User`s manual

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2900 Spafford Street Davis CA 95616 USA Tel: +916.757.3737 Fax: +916.753.5141 www.zworld.com Revision: D

The PLCBus

is a Z-World concept that allows you to extend

your control system by the addition of expansion boards.

Rather than buy controllers with many I/O lines, you can get

smaller controllers to which you add lines, according to your

needs. Z-World’s PLCBus concept also allows you to build your

own expansion boards, following a few guidelines.

Z-World offers these expansion boards:

Series Name Description

XP8100 IO32 32 protected digital I/O lines, configurable as

inputs or outputs in groups of eight.

3.525×2.835 (89.5 ×72 mm)

XP8200 UIO Six high-current outputs and 16 universal in-

puts, which can be used as digital inputs (with

single or dual thresholds) or analog inputs.

3.525×2.835 (89.5 ×72 mm)

XP8300 RELAY6 Six SPDT 10A relays.

3.525×2.835 (89.5×72 mm)

XP8400 RELAY8 Eight DIP relays, each SPST, 500 mA, normally

open.

2.2×2.835 (55.9×72 mm)

XP8500 ADC4 Four 12-bit ADC channels with signal condi-

tioning, seven channels without.

3.525×2.835 (89.5×72 mm)

* A/D12 Eight configurable ADC channels. Selectable

gain, differential or single-ended.

3.525×2.835 (89.5×72 mm)

XP8600 DAC2 Two DAC channels.

3.525×2.835 (89.5×72 mm)

XP8700 RS232 Single RS232 serial communication channel.

2.2×2.835 (55.9×72 mm)

XP8800 SMC Single-axis stepper motor controller with

quadrature decoder and high-speed counter.

4.0×2.835 (101.6 × 72 mm)

XP8900 DAC8 Four or eight DAC channels.

4.0×2.835 (101.6 × 72 mm)

The PLCBus, physically, is a set of one or more 26-wire ribbon

cables with which you connect a series of expansion boards to

a controller. When you have several boards connected, the

cables act as a “flexible backplane.” The limits to the number

of boards on a bus are power and addressability. You can ad-

dress up to 64 relay boards and up to 64 A/D12 boards and up to

32 UIO boards, and so forth, on a single bus. TTL loading limits

the number of boards on a single bus.

You can also build networks of controllers, each having expan-

sion boards.

All PLCBus expansion boards are 72 mm in width and fit in

DIN rail cards. Z-World expansion cards can also be installed,

with standoffs, on almost any flat surface that accepts screws.

Generally, mounting holes are 1/8″ (0.125″) in from the edge of

a board, with a diameter of 0.187.″

A RELAY6, a UIO board and an ADC4 board, when properly

cabled to a PK2200, would look something like this:

Most Z-World controllers support the PLCBus, although some

require special connectors. (Some controllers have limited soft-

ware support. Some do not have an actual PLCBus port.)

Z-World software usually hides most of the detail of operating a

PLCBus board. In practice, you need only make “plug and

play” physical connections, and make a few function calls in

your software.

The Concept

PLCBus devices connect with 26-wire ribbon cable (included

with the board) with the following pin assignments:

109

1211

1413

1615

1817

2019

2221

2423

2625

GND

D7X

D5X

D3X

D1X

–

GND

GND VCC (+5V)

attention /AT +V (normally +24V)

strobe /STBX GND

A3X GND

A2X GND

A1X

–

(+5V) VCC

D0X

–

D4X

D2X

D6X

The PLCBus core signals consists of

/AT Attention line (open drain). May be pulled low by

any

PLCBus device, causing an interrupt.

/STBX Negative going strobe.

A1X, A2X, A3X Three mode lines, for selecting bus operation.

D0X–D7X Bidirectional data lines.

+V PLCBus power. Either 24VDC (for 24V boards) or

12VDC (for 12V boards).

VCC, GND Normal regulated +5V and ground.

