GPIO4D User Guide

3/29/10

Overview
The GPIO4D allows MPU11 based control systems to interface to third party servo drives that accept -10 to +10 VDC current or velocity requests. The GPIO4D combines the functions of a PLC and third party drive interface to reduce system component count and increase value. GPIO4D Features
Application: Number of Axes: Maximum number of Axes: DAC resolution: Analog Output Voltage: General Purpose Digital Inputs: General Purpose Digital Outputs: Control Interface: Dimensions (W*D*H): Third Party Drive Interface 4 4 16 bits -10 to +10 Volts 16 16 2 fiber optics to MPU11 motion control card 12 * 5 * 0.75 inches

GPIO4D Connection Overview The GPIO4D communicates with an MPU11 motion control card through two optical fibers. The PLC protocol fibers (1 and 3) handle communication of drive interface signals as well as general purpose I/O. Encoder feedback returns directly to the MPU11.

MPU11
Encoder 1 Encoder 2 Encoder 3 Encoder 4 Encoder 5

GPIO4D
Fiber 1 Fiber 1 Fiber 3 Encoder 6 Spindle Analog Fiber 3

Drive I/O

Drive I/O

Drive I/O

Spindle Inverter

Third Party Drive

GPIO4D User Guide

Drive I/O

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GPIO4D Outputs
Sixteen general purpose relay outputs and four axis enable outputs are available on the GPIO4D. Four axis brake outputs and a fault output are also provided, but are not part of the PLC I/O space. The brake outputs follow the state of their axis enables. The fault output will remain closed as long as the GPIO4D does not detect any serious errors, such as a loss of communication.
GPIO4D Internal Circuitry SPST Relay Output GPIO4D Internal Circuitry SPDT Relay Output
Out put COM Out put NC Out put NO

Out put COM Out put NO

Motor Brake and Enable Outputs Each axis has brake and enable outputs, which are functionally equivalent. These open collector outputs may be used to drive a relay to release axis brake solenoids or activate an enable input on a servo drive. Note that the GPIO4D has no noise suppression on the outputs. Appropriate suppression must be added to devices connected to the open collector outputs. Typically, a DC relay coil is driven by a brake output and a diode is placed across the coil leads to suppress voltage transients, as in the wiring example. Motor brake mechanisms may also require noise suppression, such as a resistor and capacitor network for AC solenoids or a diode for DC solenoids. Typical Brake Wiring Example
External Power Supply 5 VDC External Power Supply 24 VDC

GPIO4D Internal Circuitry Enable and Brake Relay Driver Outputs

Out put

5 COM

24 COM Brake Release Solenoid

Out put Co m m on 5V COMMON

GPIO4D User Guide

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Analog Outputs Five analog outputs are provided by the GPIO4D. Four analog outputs are used to request motion from servo drives. These motion request outputs have 16 bit resolution and a fixed output range of -10V to +10V. Motion request analog channels are digitally trimmed at the factory. The remaining analog output is used to request a spindle speed from an inverter. The spindle analog output has 12 bit resolution and an output range from 0 to 10V. Minor adjustment can be made to the spindle analog output range using the OFFSET potentiometer (pot) (VR4) and GAIN pot (VR2). Only adjust the OFFSET pot at the minimum possible spindle speed. This adjustment is intended only to null the voltage level when 0 RPM is commanded. The GAIN pot should be used at maximum speed to match actual RPM with commanded RPM. Adjustments to the analog output should be very minor and cannot be used to compensate for incorrect inverter or control settings. VR1 and VR3 pots should not be used. If VR1 has been turned, measure from TP11 to analog common and adjust the voltage back to 2.5V. If VR3 has been turned, measure from TP13 to analog common and adjust the voltage back to 5.0V.
Internal Circuitry Analog Output
+12 VDC

Analog Out put

ANALOG -12 VDC COMMON

GPIO4D User Guide

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GPIO4D Inputs
The GPIO4D has 16 general purpose inputs and 4 drive fault inputs. Inputs are divided into banks of four. Each bank is configurable for various voltages and sinking or sourcing polarity. Voltage may be selected by installing the appropriate value resistor pack or SIP into a socket for each bank. Polarity is determined by wiring the common terminal for the bank to the supply positive or supply common.
Sinking (NPN) Sensor Wiring Example External Power Supply +24 VDC GPIO4D Inputs COMMON INPUT +24 VDC +24 COM Sensor INPUT INPUT INPUT +24 COM SIP

Sourcing (PNP) Sensor Wiring Example External Power Supply +24 VDC COMMON INPUT INPUT +24 COM +24 VDC INPUT Sensor INPUT SIP +24 COM

