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NEXGEN PLC I/O Modules

NEXGEN PLC

8 Channel Analog Input Module (Ordering Code – 4308)

Document No.:ED-2002-015

Version: 1.01

Code – 4308) Document No.:ED-2002-015 Version: 1.01 MESSUNG SYSTEMS EL-2, J- Block MIDC Bhosari, Pune –

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

Tel: (+91)-020-2712 0807, 2712 2807. Email : marketing@ms.messung.com WEB: www.messung.com

8 Ch Analog Input Module (4308) Document No.: ED-2002-015/V1.01

Published Feb 2004 Page 1 of 38

NEXGEN PLC I/O Modules

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Revision

Version

Date

Description

1.0 Jun 2003

 

8 Channel, Analog Input Module (Ordering Code–4308) NEXGEN Series of PLCs.

   

In the Section 1.3 General Specifications, specifications of accuracy, input impedance for current input and back

1.01 Feb 2004

plane current updated. In the section 4.1 Slot Configuration, Nexgen5000 related PLC Configuration information added. Section 4.4 Programming with Nexgen5000 added.

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INDEX

1. Module Overview

7

1.1

Analog Input Module Overview

7

1.2

LED Indications

9

1.3

General Specifications

10

2. Module Operation

11

2.1

Block Diagram

11

2.2

Analog Input types and range of binary values 12

2.3

On-Board Processor Operations

12

2.3.1 Power On Operations 12

2.3.2 Analog to Digital Conversion 13

2.3.3 Averaging

14

2.4

Module Information

15

2.4.1 Input Output Image Mapping 15

16

2.4.3 Commands 17

2.4.2 Memory Mapping

2.4.4 Module Status Bits

17

3. Installations and Wiring

18

3.1

Module Installation

18

3.2

Connection Details

18

3.3

Precautions to be taken

20

4. Configuration and Programming

21

4.1

Slot Configuration

21

4.2

Channel Configuration

22

4.3

Programming with Nexgen 4000 CPU

26

4.4

Programming with Nexgen 5000 CPU

30

5. Troubleshooting

35

5.1

LED Indications for Diagnostics 36

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Index of Figures

Figure 1 : Front View

8

Figure 2 : Block diagram

11

Figure 3 : ADC Conversion Cycle

13

Figure 4 : Input Output Image Mapping

15

Figure 5 : Memory Mapping

16

Figure 6 : Connection diagram

19

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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 the I/O Modules. 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) 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 that role. These engineers should be fully aware of all aspects of safety with regards to automated equipment.

b) Any commissioning or service engineer must be of a competent nature, trained and

qualified to the local and national standards required to fulfill that job. These engineers should also be trained in the use and maintenance of the completed product. This Includes being completely familiar with all associated documentation for the said product. All maintenance should be carried out in accordance with established safety

practices.

c) All operators of the completed equipment should be trained to use that product in a

safe and coordinated manner in compliance to established safety practices. The operators should also be familiar with documentation, which is connected with the

actual operation of the completed equipment.

Note: The term-completed equipment refers to a third party constructed device, which contains or uses the product associated with this manual. Note on the Symbol used in this Manual At various times through out this manual certain symbols will be used to highlight points of Information, which are Intended to ensure the users personal safety and protect the integrity of equipment. Whenever any of the following symbols are encountered it’s associated.

Note must be read and understood. Each of the symbols used is listed below; with a brief description of its meaning.

Warning !

This product can only function correctly and safely if it is transported, stored, setup, and

This product can only function correctly and safely if it is transported, stored, setup, and installed correctly, and operated and maintained as recommended.

Warning !

The specifications of product and contents of manual are subject to change without notice.

The specifications of product and contents of manual are subject to change without notice.

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1. Module Overview

This chapter describes the following Analog Input Module Overview LED Indications General Specifications

1.1 Analog Input Module Overview

This analog input module converts input voltage or current values into equivalent binary values. This is sigma - delta type A/D conversion. It provides 8 non- isolated channels. The individual channel can be configured for specific type of voltage or current input. The voltage and current ranges are – -10 to 10V

0

to 10 V

0

to 5 V

1

to 5 V

0

to 20 mA

4

– 20 mA

The resolution of ADC is 305.176 µV / 1.221 µA for voltage / current input irrespective of range. The parameters that are passed to the module for advanced processing are – input filter frequency (50 / 60 / 250 / 500 Hz) open circuit value number of averaging samples

The module provides diagnostic information for each channel. It includes – open circuit invalid configuration

This is an intelligent module with on-board processor and memory. The data transfer between CPU module and analog input module takes place by 'READ_W' / ‘IM_Read’ and 'WRITE_W' / ‘IM_Write’ functions in the application program. The module status is available in input image and commands can be issued through output image.

