Technical Manual

3000/01-002
2-Channel
Servo Card
© 2002 - 2014 RTP Corporation
Specifications, information and graphics are subject to change without notice. Contact
RTP’s corporate office for specifics regarding any changes.
Not for reproduction in any printed or electronic media without express written consent
from RTP Corp.
All information, data, graphics and statements in this document are proprietary
intellectual property of RTP Corp. unless otherwise indicated and are to be considered
RTP Corp. confidential. This intellectual property is made available solely for the direct
use of potential or licensed RTP Corp. customers in their application of RTP Corp.
products, and any other use or distribution is expressly prohibited. If you have received
this publication in error, immediately delete, discard or return all copies to RTP Corp.

RTP Corporation
2832 Center Port Circle
Pompano Beach, FL 33064
Phone: (954) 597-5333
Internet: http://www.rtpcorp.com

Last Updated: 9/16/2014

2
TABLE OF CONTENTS
INTRODUCTION ........................................................................................ 4 
SPECIFICATIONS ..................................................................................... 5 
FAILURE RATES IN ACCORDANCE TO IEC 61508 ............................... 8 
CABLING……………. ................................................................................ 9 
SOFTWARE CONFIGURATION ............................................................. 21 
Firmware Upgrades ....................................................................................... 21 
Firmware Upgrade Order ......................................................................... 21 
Firmware Upgrade Procedure ................................................................. 21 
NetArrays Software Configuration ................................................................. 22 
Adding a Distributed Servo Card to the IOC ............................................ 22 
Configuring Redundant Distributed Servo Controllers ............................. 22 
Card Properties ....................................................................................... 23 
Redundant Card ID.................................................................................. 23 
Distributed Logic ...................................................................................... 23 
Scan Rate ................................................................................................ 23 
Integer Error Detection ............................................................................ 23 
Float Cal High Input ................................................................................. 24 
Integer Channel Error Status ................................................................... 24 
Output Channel (Output 00 – Output 01) ................................................ 25 
I/O Tag..................................................................................................... 25 
Readback Tag ......................................................................................... 25 
Channel (Input 00 – Input 01) .................................................................. 25 
I/O Tag..................................................................................................... 25 
Filter......................................................................................................... 25 
Threshold................................................................................................. 26 
Type......................................................................................................... 26 
Channel (Input 02 – Input 07) .................................................................. 26 
I/O Tag..................................................................................................... 26 
Distributed I/O User Application Logic Programming .............................. 26 
Node Info ................................................................................................. 28 
COMPLIANCE WITH CE MARK ............................................................. 29 
ENVIRONMENTAL CONDITIONS .......................................................... 31 
REFERENCED COMPANIES .................................................................. 32 
DEFINITIONS……….. .............................................................................. 32 

3
Introduction

The 3000/01-002 2-Channel Servo Controller Card interfaces typically to two servo devices.
Each channel consists of a ±100 control output, an optional LVDT (Linear Variable Differential
Transformer) position input and a shared excitation voltage output for the LVDT located on the
Termination Module.
In addition, the card provides eight sinking digital input channels that may be used for external
manual controls as determined by the user.
Analog to digital conversion is performed by a 16-bit switched capacitor successive
approximation A/D converter. A precision voltage source provides a self-test function for the
card’s amplifiers and A/D converter and can be used to verify accuracy in user application logic.
No field adjustments are necessary after the initial factory setup.
A Readback input can be read to determine the actual output of a channel. The analog inputs can
provide positional feedback from the device being controlled. NetArrays also returns an error
detection status integer for the card, calibration inputs, plus a switch status integer for the
external digital inputs.
This card also includes a Watchdog Timer, which can disable the outputs in the event of a
detected failure.
Two indicator LEDs are located near the top of the front panel. The left LED indicator displays
the overall health status of the card. If this LED is on, the card is functioning normally; if it is off,
the card has detected an error or is offline. The right indicator LED indicates the node processor
status as shown below:

4
 ON Primary No errors
1 Blink Primary Card error
2 Blink Secondary No error
3 Blink Secondary Card error
4 Blinks Bootloader mode
6 Blinks Rack address error
OFF Card Offline

This card executes its own control program, scanning its own inputs, solving logic, and generating
its own outputs at user configured rate. The servo card may then share data with the Node
Processor on each scan cycle of the Node Processor’s project program.

Specifications
Module Safety Integrity Level: Non-Interfering with Safety Functions
Card Address: Determined by onboard switch settings
Number of channels: 2 Servo Analog Output Channels
2 Servo Feedback Channels
2 Analog Inputs
8 Digital Input Channels
Isolation: 500 Volts to RTP system
Type of protection: Digital isolators (magnetic)
Outputs may be shorted to 0V indefinitely
Maximum permanent allowed
voltage (no damage):
Analog Inputs: ±15 VDC
Digital Inputs: +40 VDC
Reading under overload condition: Reported in error status word.
Crosstalk between Channels: -80 dB at D.C. / A.C. (50 Hz / 60 Hz)
Common Points between Channels: Inputs and outputs share a common return
Normal Mode Rejection: 0 dB at 50 Hz / 60 Hz
Type of Input:
Analog: Single Ended
Digital: IEC 61131-2 Type 3
Conversion method: Successive approximation
Analog Input Signal Ranges: -10 VDC to +10 VDC
0 VDC to +10 VDC
0 mA to +20 mA (*)
+4 mA to +20 mA (*)
(*) Requires a 250 external resistor on the 3099/15-X03 Termination
Module