RELAY6

UIO

ADC4

PK2200

PLCBus Cable

DIN Rail

PLCBus Cable

XP8000 Series Expansion Products

PLCBus

Summary of content (22 pages)

PAGE 1
XP8000 Series Expansion Products PLCBus The PLCBus is a Z-World concept that allows you to extend your control system by the addition of expansion boards. Rather than buy controllers with many I/O lines, you can get smaller controllers to which you add lines, according to your needs. Z-World’s PLCBus concept also allows you to build your own expansion boards, following a few guidelines.
PAGE 2
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 2 References Bus Topology Please refer to • Zilog: Z180 MPU User’s Manual • Zilog: Z180 Serial Communication Controllers • Zilog: Z80 Microprocessor Family User’s Manual • Z-World: Dynamic C Data Sheet • Z-World: PCL-AK Tech Note (101) • Signetics: SCC2691 (UART) Data Sheet A device on the PLCBus generally has one or more ports (control registers or data registers). For example, Z-World relay boards each have one 4-bit control register.
PAGE 3
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Primitive functions are available in Z-World’s software libraries to carry out these bus cycles. Higher level functions are also available. They take care of the details for you. Bus Addresses To allow you to use an arbitrary combination of bus devices, in anticipation of future products and third-party products, Z-World has established a two-level addressing scheme. The first level in the scheme specifies how addresses are encoded when placed on the bus.
PAGE 4
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Relay Boards Z-World’s RELAY6 (XP8300) and RELAY8 (XP8400) expansion boards provide a simple way to add relays to your control system. Up to 64 relay boards can be addressed on a single bus. The RELAY6 board has six high-power relays installed as standard equipment. The board has six LEDs that correspond to the six relays. An LED turns on while the corresponding relay’s coil is activated. The RELAY8 board has eight DIP relays installed as standard.
PAGE 5
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 the +V line on the PLCBus. When J2:2-3 are connected, the actuation voltage is supplied by the VCC line on the PLCBus. To supply actuation voltage at header H1, leave J2 unconnected and connect your power supply at V+ and GND. How to use Relay Boards Whether you are using a RELAY6 board or a RELAY8 board, the method for controlling it is the same: 1 Initially, send a reset command to all boards on the PLCBus. Wait 350 ms.
PAGE 6
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Jumpers The A/D12 board uses 4 jumpers, J1 through J4. Settings for J1, coupled with the encoding of the PAL chip U7, determine the board’s PLCBus address. These settings are explained later. 3 Read one of the A/D12 board’s input channels. Allow for MUX settling time. 4 Calculate real-world values, such as temperature or displacement, from the data obtained. 5 Use the data (to control relays, switches, or other devices).
PAGE 7
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 EEPROM Coefficients Compensation coefficients, determined by precise measurement, are stored in the on-board EEPROM for each of the 18 software A/D modes. Excitation Resistors Some transducers (such as thermistors) require excitation resistors. You can install excitation resistors in the RP2 sockets.
PAGE 8
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Setting Up Your Conditioned Inputs As they comes from the factory, the conditioned inputs have a 0–10V input range. The socketed resistors are 2370 Ω (gain) and 39.2 kΩ (bias) respectively. You can have any input range you want, simply by changing the gain and bias resistors. The following tables present some useful input ranges. The table values require 1% resistors and have been adjusted from the theoretical values to account for tolerance.
PAGE 9
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 The DAC2 board’s main power supply (U9) provides +15V up to 1 amp. U8 and U2 provide V–, a regulated –5V up to 50 mA. U13, an LT1021 (the factory setting) provides a precision 10V reference (REF–). Optionally, you may install an LT1019 for U13. This provides a precision 2.5V reference for REF–. A third option is to leave U13 vacant and install a zener diode at Z1. The actual reference voltage depends on the sizes of Z1 and R4.
PAGE 10
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Eight different PALs are available and J3 can be set eight different ways, giving 64 unique addresses: 000z 001y pppx z = 1 when J3 pins 5-6 are not connected y = 1 when J3 pins 3-4 are not connected x = 1 when J3 pins 1-2 are not connected The board’s main power supply (U2, U6, U7, U17) provides +5V (VCC), +5V reference for the DACs and +12V and –12V “rails” for the op-amps. Q1 switches a +2V reference voltage to the opamps for power conservation.