The figure on next page shows front view of analog input module

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4308 Terminal Block ANALOG INTPUT 8 CH – V/I Fixing Screw NO 24 V SUPPLY
4308
Terminal Block
ANALOG INTPUT
8 CH – V/I
Fixing Screw
NO 24 V SUPPLY
Module
01
Status
CPU ERROR
02
LEDs
03
CONF. ERROR
04
05
06
07
08
09
10
CH0
11
CH1
V
IN0
Front Shield
12
V
IN1
CH2
Plate
13
I IN0
CH3
Channe
14
I IN1
Status
CH4
15
COM 0
LEDs
16
CH5
COM 1
17
CH6
38 Pin
V
IN2
18
CH7
Terminal
V
IN3
19
I
IN2
Block
20
I
IN3
21
COM 2
22
COM 3
23
V
IN4
24
V
IN5
25
I
IN4
26
I
IN5
27
IO Label
COM 4
28
COM 5
29
V
IN6
30
V
IN7
31
I
IN6
32
I
IN7
33
COM 6
34
COM 7
35
+
24 V
36
Terminal Block
GND
37
Fixing Screw
EARTH
38
LED
Connection
Front Door
Indications
Details

Figure 1 : Front View

The module provides LED indications on the front. Brief information about channel can be written on the front door. Below the front door, 38-pin removable terminal block is provided for interfacing analog signals. The connection details are shown on backside of the front door.

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The analog module can be configured in any IO slot of the PLC. The number of analog input modules is limited by back panel current capacity. In general a channel requires following information – registers to hold configuration information (2 words) register to hold data (1 word) and registers to hold status information (1 word)

1.2 LED Indications

The following table explains significance of 11 numbers of LEDs provided on the module.

No.

LED

Color

Status

 

Description

     

OFF

24

VDC supply to module healthy.

1

NO 24 V SUPPLY

Orange

ON

24

VDC supply to module absent.

24

VDC circuit on-board glass fuse blown.

     

OFF

Module hardware healthy and module is ready.

2

CPU ERROR

Orange

 

Module in self test.

ON

CPU watchdog faulty.

     

Module busy.

3

CONF. ERROR

Orange

OFF

Channel configuration valid.

ON

Channel configuration invalid.

     

OFF

Channel not enabled

Channel Status

ON

Channel enabled and healthy

4

(Eight for eight channels)

Green

 

Open circuit for input type 1- 5 VDC and 4 -20 mA.

Flashing

Over range

 

Under range

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1.3 General Specifications

General specifications of 8 channel analog input module are as given below.

Number of Input channels

8

Non isolated.

Conversion Method

 

Sigma Delta

 
   

-10 to 10 V DC

 

Voltage

0

to 10 V DC

Analog Input

0

to 5 V DC

types

 

1

to 5 V DC

Current

0

to 20 mA

4

to 20 mA

Analog to Digital conversion time

Filter

Channel Update

Significant bits

frequency

time

 
 

50

Hz

60

ms

16

bits

 

60

Hz

50

ms

16

bits

250

Hz

12

ms

13

bits

500

Hz

6 ms

 

10

bits

Digital output

-32768 to 32767

 
 

Voltage / Current range

Significant bits

 

Resolution per LSB

-10 to 10 V DC

 

16

bits

305.176

µV

Number of significant bits ( With 50 Hz filter )

0

to 10 V DC

 

15

bits

305.176

µV

0

to 5 V DC

 

14

bits

305.176

µV

1

to 5 V DC

13.67

bits

 

305.176

µV

0

to 20 mA

 

14

bits

1.2207

µA

 

4

to 20 mA

13.67

bits

 

1.2207

µA

Accuracy at filter frequency 50 Hz

Ambient at 25°C, ±5°C

Ambient at 58°C, ±5°C

Larger value ±20 counts or ±0.1 % of FSD

Larger value ±60 counts or ±0.3 % of FSD

Isolation

Channel to channel

No

 

Channel to internal circuit

1.5 KV optical

 

Absolute maximum

 

Voltage

± 15 VDC

 

input

Current

± 30 mA

 

Input Impedance

 

Voltage

1 M Ohms

 

Current

250 Ohms

 

External voltage requirement

 

24

V DC, 200 mA (18 to 30 VDC including ripple)

External supply protection

315 mA miniature glass fuse on module

Reverse polarity protection

 
 

No 24 V Supply

 

Indications

 

CPU error

Configuration error

 
 

Channel status (8 nos.)

 

Back-plane current consumption

210

mA

 

IO points consumed

 

8

input bits and 8 output bits

 

Termination

Removable 38 pin terminal block

 

Ordering code

4308

 

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2. Module Operation

This chapter helps in getting started with the analog input module. It describes the basic operation of the module. This chapter explains operational details of:

Block Diagram

Analog input Types and Range.

On-Board Processor Operations

Module Information

At the time of application program development, the module can be configured using the programming software so that above special features can be used

2.1 Block Diagram

Block diagram of analog input module is shown below.

