Messung Systems NEXGEN PLC I/O Modules

NEXGEN Series of PLCs

2 Channel, 12 bit Analog Output Module

(Ordering Code – 4332)

Document No.:ED-2002-018

Version: 1.0

Published July 2002

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

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

Email : [email protected]
WEB: www.messung.com

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NEXGEN PLC I/O Modules Messung Systems

Revision

Version Date Description

2 Channel, 12 bit Analog Output Module

1.0 7 August 2002
(Ordering Code – 4332) NEXGEN Series of PLCs.

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INDEX

1. MODULE OVERVIEW.............................................................................................................................. 5

1.1 2-CHANNEL ANALOG OUTPUT MODULE OVERVIEW ................................................................................ 5

1.2 LED INDICATIONS ............................................................................................................................... 7
1.3 GENERAL SPECIFICATIONS................................................................................................................... 7
2. MODULE OPERATION............................................................................................................................ 8

2.1 BLOCK DIAGRAM ................................................................................................................................. 8

2.2 DATA RANGE AND RESOLUTION............................................................................................................ 9
2.3 IO MAPPING ..................................................................................................................................... 11
3. INSTALLATIONS AND WIRING ............................................................................................................ 12

3.1 MODULE INSTALLATION ...................................................................................................................... 12

3.2 CONNECTION DETAILS ....................................................................................................................... 13
3.3 PRECAUTIONS TO BE TAKEN ............................................................................................................... 14
4. CONFIGURATION AND PROGRAMMING ............................................................................................ 16

4.1 MODULE CONFIGURATION .................................................................................................................. 16

4.2 PROGRAMMING ................................................................................................................................. 17
5. TROUBLESHOOTING ........................................................................................................................... 18

5.1 LED INDICATIONS FOR TROUBLESHOOTING......................................................................................... 18

5.2 FAULT DIAGNOSTIC OF MODULE ......................................................................................................... 18

INDEX OF FIGURES

FIGURE 1 : FRONT VIEW OF 2-CHANNEL ANALOG VOLTAGE/ CURRENT OUTPUT MODULE ......... 6

FIGURE 2 : 2-CHANNEL ANALOG OUTPUT MODULE BLOCK DIAGRAM........................................ 9

FIGURE 3 : DATA RANGE OF 2-CHANNEL ANALOG OUTPUT VOLTAGE SIGNAL .......................... 9

FIGURE 4 : DATA RANGE OF 2-CHANNEL ANALOG OUTPUT CURRENT SIGNAL .......................... 9

FIGURE 5 : MEMORY MAPPING ............................................................................................. 11

FIGURE 6 : CONNECTION DIAGRAM OF ANALOG OUTPUT VOLTAGE MODULE .......................... 13

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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 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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1. Module Overview

This chapter describes the following

Analog Voltage/Current Output Module Overview
LED Indications
General Specifications

1.1 2-Channel Analog Output Module Overview

This analog voltage/current output module takes digital value data from
Processor Module and output an equivalent analog output voltage. This
is R – 2R type D/A conversion. It provides two isolated channels with 12-
bit resolution (11 bits + 1 sign bit). The channels provide voltage or
current range as :

-10 to +10 VDC or

to 20 mA

The resolution is 4.88 mV / 7.8 µA.

This is discrete output type of module and data transfer with Processor
Module takes place in output scan.

The figure 1 on next page shows the front view of 2-channel analog
output module.

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4332
ANALOG OUTPUT
2 CH – V /I

NO 24 V SUPPLY Module
Status
Front Shield LED
Plate

Terminal Block
Fixing Screw

VOUT1
01
GND1
02
I REF 1
03
SHIELD
04
I OUT1
05
GND 1
06
20 Pin 07
SHIELD
Removable 08
Terminal Block 09
VOUT2
GND2
10
I REF 2
11
SHIELD
12
I OUT2
13
GND 2
14
SHIELD
15
16
+24 V.
17
0V
18
EARTH
19
FG
20

2 CH
ANALOG OUTPUT
V/I

LED Connection Front Door

Indications Details

Figure 1 : Front view of 2-Channel Analog Voltage/ Current Output Module

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Brief information about channels can be written on the IO label. Behind

front door, 20-pin removable terminal block is provided for interfacing.
The module connection details are shown on backside of front door on
yellow colored label.

2-channel analog output module can be configured in any slot of the

PLC.

1.2 LED Indications

The following table explains significance of LED provided on the front

side of module. These LEDs are useful for diagnosis of module in case of
any fault condition.

