UNITRONICS EX-D16A3-TO16 XL I-O Expansion Module User Guide

UNITRONICS EX-D16A3-TO16 XL I-O Expansion Module

The Unitronics® EX-D16A3-TO16 is an XL I/O expansion module for use in conjunction with specific Unitronics controllers.

XL modules comprise enhanced I/O configurations and detachable I/O connectors. In addition, this module comprises a built-in adapter for communicating with the PLC and providing power to the other expansion modules in the system.

This module provides:

• 16 digital inputs, including 1 HSC
• 3 analog inputs
• 16 transistor outputs, including 1 HSO

For additional information and technical specifications, visit the Technical Librar at 0H www.unitronicsplc.com

Component Identification

• Failure to comply with appropriate safety guidelines can cause severe personal injury or damage to property.
• Only qualified personnel should service and operate this device.
• When power is turned on, do not connect or disconnect the device to avoid damaging the system.

Alert Symbols and General Restrictions

When any of the following symbols appear, read the associated information carefully.

• Before using this product, the user must read and understand this document.
• All examples and diagrams are intended to aid understanding, and do not guarantee operation. Unitronics accepts no responsibility for actual use of this product based on these examples.
• Please dispose of this product according to local and national standards and regulations.
• Only qualified service personnel should open this device or carry out repairs.

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• Failure to comply with appropriate safety guidelines can cause severe injury or property damage.

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• Do not attempt to use this device with parameters that exceed permissible levels.
• To avoid damaging the system, do not connect/disconnect the device when power is on.

Environmental Considerations

• Do not install in areas with: excessive or conductive dust, corrosive or flammable gas, moisture or rain, excessive heat, regular impact shocks or excessive vibration, in accordance with the standards given in the product’s technical specification sheet.
• Do not place in water or let water leak onto the unit.
• Do not allow debris to fall inside the unit during installation.
• Ventilation: 10mm space required between controller’s top/bottom edges & enclosure walls.
• Install at maximum distance from high-voltage cables and power equipment.

UL Compliance

The following section is relevant to Unitronics’ products that are listed with the UL.

The following models: IO-AI4-AO2, IO-AO6X, IO-ATC8, IO-DI16, IO-DI16-L, IO- DI8-RO4, IO-DI8-RO4-L, IO-DI8-TO8, IO-DI8-TO8-L, IO-RO16, IO-RO16-L, IO-RO8, IO-RO8L, IO-TO16, EX-A2X are UL listed for Hazardous Locations.

The following models: EX-D16A3-RO8, EX-D16A3-RO8L, EX-D16A3-TO16, EX- D16A3-TO16L, IO-AI1X-AO3X, IO-AI4-AO2, IO-AI4-AO2-B, IO-AI8, IO-AI8Y, IO-AO6X, IO-ATC8, IO-D16A3-RO16,IO-D16A3-RO16L, IO-D16A3-TO16, IO-D16A3-TO16L, IO-DI16, IO-DI16-L, IO-DI8-RO4, IO-DI8-RO4-L, IO-DI8-RO8, IO-DI8-RO8-L, IO-DI8-TO8, IO- DI8-TO8-L, IO-DI8ACH, IO-LC1, IO-LC3, IO-PT4, IO-PT400, IO-PT4K, IO-RO16, IO- RO16-L, IO-RO8, IO RO8L, IO-TO16, EX-A2X, EX-RC1 are UL listed for Ordinary Location.
UL Ratings, Programmable Controllers for Use in Hazardous Locations, Class I, Division 2, Groups A, B, C and D
These Release Notes relate to all Unitronics products that bear the UL symbols used to mark products that have been approved for use in hazardous locations, Class I, Division 2, Groups A, B, C and D.

Caution|

• This equipment is suitable for use in Class I, Division 2, Groups A, B, C and D, or Non-hazardous locations only.

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• Input and output wiring must be in accordance with Class I, Division 2 wiring methods and in accordance with the authority having jurisdiction.

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• WARNING—Explosion Hazard—substitution of components may impair suitability for Class I, Division 2.
• WARNING – EXPLOSION HAZARD – Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous.
• WARNING – Exposure to some chemicals may degrade the sealing properties of material used in Relays.
• This equipment must be installed using wiring methods as required for Class I, Division 2 as per the NEC and/or CEC.