22 KΩ Watch V IN0 Dog Σ/ ∆ Tranzorb I IN0 Analog to Digital 4K7PF
22
KΩ
Watch
V IN0
Dog
Σ/ ∆
Tranzorb
I IN0
Analog to
Digital
4K7PF
250
Converter
COM0
O
On board
Analog Ground
P
Processor
T
I
Amplifier
C
A
L
Memory for
Configuration,
I
Multiplexer
22
KΩ
Data, Status
S
V IN7
Information
O
Tranzorb
I IN7
L
A
4K7PF
250
T
COM7
I
Analog Ground
CPU
O
Module
N
No 24 V Supply
Module
Interface
+15 V
Circuit
+ 24 VDC
-15 V
DC-to-DC
GND
Supply for
+5 V
Converter
+ 5 V
ADC Circuit
-5 V
Earth
GND
GND

Figure 2 : Block diagram

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The module provides eight analog to digital channels for voltage/ current input. CPU bus is optically isolated from ADC circuit. ADC operates on the data from the channels. The enabled channel input signals are multiplexed and then amplified for ADC input. Thus sigma-delta (Σ/ ) ADC converts only enabled analog channels to digital value one by one. The converted count for each channel is manipulated by on-board processor and binary data is transferred to module memory, which holds channel data information.

If averaging is required, depending on the averaging count, on-board processor performs averaging of those many previous readings and updates channel data information.

The configuration, data, status information is available in dual port RAM on the module. The configuration of all channels is transferred to the module memory using WRITE_W / IM_Write function in the application program. Similarly data and status of all channels can be read by READ_W / IM_Read function in the application program.

The module requires external 24 VDC supply for ADC circuit operation. Internally DC- to-DC converter generates ±15 VDC and ±5 VDC as required by each channel. If 24 VDC is absent or on-board glass fuse is blown, module generates 'No 24 V Supply' signal for main CPU. The fuse protection for external 24 VDC supply is provided on module.

2.2 Analog Input types and range of binary values

This section describes the analog input types and data range of binary values.

 

Input Type

 

Binary Value Range

-10 to 10 VDC

-32000 to 32000

0

to 10 VDC

0

to 32000

0

to 5 VDC

0

to 16000

1

to 5 VDC

3200

to 16000

0

to 20 mA

0

to 16000

4

to 20 mA

3200

to 16000

2.3 On-Board Processor Operations

The analog input module is intelligent module with on-board processor. The functions of on-board processor are explained in the sections below.

2.3.1 Power On Operations

After power ON, if 24 V supply to module is absent or on-board fuse is blown then on- board processor sets Ix.0 bit of input image. After power ON, this processor carries out self test. During self-test and if hardware error is detected, Ix.0 bit is set. Also CPU fault LED on front panel is put ON indicating that module is not accessible. During module operation, if module hardware is found faulty or watchdog error is detected, Ix.0 bit is set.

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If the module hardware is OK, Ix.0 bit is cleared. The module waits for configuration from the CPU module. After reception of valid configuration of input channels, the module starts sampling and digital conversion cycle of enabled channels.

The module continues sampling, converting the channels and updating module memory even after the PLC is put in STOP mode. But In this case, CPU module does not read the channel data and status.

2.3.2 Analog to Digital Conversion

The module samples the input channel and converts voltage or current input to its digital value one by one. After power on, as shown in the figure below, only enabled channels are converted. If any error like invalid configuration is detected, channel is not converted. The disabled channels are bypassed retaining earlier values. After one channel conversion, module initiates next channel conversion. During this conversion period, module processes converted data of previous channel. This process includes averaging as per configuration. Thus the processed data for previous channel is made available during this period. After converting all healthy channels, processed data and status information of all the channels is transferred to respective memory area on the module. This cycle continues. Thus when the processor module performs READ_W operation, it reads either old or new information i.e. data and status of channels.

 

Channel 0

Channel 1

Channel 2

Channel 3

disabled

disabled

disabled

disabled

   

Channel 0

 

Channel 1    Channel 0         Channel 3  

     

Channel 3    Channel 0   Channel 1        

 
    Channel 2    
    Channel 2    
    Channel 2    
   
    Channel 2    

Channel 2       

    Channel 2    
   
    Channel 2    
 

Conversion

 

Conversion

 

Conversion

 

Conversion

 

Update all

   

channel data

and status

Channel 7   Channel 6   Channel 5   Channel 4

Channel 7

 

Channel 6

 

Channel 5

 

Channel 4

Channel 7   Channel 6   Channel 5   Channel 4
 
  Conversion   Conversion   Conversion   Conversion

Conversion

 
  Conversion   Conversion   Conversion   Conversion

Conversion  Conversion     Conversion   Conversion

 
  Conversion   Conversion   Conversion   Conversion

Conversion  Conversion   Conversion     Conversion

 
  Conversion   Conversion   Conversion   Conversion

Conversion  Conversion   Conversion   Conversion  

 

Channel 7

Channel 6

Channel 5

Channel 4

disabled

disabled

disabled

disabled

Figure 3 : ADC Conversion Cycle

The module takes certain time to sample all enabled channels and convert into digital value. The required time is the module update time. The factors affecting module update time is filter frequency selected and number of channels enabled. The module update time is minimum when only one channel is enabled. Likewise the module update time is maximum when all channels are enabled.