LED Color Status Description

OFF 24 V supply present
ON 24 V supply not present
No 24 V Supply Yellow
On board fuse blown
ON Channel ON

1.3 General Specifications

The general specifications of 2-channel analog output module are given

below

Number of output channels 2 Isolated channels with 16 bit resolution

Conversion method R – 2R ladder
Voltage Current
Input Range -2048 to + 2047 0 to 2047
Output Range -10 to +10 VDC 4 to 20 mA
Resolution 4.8 mV 7.8 µA
Load resistance > 1 KΩ < 500 Ω
Over range capability - 5%
Load current 10 mA -
Overall accuracy (% of FSR) 0.049 0.1674
Output short circuit protection Yes
Maximum conversion time 20 sec per channel
Channel to Internal
isolation 1.5 KV optical
circuit
Channel to channel 1.5 KV optical
24 VDC, 500 mA
External supply requirement
(18 - 30 V DC including ripple)
315 mA miniature glass fuse on module
External supply protection
Reverse polarity protection
Indications No 24 V Supply
Back-plane current (5 V
150 mA
consumption)
IO points consumed 32 input bits and 32 output bits
Termination / connection 20-pin removable terminal block
Ordering code 4332

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2. Module Operation
This chapter helps in getting started with the 2-channel analog output
module. It describes the basic operation of the module. This chapter
explains following points.
• Block Diagram
• Data Range and Resolution
• IO and Memory Mapping

At the time of application program development, the module can be

configured using the PC based programming and documentation
software.

2.1 Block Diagram

The following figure shows block diagram of 2-channel analog output

module

Serial
Data Opto DAC1 Channel 1
Serial
Isolation R-2R
Interface 0 to ± 10 VDC
Output Signal
Control
Opto Output 1
Isolation Driver Voltage to
Current
Conversion 4 to 20 mA
CPU Output Signal

Serial
Data Opto DAC2 Channel 2
Serial
Isolation R-2R
Interface 0 to ± 10 VDC
Output Signal
Module
Interface Opto Output 2
Circuit Isolation Driver Voltage to
Current
Conversion 4 to 20 mA
Output Signal
No 24 V
Supply
Signal
Opto Miniature
+5V Isolation Glass + 24 VDC
+12 V
-12 V 0V
GND
Supply for +5 V DC to DC
Earth
DAC Circuit -5 V Converter

GND

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Figure 2 : 2-Channel Analog Output Module Block diagram

The module provides two-isolated digital to analog channels. Processor

bus is optically isolated from DAC circuit. The digital to analog converter
operates on serial data. Parallel to serial converters in interface circuit
converts parallel data from Processor Module. DAC (R–2R type) converts
binary data inside the register to an equivalent analog output. The
module provides proportional -10 VDC to + 10 VDC. In output driving
stage, presets are provided for adjustments of gain and offset for each
channel. These are factory settings and should not be tampered. If
module is to be used for 4 to 20 mA current output external shorting link
th
must be connected. In current output mode, sign bit (12 bit) is
insignificant. Thus resolution is 11-bit.
The module requires external 24 VDC for DAC circuit operation.
Internally DC-to-DC converter generates 12 VDC and 5 VDC as
required for each channel. If 24 VDC is absent or on board fuse is blown,
module generates 'No 24 V Supply' signal for CPU module. Miniature
glass fuse protection (315 mA) for external 24 VDC supply is provided on
module.
The module does not require any software configuration as such.

2.2 Data Range and Resolution

This section describes data ranges as applicable to voltage output.

-4.88 mV +4.88 mV +10 VDC

-10 VDC
$ FFF $1 $ 7FF
$ 800

0 VDC
$0000

Figure 3 : Data Range of 2-Channel Analog Output Voltage Signal

4 mA 20 mA
$0 $ 7FF

Figure 4 : Data Range of 2-Channel Analog Output Current Signal

The module provides 12-bit resolution (11 bit + 1 sign bit). The figure
above shows digital data and associated output voltage and current
values.

For voltage range of –10 V to +10 V, the digital value ranges from -2048
to +2047 through 0.

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The resolution is the smallest detectable change in analog output signal.

For –10 V to +10 V range, the voltage span is 20 V and there can be
4096 (12 bits) equal steps. Each step corresponds to –
20 V / 4096 = 4.88 mV
For current range of 4 to 20 mA, the digital value ranges from 0 to +2047.
The resolution is the smallest detectable change in analog output signal.
For 4 to 20 mA range, the current span is 16 mA and there can be 2048
(11 bits) equal steps. Each step corresponds to –
16 mA / 2048 = 7.8 µA
The table below shows typical data values in decimal as well as
hexadecimal format and their equivalent voltage values.