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Relay Output Resistance Ratings

The products listed below contain relay outputs:
Input/Output expansion modules, Models: IO-DI8-RO4, IO-DI8-RO4-L, IO-RO8, IO- RO8L

• When these specific products are used in hazardous locations, they are rated at 3A res, when these specific products are used in non-hazardous environmental conditions, they are rated at 5A res, as given in the product’s specifications.

Mounting the Module

To mount the module on a 35mm DIN-rail, snap it squarely onto the DIN-rail, as shown below.

• Install the module in an upright position.
• To ensure good ventilation, leave at least 50mm between the device and all other objects above or below it.
• Install at a maximum distance from high-voltage cables and power equipment.

Connecting Modules

To connect a module to the adapter or expansion module:

1. Push the module-to-module connector (1) into the port (2) located on the right side of the module or adapter.
2. Push the protective cap (3) into the connector port of the last module. The cap is supplied with the adapter.

Connecting the Module to the PLC

Use the communication cable to connect the module’s PLC expansion port to the PLC.
Take care to connect the correct cable. The connectors of this cable are housed in yellow insulation. Note that one end is marked
To PLC and the other To Adapter; insert accordingly.
The module is supplied with a 1-meter cable, part number EXL-CAB100. Other cable lengths are also available.
Use only an original Unitronics cable and do not make any changes to it.

Wiring

| §   Do not touch live wires.
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| §   This equipment is designed to operate only in SELV/PELV/Class 2/Limited Power environments.

§    All power supplies in the system must include double insulation. Power supply outputs must be rated as SELV/PELV/Class 2/Limited Power.

§   Do not connect either the ‘Neutral or ‘Line’ signal of the 110/220VAC to device’s 0V pin.

§   All wiring activities should be performed while power is OFF.

§    Use over-current protection, such as a fuse or circuit breaker, to avoid excessive currents into the power supply connection point.

§   Unused points should not be connected (unless otherwise specified). Ignoring this directive may damage the device.

§   Double-check all wiring before turning on the power supply.

Caution| §   To avoid damaging the wire, do not exceed a maximum torque of:

– Controllers offering a terminal block with pitch of 5mm: 0.5 N·m (5 kgf·cm).

– Controllers offering a terminal block with pitch of 3.81mm f 0.2 N·m (2 kgf·cm).

§   Do not use tin, solder, or any substance on stripped wire that might cause the wire strand to break.

§   Install at maximum distance from high-voltage cables and power equipment.

Wiring Procedure

Use crimp terminals for wiring;

• Controllers offering a terminal block with pitch of 5mm: 26-12 AWG wire (0.13 mm2 –3.31 mm2).
• Controllers offering a terminal block with pitch of 3.81mm: 26-16 AWG wire (0.13 mm2 – 1.31 mm2).

1. Strip the wire to a length of 7±0.5mm (0.270–0.300“).
2. Unscrew the terminal to its widest position before inserting a wire.
3. Insert the wire completely into the terminal to ensure a proper connection.
4. Tighten enough to keep the wire from pulling free.

Wiring Guidelines

• Use separate wiring ducts for each of the following groups:

  • Group 1: Low voltage I/O and supply lines, communication lines.
  • Group 2: High voltage Lines, Low voltage noisy lines like motor driver outputs.
    Separate these groups by at least 10cm (4″). If this is not possible, cross the ducts at a 90˚angle.

• For proper system operation, all 0V points in the system should be connected to the system 0V supply rail.

• Product-specific documentation must be fully read and understood before performing any wiring.
  Allow for voltage drop and noise interference with input lines used over an extended distance.
  Use wire that is properly sized for the load.

Earthing the product

To maximize system performance, avoid electromagnetic interference as follows:

• Use a metal cabinet.
• Connect the 0V and functional ground points (if exist) directly to the earth ground of the system.
• Use the shortest, less than 1m (3.3 ft.) and thickest, 2.08mm² (14AWG) min, wires possible.

Daisy Chaining
To facilitate wiring, you can wire the following pins in series (daisy chain). Use both pins provided for this purpose.
Input connector pin: n/p. Output connector pins: +V, 0V. Power connector pins: +V, 0V.
Ensure that the total current drain on any single line does not exceed 10A. If a specific pin requires more than 10A, connect it with a separate wire. The following diagram demonstrates the wiring options:

Wiring the Power Supply

• Always connect the functional earth pin to the earth ground. Use a dedicated wire for this purpose; it must not exceed 1 meter.
• A non-isolated power supply can be used provided that the 0V signal is connected to the earth ground.
• Do not connect the neutral or line signal of the 110/220VAC to the device’s 0V pin.
• In the event of voltage fluctuations or non-conformity to voltage power supply specifications, connect the device to a regulated power supply.