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The module incorporates a digital low pass filter to reject noise on the input signal. The digital filter is programmable. It provides better noise rejection for low filter frequencies. Its noise rejection decreases as filter frequency is increased. Also filter frequency affects channel update time. The channel update time reduces as filter frequency is increased. The following shows update times required for different filter frequencies.

Filter Frequency

Channel Update time

50

Hz

60

ms

60

Hz

50

ms

250

Hz

12

ms

500

Hz

6 ms

2.3.3

Averaging

The module provides user selectable averaging facility so that stable value is available for processing and necessary control action. The module samples and converts enabled channels one by one. The module keeps digital value into different memory locations. Depending on the averaging count, the module performs averaging of those many previous readings and updates channel data information.

Thus if the averaging counts of channel 0, 1 and 2 are 0, 4 and 8 respectively, then initially data of channel 0, 1 and 2 are updated after 1, 4 and 8 conversion cycles respectively. After that, it gets updated in every cycle. One conversion cycle means sampling and converting all enabled channels as explained in chapter 2.3.2. Thus combination of filter frequency and averaging count can be selected to get optimum channel update time and stable temperature reading.

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2.4 Module Information

This section explains the entire information required and available with analog input module. The following points are discussed.

Input Output Image Mapping

Memory Mapping

Commands

Module Status Bits

2.4.1 Input Output Image Mapping

Input output image mapping related to analog input module is shown below. CPU Module Analog
Input output image mapping related to analog input module is shown below.
CPU Module
Analog Input Module
Input Image
Input Scan
Channel 0
No 24 V Supply or
CPU fault.
Ix.0
Invalid configuration
or out of range.
Logic Scan
Channel 1
Ix.1
IMM_IN
EN
ENO
Channel 2
SLOT
Module
Channel 3
Interface
circuit
Channel 4
Output Image
Auto calibration
Qx.0
Output Scan
Channel 5
Logic Scan
Channel 6
IMM_OUT
EN
ENO
Channel 7
SLOT

Figure 4 : Input Output Image Mapping

The module consumes 8 input bits (1 byte) of input image and 8 output bits

(1 byte)

of output image. CPU reads the status of module in input scan. CPU writes user commands to module in output scan. For immediate updation of input and output image in application program, IMM_IN / Refresh_In and IMM_OUT / Refresh_Out functions can be used in application program whenever required. For the details refer chapter 2.4.3 and 2.4.4.

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2.4.2 Memory Mapping

The memory mapping related to analog input module is shown in figure below.

CPU Module

16 words hold configuration information of 8 channels

Ch 0 Configuration

MW66

Ch 0 Configuration

MW68

Ch 1 Configuration

MW70

Ch 1 Configuration

MW72

Ch 7 Configuration

MW94

Ch 7 Configuration

MW96

9

words hold data for 8 channels

 

Ch 0 Data

MW100

 

Ch 7 Data

MW114

8

words hold status of 8 channels

Ch 0 Status

MW116

Ch 7 Status

MW134

Logic Scan

Ch 0 Status MW116 Ch 7 Status MW134 Logic Scan WRITE_W EN ENO SLOT DATA LEN
WRITE_W EN ENO SLOT DATA LEN ADDR
WRITE_W
EN
ENO
SLOT
DATA
LEN
ADDR

Logic Scan

Scan WRITE_W EN ENO SLOT DATA LEN ADDR Logic Scan READ_W EN ENO SLOT DATA LEN
READ_W EN ENO SLOT DATA LEN ADDR
READ_W
EN
ENO
SLOT
DATA
LEN
ADDR

`

16 words hold configuration informatio of 8 channels

Ch 0 Configuration

MMW256

Ch 0 Configuration

MMW258

Ch 1 Configuration

MMW260

Ch 1 Configuration

MMW262

Ch 7 Configuration

MMW284

Ch 7 Configuration

MMW286

9

words hold data for 8 channels

 

Ch 0 Data

MMW00

 

Ch 7 Data

MMW14

8

words hold status of 8 channels

Ch 0 Status

MMW16

Ch 7 Status

MMW30

Figure 5 : Memory Mapping

The configuration from PLC variable area is transferred to module memory when WRITE_W / IM_Write function gets executed in application program i.e. in logic scan. The module takes action on valid configuration information. After power on, the module starts its channel conversion operation only after receiving valid configuration. If channel configuration is modified, it takes effect only in the subsequent conversion cycle. The channel configuration can be modified using WRITE_W / IM_Write function. Similarly channel can be enabled or disabled during normal operation for optimum results.