Output Data Data Output Data Data

Value (Decimal) (Hexadecimal) Value (Decimal) (Hexadecimal)
0 0 0 -10 V -2048 800
4.88 mV 1 1 -9 V -1843 8CD
1V 204 CC -8 V -1638 99A
2V 409 199 -7 V -1434 A66
3V 614 266 -6 V -1229 B33
4V 819 333 -5 V -1024 C00
5V 1023 3FF -4 V -820 CCC
6V 1228 4CC -3 V -615 D99
7V 1433 599 -2 V -410 E66
8V 1637 665 -1 V -205 F33
9V 1842 732 -4.88 mV -1 FFF
10 V 2047 7FF 0 0 0

The table below shows typical data values in decimal as well as

hexadecimal format and their equivalent current values.

Data
Output Data Data Output Data
(Hexadecimal
Value (Decimal) (Hexadecimal) Value (Decimal)
)
4 mA 0 0 11 mA 896 380
5 mA 128 80 12 mA 1024 400
6 mA 256 100 13 mA 1152 47F
7 mA 384 180 14 mA 1279 4FF
8 mA 512 200 15 mA 1407 57F
9 mA 640 280 16 mA 1535 5FF
10 mA 768 300 17 mA 1663 67F
18 mA 1791 6FF
19 mA 1919 77F
20 mA 2047 7FF

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2.3 IO Mapping

The figure below shows I/O mapping related to 2-channel analog output
module.

Processor module

IO Image 2-Channel Analog Output

module

Input Output

Channel 1

Output Scan
Channel 1
Module
Channel 2 Interface circuit
Logic Scan
IMM_OUT
EN ENO
SLOT
Channel 2

Figure 5 : Memory Mapping

The module consumes 32 input bits (4 bytes) of input image and 32

output bits (4 bytes) of output image in the Processor Module. Processor
writes binary data to module in output scan. For immediate updation of
output image in application program, IMM_OUT functions can be used
whenever required.

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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 voltage output 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.

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3.2 Connection Details

The figure shows the connection diagram of 2-channel analog voltage

output module

Voltage
Output
VOUT1
01
GND1
02
I REF 1
Earth 03
SHIELD
04
Connect this shield to Connect this shield I OUT1
05
Earth busbar or to to ‘SHIELD’ GND 1
06
shield terminal on terminal. SHIELD
07
external Electronic
08
controller to which VOUT2
09
output signal is GND2
10
I REF 2
11
Current 12
SHIELD
Output 13
I OUT2
GND 2
14
SHIELD
15
16
+24 V.
Earth 17
0V
18
EARTH
19
FG
20

2 CH
+ 24 V GND Earth
Earth ANALOG OUTPUT
V/I

Figure 6 : Connection Diagram of Analog Output Voltage Module

In figure 5, first channel is connected for analog voltage output (-10 VDC
to +10 VDC). For interfacing analog signals, 20-pin removable terminal
block is provided. Voltage output is taken from terminals V OUTn and
GNDn. n is a channel number.

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Second channel is connected for analog current output (4 to 20 mA).

Current output is taken from terminals I OUTn and GNDn. n is a channel
number. To get current output, it is necessary to short terminals I OUTn
and I REFn .
Being susceptible to industrial noise, analog signal is to be carried out on
the field through shielded cable. Connect one end of shield (towards 2-
channel analog output module to SHIELD terminal on 20 pin terminal
block. This SHIELD terminal is internally connected to frame ground.
Connect other end of shield (toward external device to which analog
output signal is connected) to Earth busbar in control panel or this end
can be connected to shield terminal of respective external device.
Connect terminal number 19 (EARTH) to earth busbar in control panel
and connect frame ground terminal number 20 (FG) to earth busbar
independently.
For functioning of 2-channel analog output module, external 24 VDC
supply is required. Connect 24 VDC supply between terminals 17 (24 V)
and 18 (0 V)

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 twisted cables with shield.

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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 and
for communication.
• Wherever possible, it is recommended to
• Avoid parallel routing over long distances
• Ensure that wires cross at right angles
• 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 module and transferring
information with 2-channel analog output module. This information is
useful for application program development. This is explained in following
sections
• Module Configuration
• Programming

4.1 Module Configuration

2-channel analog output module provides 2 isolated channels, which can

be independently operated.

The configuration consists of configuring the slot for 2-channel analog

output module (like any other discrete IO module) only. The
Programming and Documentation software is used for configuration and
programming.

The module consumes 4 bytes of input image and 4 bytes of output

image. The output image is used for writing binary data for two channels
to the module.