Wiring Inputs

The following diagram shows the input connectors with pin numbers and corresponding input numbers

Wiring Digital Inputs

• Wiring Digital Inputs
• Inputs may be wired as either pnp (positive logic) or npn (negative logic).
• Input 36 can function as a high-speed counter, frequency measurer, or general purpose digital input (set in software).
• Input 37 can function either as a counter reset input or general purpose digital input (set in software).
• For correct operation of the digital inputs, connect the n/p pin according to the following figures.
• For information on connecting RG pins, refer to Connecting RG Pins.
  

Wiring Analog Inputs
The following diagram shows the 2-wire and 4-wire current connection.

• Use shielded twisted pair cable.
• Connect shields to the earth ground at the signal’s source.
  

Wiring the Power Supply

Connecting RG Pins
For correct operation of digital and analog inputs and for EMI immunity, connect the RG pin of all the expansion modules containing RG signals to the adapter module 0V signal.

• The overall length of the wire connecting the RG pins to the adapter 0V signal must be less than 3 meters.
• Connect the RG pins in series (daisy chain). To facilitate this, use both the RG pins.
  

Wiring Outputs

The following diagram shows the output connectors with pin numbers and corresponding output numbers.

Wiring the Output Power Supply

• A non-isolated power supply can be used provided that the 0V signal is connected to the earth ground.
• Do not connect the neutral or line signal of the 110/220VAC to the device’s 0V pin.
• In the event of voltage fluctuations or non-conformity to voltage power supply specifications, connect the device to a regulated power supply.
• The adapter 0V and the I/O 0V must be connect to the same line, Ignoring this  may damage the device.

Wiring Transistor Outputs

• Output 32 can be wired either as pnp (source) or npn (sink). pnp and npn can be used simultaneously.
• Output 32 can be used as a high speed output.
  

Technical Specifications

General

• I/O module capacity
  Up to 7 I/O expansion modules can be connected to this module. This number may vary according to the modules used.

• Status indicators RUN: Green LED

  • Lights when a communication link is established between the module and the PLC
  • Blinks when the communication link fails

• PWR: Green LED

  • Lights when power is supplied

Power Supply

• Input voltage 24VDC

• Permissible range 20.4 to 28.8VDC, ripple < 10%

• Maximum current consumption 90mA @ 24VDC – EX-D16A3-TO16 alone
  220mA @ 24VDC – maximum load on the 5VDC supply when the EX D16A3-TO16 powers seven additional I/O expansion modules

• Current for additional modules 500mA maximum from 5VDC, see note 1

Notes:

1. For example, 2 IO-DI8-TO8 modules consume a maximum of 140mA of the adapter’s 5VDC supply.

Digital Inputs

• Number of inputs 16 (in a single group)

• Input mode pnp (positive logic) or npn (negative logic) – configurable by hard-wiring

• Galvanic isolation None

• Status indicators
  IN: Green LEDs ■ One green LED for each input: Lights when the input is active, see note 2
  Nominal input voltage 24VDC

• Input voltage
  pnp (positive logic) 0–5VDC for logic state 0 17– 28.8VDC for logic state 1
  npn (negative logic) 17–28.8VDC for logic state 0 0–5VDC for logic state 1

• Input current 3.7mA @ 24VDC

• Input impedance 6.5kΩ

• Response time 10ms typical

• High-speed input The specifications in this section apply when an input is configured as a high-speed counter or frequency measurer. If configured as a general purpose digital input, the specification is as above. See notes 3, 4, and 5.

• Resolution 16-bit or 32-bit, depending on the PLC

• Frequency 30kHz maximum (at 24VDC ±10%)

• Minimum pulse width 14μs

Notes:

1. If the input is active but there is no communication with the PLC (RUN blinks), the status LED does not light.
2. Input 36 can function either as a high-speed counter, frequency measurer, or general purpose digital input.
3. Input 37 can function either as a counter reset input or general purpose digital input. In both cases, the specifications of this input are those of a general purpose digital input.
4. If input 36 is set as a high-speed counter and no reset input is configured, input 37 functions as a general purpose digital input.