The channel data and status information can be read from the module using READ_W / IM_Read function.

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2.4.3 Commands

As discussed in chapter 2.4.1, output image bits are used as user commands to module. User can issue various commands to module through application program. CPU writes commands in output image area of module in output scan. The module reads output image area cyclically and takes appropriate action. If 'IMM_OUT' / ‘Refresh_Out’ function is executed in logic scan for a particular slot, it stops current logic scan, executes output scan for defined slot and resumes logic scan again. This is useful when ever immediate updation of output image is needed. The functions of output image bits are given below.

 

Bit

     

No.

Address

Command

Status

Description

   

Auto

ON

It gives command to ADC to calibrate itself.

1

Qxx.0

Calibration

OFF

Auto calibration command is OFF.

Note – Qxx.1 to Qxx.7 are reserved and should not be used.

Normally, ADC is calibrated during self test after power ON and when ever 24 VDC power to the module is switched ON. Also, it is calibrated at regular interval during operation. The output image bit Qxx.0 is additional facility to the user to calibrate ADC when ever required.

2.4.4 Module Status Bits

As discussed in chapter 2.4.1, input image bits are used as module status indications. User can check the module status through application program. The module writes status in its input image area cyclically. The CPU reads this input image area in input scan. If 'IMM_IN' / ‘Refresh_In’ function is executed in logic scan for a particular slot, it stops current logic scan, executes input scan for defined slot and resumes logic scan again. This is useful when ever immediate updation of input image is needed. The functions of input image bits are given below

No.

Bit Address

Module Status

Status

 

Description

       

24

VDC supply to module absent

ON

24

VDC circuit fuse blown.

1 Ixx.0

Module Not Read

Module CPU watch dog fault.

 

Module not ready.

     

OFF

24

VDC Supply to module healthy

Module healthy and ready

   

Invalid

ON

Invalid static configuration

 

2 Ixx.1

Configuration or

 

Parameter mismatch

 

Valid static configuration

   

Open circuit

OFF

Valid parameters

Note – Ixx.2 to Ixx.7 are reserved and should not be used.

Whenever accessing the module, user must check the module status bit Ixx.0.

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3. Installations and Wiring

This chapter provides the following information –

Module Installation

Connection Details

Precautions to be taken

3.1 Module Installation

The installation procedure for analog input module is same as any other discrete I/O module. Put the module in to the desired slot of the PLC. Tighten the screw provided at the top of the module. Connect the terminal block at the front of the module and tighten it.

3.2 Connection Details

The figure shows the connection diagram of analog input module

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01 02 03 04 05 06 Voltage Input connected to channel 0 07 08 09
01
02
03
04
05
06
Voltage Input connected
to channel 0
07
08
09
+
10
11
-
V
IN0
12
V
IN1
13
I
IN0
14
I
IN1
15
Current Input connected to
channel 3
COM 0
16
COM 1
17
V
IN2
18
V
IN3
19
I
IN2
20
I
IN3
21
COM 2
22
COM 3
23
V
IN4
24
V
IN5
25
I IN4
26
I IN5
27
COM 4
28
COM 5
29
V
IN6
30
V
IN7
31
I IN6
32
+ 24 VDC
GND
I
IN7
33
COM 6
34
COM 7
EARTH
35
+
24 V
36
GND
37
EARTH
38

Figure 6 : Connection diagram

In figure, first channel is configured for voltage input where as fourth channel is configured for current input.

For interfacing analog signals, 38 pin removable terminal block is provided. The voltage input is connected to terminals V INn and COMn. Here n is channel number from 0 to 7. Current Input is connected to terminals I INn and COMn. To connect current input, short terminals V INn and I INn for respective channel. This is shown for the channel 3 in figure.

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Being susceptible to industrial noise, analog signal is to be carried out on the field through shielded twisted cable. Connect both ends of shield to Earth busbar in control panel.

For functioning of analog input module, external 24 VDC supply is required. Connect

24

VDC supply between terminals 36 (+ 24 V) and 37 (GND). Connect terminal

38

to earth busbar in the control panel.

3.3 Precautions to be taken

All the normal precautions concerning the wiring and protection of an electronic equipment in an industrial environment should be observed. To guard against coupling noise from one conductor to another, follow the guidelines given below.

Inside control panel

Following guidelines to be observed inside control panel.

All power circuit wiring e.g. connected to Power Supply Module, power contactors, etc i.e. high voltage wiring should be kept separate and apart from analog signals.

Digital Input wiring and Digital Output wiring (especially, relay output and AC output) should be separately bundled and kept as apart as possible from analog signals.

Analog signals should be carried through shielded cables.

Outside control panel

Following guidelines to be observed outside control panel.