The IO byte consumption along with configuration of NEXGEN PLC is

shown below

Power Supply CPU Module Slot 0 Slot 1 Slot 2 Slot 3

Module
32 DC Input 32 DC Input 2 Ch Analog Voltage 16 DC Output
Module Module Output Module Module

I0.0 to I0.7 I4.0 to I4.7 Q8.0 to Q8.7 Q12.0 to Q12.7

I1.0 to I1.7 I5.0 to I5.7 Q9.0 to Q9.7 Q13.0 to Q13.7
I2.0 to I2.7 I6.0 to I6.7 Q10.0 to Q10.7
I3.0 to I3.7 I7.0 to I7.7 Q11.0 to Q11.7

Input module in first two slots consumes IB0 to IB7 of input image. 2-
channel analog output module in slot 2 consumes four bytes i.e. QB8 to
QB11 of output image. 16 DC output module in slot 3 consumes QB12
and QB13 of output image.

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4.2 Programming

The programming is explained with reference to Programming and

Documentation software DOXMINI+. The data in PLC variables is
transferred to 2-channel analog output module when output scan is
executed. The data in the output bytes can be updated using functions
like MOV_W, Arithmetic or any other functions. The data values required
for specific output is explained in Chapter 2.2.

Consider PLC configuration discussed in section 4.4. To write binary data

from PLV memory variable MW116, function MOV_W can be used as
shown below. Here, memory bit M0.1 is enable condition with interlock
for module error bit S4.2. The binary value of MW116 is copied to output
word QW8 ( for output channel 1).

The value of output word QW8 is transferred to channel 1 in output scan

and equivalent analog output is available at output terminals.

M0.1 S4.2 ------MOV_W------ M0.4

+---| |---+---|/|---+---------+---------|EN ENO|---( )---
| |
MW116 -|DATA DOUT|- QW8
-----------------

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5. Troubleshooting

In this chapter, following points related to analog voltage output module

are discussed.
• LED Indications for Troubleshooting
• Fault Diagnostic of Module

5.1 LED Indications for Troubleshooting

The following table explains significance of LED provided on the front

side of module.

LED Color Status Description

OFF 24 V supply present
No 24 V Supply Yellow 24 V supply not present
ON
On board fuse blown

5.2 Fault Diagnostic of Module

This section explains various possibilities of faults related to analog

voltage output module and external interface and corrective action to be
taken. Faults may occur in:

• Module as a whole
• Specific channel only
• Application Program.

In first two cases, replacement of module is required where as third case

can be sorted out by on line monitoring of application program.

Equipment required

Following equipments are required for fault diagnosis of analog voltage

output module

Screw driver
Digital multi-meter with measuring facility for
DC voltage (with high precision)
Continuity and resistance
Set up for on line monitoring of application program as follows
PC with Programming and Documentation software.
PC to NEXGEN PLC Cable

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Following diagnostic flow chart shows various possibilities of faults if

analog voltage output module is not in operation as per requirement and
corrective action to be taken.

Module not working

No 24V Supply LED status?

ON OFF

Confirm 24 VDC supply at terminals 17 & 18.

Take proper action.

ON No 24V Supply OFF

LED status?

Check on board glass fuse. *

If blown, replace it by same type. Module
YES working OK? NO

Diagnosis Over
ON No 24V Supply OFF
LED status? O ERR LED
ON Status ? OFF
Replace Module

ON Module Error OFF

System bit Status ?

Fix module properly. Check expansion

cable if it i9s in expansion rack. Check
configuration of PLC. Take proper action.

Module Error
ON System bit Status? OFF

Replace Module
YES Module NO
working OK?

Diagnosis Over
A

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Diagnostic flow chart continue

A

Voltage output OK as
NO per binary data? YES

Remove analog output signal

Diagnosis Over
wires from terminal block.
Connect multi meter at terminals.

Voltage output OK as
NO per binary data? YES

Check application program. Monitor binary data value

Check for JMP, MCR-ME for channel with PC based
interlocks if any. Programming Software

NO Voltage output OK as YES

per binary data?

Probably problem is on load side.

Check load wires for short, open.
Confirm load> 1K.
Take proper action.
Connect wires to terminal block.

Voltage output OK as
YES per binary data? NO
* The fuse should be replaced by same type
strictly Diagnosis Over Contact MESSUNG
Rating - 315 mA, 250 V SYSTEMS
Sub- miniature fuse link no. 372
Make – WICKMANN

Note – For healthy operation of module always ensure that supply to module is within specified
range i.e. 18 VDC to 30 VDC including ripple.

If PLC is in 'STOP' mode, voltage output remains at zero whereas current output remains at 4 mA.

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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, 12 bit Analog Output Module (Ordering Code – 4332)

2 CH AO Manual(4332)

Document No.:ED-2002-018

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