Analog Inputs

• Number of inputs 3
• Input type 0–20mA or 4–20mA
• Input impedance 191Ω
• Maximum input rating 28mA, 5.3VDC
• Galvanic isolation None
• Cable type Shielded twisted-pair
• Conversion method Successive approximation
• Resolution (0-20mA) 10-bit (1024 units)
• Resolution (4-20mA) 204 to 1023 (820 units)
• Conversion time Each configured input is sampled once per 1.67ms. For example, if 3 inputs are configured, it takes 3*1.67 = 5ms to sample all the analog inputs. See note 6.
• Accuracy ±0.9% of full scale
• Status indication In software: If a specific input value is 1024, a single analog input deviates above the permissible range.
  If all the input values are 1024, either all the inputs deviate above the permissible range or the RG signal is not connected.

Notes:

1. The conversion time does not include communication time with the PLC and PLC scan time.

Digital Outputs

• Number of outputs 16 transistors
• Output type Output 32: Either pnp: P-MOSFET (open drain) or npn: N MOSFET (open drain) Outputs 33–47: pnp: P-MOSFET (open drain) Refer to notes 10 and 11
• Galvanic isolation None
• Status Indicators
• OUT: Red LEDs ■ One red LED for each output: Lights when the corresponding output is active
• S.C.: Red LED ■ Lights when a pnp output transistor load causes a short circuit, see note 12
• Maximum output current
  Maximum surge current
  Maximum delay OFF to ON
  Maximum delay ON to OFF
  HSO freq. range with resistive load
  Maximum ON voltage drop
  Short circuit protection
  Voltage Reference pnp| npn
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  0.5A per output, 4A total| 50mA
  0.6A peak, once every 2 seconds, for a duration of 10ms per output, not simultaneously| N/A
  1ms| 1µs
  0.15ms| 10µs
  1Hz–500Hz (at max. load resistance of 470kΩ)| 1Hz–32kHz (at max. load resistance of 1.5kΩ)
  0.5VDC| 0.4VDC
  Yes| No
  Digital output power supply| 3.5VDC to 28.8VDC, unrelated to the voltage of either the I/O module or the controller
• Output power supply
  utput power supply
  Nominal operating voltage 24VDC
  Operating voltage 20.4VDC to 28.8VDC

Notes:

1. Output 32 can be wired either as pnp (source) or npn (sink). pnp and npn can be wired simultaneously.
2. Output 32 can be used as a high speed output.
3. When an output load causes a short-circuit, the system disconnects that output and lights the S.C. LED on the module’s front panel. The short circuit is also identified by the PLC software. For example, in the Vision OPLC, SB 5 turns on and SDW 5, containing a bitmap, indicates which module has caused the short-circuit. For more information, refer to the PLC online help.

Dimensions

• Size (W x H x D) 80 x 135 x 60mm (3.15 x 5.31 x 2.36″).
• Weight (approximate) 383g (13.5oz)

Environmental

• Operating temperature 0 to 50 C (32 to 122 F)
• Storage temperature –20 to 60 C (–4 to 140 F)
• Relative Humidity (RH) 10% to 95% (non-condensing)
• Mounting Snap-mounted on 35mm DIN-rail (IP20/NEMA1)

The information in this document reflects products at the date of printing. Unitronics reserves the right, subject to all applicable laws, at any time, at its sole discretion, and without notice, to discontinue or change the features, designs, materials and other specifications of its products, and to either permanently or temporarily withdraw any of the forgoing from the market. All information in this document is provided “as is” without warranty of any kind, either expressed or implied, including but not limited to any implied warranties of merchantability, fitness for a particular purpose, or non-infringement. Unitronics assumes no responsibility for errors or omissions in the information presented in this document. In no event shall Unitronics be liable for any special, incidental, indirect or consequential damages of any kind, or any damages whatsoever arising out of or in connection with the use or performance of this information. The tradenames, trademarks, logos and service marks presented in this document, including their design, are the property of Unitronics (1989) (R”G) Ltd. or other third parties and you are not permitted to use them without the prior written consent of Unitronics or such third party as may own them.

References

• Unitronics- Programmable Logic Controller + Built-in HMI

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