PAGE 11
XP8000 Series (PLCBus ) TM Jumpers The DAC8 board uses 3 jumpers, H1 through H3 to select the ±12V source: Internal ±12V External ±12V H1 H1 1 1 H2 H2 1 H3 EEPROM The DAC8 board’s EEPROM (U5) stores calibration constants and is controlled by the CPLD (U1). 11 Bipolar and Unipolar Operation The AD5320 was designed for unipolar operation, but with an op-amp and the right resistors, bipolar output can be achieved. The default output for the XP8900 is bipolar.
PAGE 12
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 12 Typical Operations The RS232 Board In the examples given below, the shorthand notation Z-World’s RS232 (XP8700) expansion boards provide a simple way to add an RS232 channel to your control system. Each board has a single Signetics SCC2691 UART. Up to 4 RS232 boards can be addressed on a single PLCBus.
PAGE 13
XP8000 Series (PLCBus ) TM There are 14 internal registers, 7 of which you can read and 9 of which you can write: A2 A1 A0 Read Write 0 0 0 0 1 1 1 1 MR1, MR2 SR Reserved RHR Reserved ISR CTU CTL MR1, MR2 CSR CR THR ACR IMR CTUR CTLR 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 Z-World 530-757-3737 Reading and Writing to the UART The PLCBus cycles have specific meaning when addressing an RS232 board. Write data to either CTRL or DATA register. Read RS232 board status.
PAGE 14
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Universal Input/Output Board The signals on J1 are shown here: Z-World’s Universal Input/Output board (XP8800) adds 16 universal inputs and six high-current outputs to your control system. The universal inputs can be used as • digital inputs with single fixed threshold • digital inputs with two adjustable thresholds • analog inputs. For the latter 2 cases, an external voltage source is required.
PAGE 15
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Each input channel can be pulled high to an excitation voltage (which can be external or V+) or pulled to ground, depending on the setting of jumpers J2, J3, J4 and J5. Universal Inputs As Digital Inputs When the negative side is connected to VL, the inputs function as digital inputs: the channel read “1” when the input voltage is more positive than its threshold voltage and “0” otherwise.
PAGE 16
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 The Stepper Motor Controller Z-World’s stepper motor controller (XP8800) is a special purpose expansion board. This document will use the abbreviation SMC to refer to the stepper motor controller. ture counter by ignoring the PCL-AK and the motor driver. It can even be used as a timer by ignoring or disabling its outputs.
PAGE 17
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Communicating with the PCL-AK You tell the PCL-AK what to do by (A) writing to its command buffer and (B) writing values to its control registers. You find out what it’s doing by reading the status register or a control register. Only two registers are readable: the counter and rampdown point register. You can issue a hard reset to the PCL-AK by pulsing the /RESET line. This resets internal registers.
PAGE 18
XP8000 Series (PLCBus ) TM H6 Motor Drive Quadrature Sense Input Z-World 530-757-3737 Power 1 PHA PHC PHB GND PHD BIN AIN /EL+ /ORG /SD+ /EL– /SD– K GND +5V +24V • PHA, PHB, PHC, PHD Open-collector motor control outputs, connecting to motor phase lines. They can sink up to 1A. • AIN, BIN TTL-compatible quadrature-encoded inputs. • /ORG Active-low origin pulse. Readable in the PCL-AK (address 0) status bits.
PAGE 19
XP8000 Series (PLCBus ) TM the quadrature decoder/counter, and the control register.
PAGE 20
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 XP8100 (IO32) An XP8100 Series expansion board adds up to 32 digital I/O lines to your control system. The lines can be inputs or outputs, depending on the configuration you order. The XP8100 Series is available from the factory in three standard configurations: • XP8100 16 inputs, 16 outputs. • XP8110 32 inputs • XP8120 32 outputs.
PAGE 21
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Outputs The XP8100 high-current outputs normally have “sinking” drivers. The sinking drivers (2803s) are rated at a maximum output of 48V at 500 mA per individual output (when only one output is active). You can get sourcing drivers (2985s) by special order. Each driver chip can, and should, be connected to a “K” line to prevent inductive kickback current from damaging the drivers.
PAGE 22
XP8000 Series (PLCBus ) TM Z-World 530-757-3737 Jumpers FWT-Opto There are 4 locations for jumper blocks. Not all of the jumper blocks may be installed on your particular model. Total I/O Channels Pitch Maximum Wire Quick Disconnect Wire Orientation Input Protection AC Input Response XP8100 Jumpers (16 Inputs, 16 Outputs) J1 J2 J4 Bank A outputs 0–15, sinking vs.