Depending upon the type of modules used in PLC, separate ducts should be provided for

Power circuit wiring and power cables.

Input cables.

Output cables.

All cables carrying low level signals for analog IO modules, thermocouple/ RTD input modules, for communication, high frequency pulse input and output.

Wherever possible, it is recommended to

Avoid parallel routing of cables carrying analog signals and power cables, etc over long distances

Ensure that cables carrying analog signals cross at right angles to power cables so that minimum length of cable will be in close vicinity of power cables.

Run cables on metallic surfaces

Avoid number of joints

Keep cable lengths as short as possible.

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4. Configuration and Programming

This chapter explains configuration of analog input module and information exchane with analog input module. This is useful for application program development. The module configuration consists of

Slot configuration and

Channel configuration

4.1 Slot Configuration

The analog input module provides 8 analog input channels, which can be independently operated. Configuring the slot for the module is just like any other discrete IO module only. The programming software DOXMINI+ (for Nexgen 4000 PLC) and CoDeSys (for Nexgen 5000 PLC) is used for configuration and programming. The module consumes 1 byte of input image and 1 byte of output image. The input image is used for reading status of the module. The output image is used for writing user commands to the module. For more details, refer chapter 2.4.3 and 2.4.4. The IO byte consumption along with configuration of Nexgen4000 PLC is shown below.

Power Supply

Nexgen4000

Slot 0 32 DC Input Module (4632)

Slot 1 32 DC Output Module (4732)

Slot 2

Slot 3 16 DC Output Module (4716)

Module

CPU Module

Analog Input

Module (4308)

I0.0 - I0.7 I1.0 - I1.7 I2.0 - I2.7 I3.0 - I3.7

Q4.0 - Q4.7 Q5.0 - Q5.7 Q6.0 - Q6.7 Q7.0 - Q7.7

I8.0 - I8.7 Q8.0 - Q8.7

Q9.0 - Q9.7 Q10.0 - Q10.7

Input module in first slot 0 consumes IB0 to IB3 of input image. Output module in slot 1 consumes QB4 to QB7 of output image. The analog input module consumes IB8 of input image and QB8 of output image.16 DC Output module in slot 3 consumes QB9 and QB10 of output image.

The IO byte consumption along with configuration of Nexgen5000 PLC is shown below.

Power Supply

Nexgen5000

Slot 0 32 DC Input Module (4632)

Slot 1 32 DC Output Module (4732)

Slot 2

Slot 3 16 DC Output Module (4716)

Module

CPU Module

Analog Input

Module (4308)

%IX0.0 - %IX0.7 %IX1.0 - %IX1.7 %IX2.0 - %IX2.7 %IX3.0 - %IX3.7

%QX0.0 - %QX0.7 %QX1.0 - %QX1.7 %QX2.0 - %QX2.7 %QX3.0 - %QX3.7

%IX4.0 - %IX4.7 %QX4.0 - %QX4.7

%QX5.0 - %QX5.7 %QX6.0 - %QX6.7

Input module in first slot 0 consumes IB0 to IB3 of input image. Output module in slot 1 consumes QB0 to QB3 of output image. The analog input module consumes IB4 of input image and QB4 of output image.16 DC Output module in slot 3 consumes QB5 and QB6 of output image.

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4.2 Channel Configuration

The analog input module can be configured in any slot of the PLC. The 8 channels can be independently configured for different types of analog inputs. After power on the configuration of one or more channels can be transferred to the module using WRITE_W / IM_Write function. The PLC variables hold channel configuration. The channel configuration information includes – Input type Filter frequency Open circuit value Channel Enable Averaging

The configuration of channels is to be written at module memory adress starting from 256. This information is stored in bit form in 2 consecutive words for each channel. The tables below give information required to configure any channel. The valid combination of bits must be set. Any invalid combination of bits may result in unpredictable module operation.

Configuration word 1 for a channel -

Item

Description

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

 

-10 to +10V

                     

0

0

0

0

0

0

to 10V

                     

0

0

0

0

1

Input

0

to 5V

                     

0

0

0

1

0

Type

1

to 5V

                     

0

0

0

1

1

0

to 20mA

                     

0

0

1

0

0

4

to 20mA

                     

0

0

1

0

1

   

50

Hz

               

0

0

0

         

Filter

 

60

Hz

               

0

0

1

         

frequency

250

Hz

               

0

1

0

         

500

Hz

               

0

1

1

         

Open

Zero

           

0

0

               

Upper scale

           

0

1

               

Circuit

                                 

Value

Lower scale

           

1

0

               

Invalid

           

1

1

               

Reserved

--

         

0

                   

Channel

Disabled

       

0

                     

Status

Enabled

       

1

                     

Reserved

 

0

0

0

0

                       

Configuration Word 2 for a channel -

 

Item

Description

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

 

0

                           

0

0

Averaging

4

                           

0

1

8

                           

1

0

   

16

                           

1

1

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The configuration information for channel 0 is to be written at module memory address MMW#256 and MMW#258 and so on.