.
Typical Fault Input Wiring Example
Servo Drive Internal Circuitry Fault or Alarm Relay 24 VDC

GPIO4D Fault Inputs FAULT COMMON INPUT17 INPUT18 INPUT19 INPUT20

24 COM

SIP5

GPIO4D User Guide

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SIP Identification - XXX Indicates Value

4308R-102 -XXX

SIP Internal Wiring / Pinout

SIP Input Voltage Selection SIP Value Marking 471 102 222 Resistor Value (Ohms) 470 1.0k 2.2k Input Voltage 5 12 24

PLC Expansion
PLC I/O expansion is possible through the four PLC ADD connectors. Each PLC expansion port can accept 16 128 inputs, outputs, or inputs and outputs in 16 bit increments. This allows for digital I/O, DACs, ADCs, or other devices to be added to the system as needed. PLC ADD 1 4 Connector Pinouts
DATA TO EXPANSION CARD + DATA TO PLC + CLOCK + +12V +5V 5V RETURN * 1 3 5 7 9 11 2 4 6 8 10 12 DATA TO EXPANSION CARD DATA TO PLC CLOCK -12V +12V AND -12V RETURN * 5V RETURN *

* +12V AND -12V RETURN and 5V RETURN are connected on the GPIO4D

PLC I/O is arranged in 16 bit groups or slots. As a general rule, slots 0-14 are used for individual I/Os such as switches and have a programmable debounce time for the inputs. Slots 15-47 are reserved for ADCs, DACs, or other devices that do not require debounce. Every device using I/O space must use space in 16 bit multiples by reserving slots. PLC expansion boards with inputs and outputs must have a matching number of input and output slots. A GPIO4D uses 2 slots for its inputs and 7 slots for outputs. Since I/O space must be reserved in 16 bit increments, some I/O space is lost. For example, the GPIO4D has 20 inputs which reserve 2 slots or 32 inputs, leaving 12 inputs unused. Also note that the GPIO4D outputs are not assigned contiguously. The individual outputs take slots 0-1, while the DACs are assigned to the group output area starting at slot 15. Assignment of I/O slots occurs sequentially starting at the main PLC, then PLC ADD port 1, PLC ADD port 2, etc. In the GPIO4D I/O Organization example, GPIO4D I/O will always be at the same location since local PLC resources are assigned slots first. Other devices may change locations if they are plugged into PLC ADD ports in a different order. Devices plugged into the PLC ADD ports that require debounce will be assigned starting at the slots marked A, while devices that do not require debounce will start being assigned at the slots marked B.

GPIO4D User Guide

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GPIO4D I/O Organization

Input Space
Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 15 Slot 16 Slot 17 Slot 18 Slot 19 Slot 20 Slot 47

GPIO4D Inputs

Output Space
Slot 0 Slot 1 Slot 2 A Slot 3 Slot 4 Slot 5 Slot 15 Slot 16 Slot 17 Slot 18 Slot 19 GPIO4D Spindle Analog Slot 20 B Slot 47

GPIO4D Outputs

GPIO4D Axis Analog Outputs

GPIO4D I/O Map Input Map

Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Input Specification Function General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose Drive Fault 1 Drive Fault 2 Drive Fault 3 Drive Fault 4 Type Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Configurable Input Location Connector Pin H10 1 H10 2 H10 3 H10 4 H10 6 H10 7 H10 8 H10 9 H9 1 H9 2 H9 3 H9 4 H9 6 H9 7 H9 8 H9 9 H14 3 H13 3 H12 3 H11 3 Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 17 18 19 20 241-256 257-272 273-288 289-304 305-316 317-320

Output Map
Output Specification Function General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose Drive Enable 1 Drive Enable 2 Drive Enable 3 Drive Enable 4 Axis 1 Brake Axis 2 Brake Axis 3 Brake Axis 4 Brake Axis 1 Analog Axis 2 Analog Axis 3 Analog Axis 4 Analog Spindle Analog Reserved Fault Relay SPDT H2 15,16,17 Type Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Relay SPDT Relay SPDT Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Relay SPST Open Collector Open Collector Open Collector Open Collector Open Collector Open Collector Open Collector Open Collector 16 bit DAC 16 bit DAC 16 bit DAC 16 bit DAC 12 bit DAC Output Location Connector Pin H1 1,2 H1 3,4 H1 5,6 H1 7,8 H1 9,10 H1 11,12 H1 13,14 H1 15,16,17 H1 18,19,20 H1 1,2 H1 3,4 H1 5,6 H1 7,8 H1 9,10 H1 11,12 H1 13,14 H14 5 H13 5 H12 5 H11 5 H14 6 H13 6 H12 6 H11 6 H14 H13 H12 H11 H6 1 1 1 1 11

