CH HSC+2 CH PTO User Manual


Page 26 of 26 Document No.: ED-2002-053/V1.0

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