MMW#256

Configuration word 1 for channel 0

MMW#258

Configuration word 2 for channel 0

MMW#284

Configuration word 1 for channel 7

MMW#286

Configuration word 2 for channel 7

Input type

The analog input module supports different types of inputs. The inputs include -10 to 10V

0

to 10 V

0

to 5 V

1

to 5 V

0

to 20 mA

4

to 20 mA

Bits 0 to 4 hold input type information.

Refer chapter 3.2 for connection of voltage/ current input.

Filter frequency

Next three Bits, Bit5 to Bit 7 define the low-pass filter frequency. One out of four filter frequencies can be selected for a module. The filter frequency selected for channel 0 is applied for all the channles irrespective of any selection.by user for remaining channels.

Bit7

Bit6

Bit5

Filter Frequency

Update time for a Channel

0

0

0

50Hz

60ms

0

0

1

60Hz

50ms

0

1

0

250Hz

12ms

0

1

1

500Hz

6ms

The filter frequency affects noise rejection on incoming analog signal. A lower filter frequency increases noise rejection. Also it affects channel update time. So select a filter frequency considering acceptable noise and channel update time.

Open circuit value

Next two bits, bit 8 and bit 9 define the value of the channel when the open circuit is detected.

Bit9

Bit8

Open Circuit value

0

0

Zero

0

1

Upper scale

1

0

Lower scale

1

1

Invalid

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The module detects open circuit of a channel for 4-20 mA and 1 to 5 V input types. In such open circuit condition, the channel value can be set to any one of above options considering safety in control action. If such open circuit is detected for a channel, corresponding channel LED starts flashing.

Channel Enable

Bit11 defines the enable status of the channel. If it is ‘0’ Channel is disable and if it is ‘1’ Channel is enable. The module samples only enabled channels and converts into digital value. Thus enabling only used channels can minimize the channel update time.

Bit12 to Bit15 are reserved and these must be ‘0’

Averaging

Next two Bits, Bit16 and Bit 17 define the selection of sampling value for averaging.

Bit16

Bit17

Averaging Sample

0

0

No

0

1

4

1

0

8

1

1

16

The module provides averaging facility so that stable value is available for processing and necessary control action. The module samples and converts enabled channels one by one. The module keeps digital value into different words. Depending on the averaging count, the module performs averaging of those many words and updates channel data information.

Thus if the averaging counts of channel 0, 1 and 2 are 0, 4 and 8 respectively, then data of channel 0, 1 and 2 are updated every 1, 4 and 8 conversion cycles respectively. One conversion cycle means sampling and converting all enabled channels. Thus combination of filter frequency and averaging count can be selected to get optimum channel update time.

Channel Data

The module memory words MMW #0 to MMW #14 are module memory words for channel data. For enabled channels, this information is updated cyclically in module. The data is read and stored in PLC variables using READ_W / IM_Read function in application program.

MMW#0

Channel 0 data

MMW#2

Channel 1 data

MMW#12

Channel 6 data

MMW#14

Channel 7 data

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Channel Status

The module continuously updates status of all channels into its memory. The processor module can read the status information as required using READ_W function. This information is also useful to check validity of configuration data.

This status information is stored in bit form in one word for each channel starting from module memory address 16. The following table gives status bit information available.

 
  The copy of Bit 0 to Bit 11  

The copy of Bit 0 to Bit 11

 
  The copy of Bit 0 to Bit 11  

from configuration word.

 

Item

Description

15

14

13

12

 

11

10

9

8

7

6

5

4

3

2

1

0

 

-10 to +10V

                     

0

0

0

0

0

0

to 10V

                     

0

0

0

0

1

Input

0 to 5V

                     

0

0

0

1

0

Type

1 to 5V

                     

0

0

0

1

1

0

to 20mA

                     

0

0

1

0

0

4

to 20mA

                     

0

0

1

0

1

   

50

Hz

               

0

0

0

         

Filter

 

60

Hz

               

0

0

1

         

frequency

250

Hz

               

0

1

0

         

500

Hz

               

0

1

1

         

Open

Zero

           

0

0

               

Upper scale

           

0

1

               

Circuit

                                 

Value

Lower scale

           

1

0

               

Invalid

           

1

1

               

Reserved

--

         

0

                   

Channel

Disabled

         

0

                     

Status

Enabled

         

1

                     

Config

Valid

     

0

                       

Invalid

     

1

                       

Open

No open circuit

   

0

                         

Ckt.

Open circuit

   

1

                         

Under-

No under range

 

0

                           

range

Under range

 

1

                           

Over

No over range

0

                             

range

Over range

1

                             

The copy of Bit 0 to Bit 11 from configuration word is available in status word as it is. This information is useful to check validity of configuration as written by WRITE_W function when ever configuration is set or modified. The application program should confirm validity of configuration before reading channel data.