*Note: Outputs 17-20 each control two physical outputs

GPIO4D User Guide

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GPIO4D Specifications
Characteristic 5 Volt Supply Current 12 Volt Supply Current -12 Volt Supply Current Input Pullup Voltage (Vinp) Input On Voltage Input Off Voltage Input Operating current Relay Output Current Relay Output Current Open Collector Output Current Open Collector Output Voltage Spindle Analog Output Resolution Spindle Analog Output Voltage Spindle Analog Output Current Axis Analog Output Resolution Axis Analog Output Voltage Axis Analog Output Current PLC ADD Port 5V Current Output* PLC ADD Port 12V Current Output* PLC ADD Port -12V Current Output* Fiber 1 and 3 Length Size: 12 * 5 * 0.75 (W*D*H) Min. 1.4 0.09 0.07 4.5 Vinp-1.25 9 0.1 0.1 0 0 -10 0 0 0 0 Typ. 5 11 10 5 12 1 16 1 Max. 25 1.25 15 10 5 90 25 10 20 10 20 1 0.8 0.8 100 Unit A A A V V V mA A @ 125VAC A @ 30VDC mA V bits V mA bits V mA A A A feet Inches

*PLC ADD Port Current is a total for all 4 ports in any combination. The power supply may be the limiting factor; make sure it can handle the GPIO4D current ratings in addition to the PLC Expansion board requirements.

GPIO4D Troubleshooting
Symptom PLC OK LED out Possible Cause Motion control card hasn't booted up Fibers 1 or 3 connected incorrectly or faulty Logic power not applied Power supply or connection problem Internal Problem Incorrect wiring Corrective Action Start software, wait for the main screen to load Check connections one at a time, swap with a known good set of fibers Measure AC coming into power supply, correct wiring or supply problems Measure AC coming into power supply, correct wiring or supply problems Return for repair Correct wiring for sensor type (sinking or sourcing), check that SIP values are appropriate for the input voltage Use 3-wire sensors with lower voltage drop spec.

All status LEDs out 5V, +12V, or -12V LED out 3.3V LED out, 5V LED lit Input doesn't work with sensor

Voltage drop across sensor is too high

GPIO4D User Guide

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GPIO4D Connections
Spindle Analog Analog Common 5V 5V Common +12V -12V 12V Common PLC OK

+12V

-12V
Pin 1

3.3V

5V

Enable LED 1

Fault NC Fault NO Fault COM Output 16 NO Output 16 COM Output 15 NO Output 15 COM Output 14 NO Output 14 COM Output 13 NO Output 13 COM Output 12 NO Output 12 COM Output 11 NO Output 11 COM Output 10 NO Output 10 COM

Pin 1

Axis Analog 1 Analog Common Fault Input Axis 1 (Input 17) Fault Common Enable Output Axis 1 (Output 17) Brake Output 1 (Output 17) Output Common Axis Analog 2 Analog Common Fault Input Axis 2 (Input 18) Fault Common Enable Output Axis 2 (Output 18) Brake Output 2 (Output 18) Output Common Axis Analog 3 Analog Common Fault Input Axis 3 (Input 19) Fault Common Enable Output Axis 3 (Output 19) Brake Output 3 (Output 19) Output Common

Enable LED 2

Pin 1

Enable LED 3

Pin 1 Pin 1

Fiber 3 to MPU11 Fiber 1 from MPU11

Enable LED 4

SIP5 Output 9 NC Output 9 NO Output 9 COM Output 8 NC Output 8 NO Output 8 COM Output 7 NO Output 7 COM Output 6 NO Output 6 COM Output 5 NO Output 5 COM Output 4 NO Output 4 COM Output 3 NO Output 3 COM Output 2 NO Output 2 COM Output 1 NO Output 1 COM

Axis Analog 4 Analog Common Fault Input Axis 3 (Input 20) Fault Common Enable Output Axis 4 (Output 20) Brake Output 4 (Output 20) Output Common Input 1 Input 2 Input 3 Input 4 Common 1-4 Input 5 Input 6 Input 7 Input 8 Common 5-8
Pin 1

SIP4

SIP3

SIP2

SIP1
Pin 1

Input 9 Input 10 Input 11 Input 12 Common 9-12 Input 13 Input 14 Input 15 Input 16 Common 13-16

PLC Expansion 1

PLC Expansion 2

PLC Expansion 3

GPIO4D User Guide

PLC Expansion 4

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GPIO4D Mounting Dimensions

5.0" (127mm) 4.4" (112mm)

12.0" (305mm) 11.4" (290mm)

6.0" (152mm)

GPIO4D User Guide

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