MMW#16

Channel 0 status

MMW#18

Channel 1 status

MMW#28

Channel 6 status

MMW#30

Channel 7 status

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Configuration Error

Bit 12 of status word is set if Invalid configuration is written Bit 12 to 15 in configuration word are non zero

If configuration error bit is set, ‘configuration Error’ LED ( yellow colour )on module glows.

Open Circuit Error

Open circuit detection is applicable for

Input type

Input type 4 to 20 mA

1 to 5 V

Bit 13 of status word is set if Input voltage is less than 0.75 V for input type 1 to 5 V Input current is less than 3 mA for input type 4 to 20 mA

If open circuit error bit is set for a channel , corresponding input indication LED (green colour) on module starts flashing. The channel data holds the data as per configuration. It can be zero or upper scale reading or lower scale reading.

4.3 Programming with Nexgen 4000 CPU

The configuration data in PLC variables is transferred to the analog input module when 'WRITE_W' function is executed. The data in the PLC variables can be updated using functions like 'MOV_W', arithmetic or any other functions. The data from analog input module memory can be transferred to PLC variables when 'READ_W' function is executed.

The WRITE_W function below shows data transfer from the CPU module's memory to analog input module memory. The details of transfer are -

The analog input module is configured in slot 2 of PLC

Start address of memory on the CPU module is MW50

Length of data area to be transferred is 16 words

Address on the analog input module in slot 2 is #256

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'WRITE_W' function gets executed when condition for enable 'EN' is ON. 'ENO' output becomes ON, when EN is ON and function is executed successfully. ENO is OFF if

Parameters of function are invalid or not within specified range.

analog input module is not accessible to CPU module

M0.0

----- WRITE_W -----

M0.1

+---| |---+--------- |EN

ENO|-+---------+---( )---

 

|

|

#2

-|SLOT

|

|

|

MW50 -|DATA

|

 

|

|

#16 -|LEN

|

 

|

|

#256 -|ADDR

|

 

|

|

-------------------

So 16 words (MW50 to MW80) information from CPU memory is transferred to the memory at address #256 onwards of analog input module fitted in slot 2.

The 'READ_W' function below shows data transfer from the analog input module memory to CPU memory. The details of transfer are -

The analog input module is configured in slot 2 of PLC

Address on the analog input module in slot 2 is #0

Start address of memory on the CPU module is MW100

Length of data area to be transferred is 8 words

'READ_W' function gets executed when condition for enable 'EN' is ON. 'ENO' output becomes ON, when EN is ON and function is executed successfully. ENO is OFF if Parameters of function are invalid or not within specified range. The module is not accessible to CPU module

M0.2

------ READ_W -----

M0.3

+---| |---+--------- |EN

ENO|-+---------+---( )---

 

|

|

#2

-|SLOT

|

|

|

#0

-|ADDR

|

|

|

#8

-|LEN

|

|

|

MW100-|DATA

|

 

|

|

-------------------

So 8 words (MMW0 to MMW14) information on analog input module fitted in slot #2 are transferred to the CPU memory words (MW100 to MW114).

Example of basic application program is given below. For the same, refer Nexgen PLC configuration shown in chapter 4.1.

In the configuration, following points are to be noted.

8 Ch Analog Input Module (4308) Document No.: ED-2002-015/V1.01

Published Feb 2004 Page 27 of 38

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I 8.0 is a module status bit as 'Module Not OK' bit. I8.0 is set if 24 VDC supply to module is not healthy and / or hardware fault, watchdog fault is observed on module.

I 8.1 is a channel status bit as. I 8.1 is set if for one or more channels, configuration is invalid and / or any channel error like open circuit is observed.

S 4.2 is a 'Module Error' bit for the module fitted in slot 2.

While developing application program, first check whether the module is healthy. For the same, check 'Module Error' bit S 4.2 and 'Module Not Ok' bit I8.0. If any bit is set, declare respective fault. In this case, module is not accessible. If both are OFF, then only enable 'WRITE_W' and 'READ_W' functions for analog input module.

The configuration information consists of basic attributes like input type, filter (50 Hz, 60 Hz, 250 Hz, 500 Hz), return value in case of open circuit of input signal (zero, upper scale, lower scale) and no. of averaging samples (1, 4, 8, 16). This configuration is to be transferred to module memory MMW#256 to MMW#286, if all the 8 channels are used. In this example, channels are configured for

0 – 10 VDC

50 Hz filter

Return value is of upper scale in case of open circuit of input signal

No. of averaging samples is 16

For this configuration, the value $0801 and $0003 should be written to respective module memory word.

Configuration Word 1

15

14

13

12

11 10

 

9

8

7

6

5

4

3

2

1

0

$0801

0

0

0

0

 

1 0

0

1

0

0

0