5
Guard Bands: < -10.0308 V
> +10.0308 V
< –0.0308 V
> +10.0308 V
< –0.1233 mA)
> +20.1227 mA
< +3.8756 mA
> +20.1227 mA
Digital Input Levels:
ON: > 17.8 VDC
OFF: < 5.8 VDC
Digital Input Currents:
High-Level Input Current: 4.2 mA maximum at 24 VDC
Low-Level Input Current: 0.95 mA maximum at 24 VDC
Analog Output Signal Ranges: ±100 mA
Sample Repetition Rate: 154 microseconds (6500 scans per second)
Sample Duration & Settling Time: 8 microseconds
Input Filter characterization:
Order: First Order
Transition: -3 dB at 3.7 kHz
Multiplexer Type: Solid state multiplexers
Analog input error:
Maximum error at 25 °C: ±0.0280% of Full Scale Voltage
Temperature Coefficient: ±0.0025% of Full Scale Voltage/K
Maximum error (0 to 55 °C): ±0.1030% of Full Scale Voltage
Analog output error:
Maximum error at 25 °C: ±0.070% of Full Scale Current
Temperature Coefficient: ±0.005% of Full Scale Current /K
Maximum error (0 to 55 °C): ±0.220% of Full Scale Current
Non-Linearity: ±0.028% of Full Scale
Repeatability: ±0.028% of Full Scale at fixed temperature
Monotonicity with no missing codes: Yes
Resolution: 16 Bits
Value of LSB:
Analog input: 308.2 µV
Analog output: 6.1035 µA
Settling Time: Less than 80 s for full range change
Overshoot: 0% over full scale
Typical Slew Rate: 2 mA/s
Input Impedance: 400 k
Output Impedance: Greater than 10 Mwhen outputs turned off
Greater than 220 when outputs turned on

6
Output Response: Outputs are in a high-impedance state at power-up. Outputs
drive to commanded levels when initialized by software.
Outputs are in a high-impedance state when powered-down.
Input Source Impedance: 1 k to meet specifications
Type of Loads: Floating or grounded
Load Resistance: 40 Ohms minimum and 100 Ohms maximum for floating
outputs
24 Ohms minimum and 45 Ohms maximum for grounded
outputs
Watchdog Timers:
Fixed: 3.4 s maximum
Windowed: 0.3 ms minimum, 26.6 ms maximum
Programming Tools: NetArrays Developer Studio
Programming Languages: Flow Charts, Objects, Structured Text, C/C++, Fuzzy Logic
Memory Utilization: Processor can be configured for cyclic execution: 1 ms, 1.5
ms, 2 ms, 2.5 ms, 3 ms or 3.5 ms. Memory utilization is
measured via Node Info Object, which reports the reserve
time in each execution cycle. Minimum 20% reserve time is
recommended.
Processing of I/O: The 3000/02 Node Processor sends outputs each scan cycle
to the 3000/01-002 Servo Card via CO_ variables. Field
inputs are acquired onboard by the 3000/01-002 Servo Card,
processed in the user application program executing
onboard and after two scan cycles computational results are
presented to the onboard outputs. Logical input variables
CI_ are transferred to the 3000/02 Node Processor and are
processed in the main user application program after two
scan cycles.
Ethernet Cable Length: 328 feet (100 meters) maximum, card to switch or card to
card
Ethernet Cable Type: STP Category 5 (EIA 568B, Cat 5) shielded Ethernet cables
with 4 twisted-pair wires and RJ-45 tips
Power Requirements: +5 VDC @ 1.4 A
+24 VDC @ 550 mA
External Power to Termination: 24 VDC nominal (19 to 30 VDC) at 40 mA maximum
Termination Module Connectors: 37 pin D-Sub connector for use with the 3058/00 Analog
Cables. These cables have a diameter of 0.5 inches (1.27
centimeters) with a minimum bend radius of 4.6 inches
(11.69 centimeters).
Termination Modules:
5/6 Wire LVDT: 3099/15-100 Single Termination Module
3099/15-000 Triple Redundant Termination Module
3 Wire LVDT: 3099/15-101 Single Termination Module
3099/15-001 Triple Redundant Termination Module
4 Wire LVDT: 3099/15-102 Single Termination Module
3099/15-002 Triple Redundant Termination Module

7
 Analog Voltage Input: 3099/15-103 Single Termination Module
3099/15-003 Triple Redundant Termination Module
Effect of Incorrect Field Wiring: Shorted input connections produce zero analog input
reading. Shorted digital inputs will produce an OFF. Open
input connections produce incorrect analog input reading in
voltage mode. Open digital inputs will produce an OFF
state. Reverse input connections produce (sign) inverted
analog input readings in voltage mode. Outputs can be
shorted to ground indefinitely. Shorted output connections
will de-energize and shut down the output. Reversed output
connections apply reverse voltage to the load.
LVDT Specifications:
LVDT Input Voltage Range: 0.1 VRMS minimum to 3.5 VRMS maximum
LVDT Input Accuracy: 2.5% of Full Scale Value
LVDT Excitation Frequency: 3.5 kHz ±10%
Excitation Output Range: 2.5 VRMS minimum to 24 VRMS maximum
Excitation Output Current: 12 mARMS maximum
LVDT Cable Length: 300 feet maximum
Termination Module Dimensions: All Termination Modules are 4.38 inches (11.1 centimeters)
in height and have 3.75 inches (9.5 centimeters) of depth.
The width for each termination module and the compatible
field wiring size is tabulated as following:
Width Width Minimum Maximum
Model # Description
(") (cm) AWG AWG
Triple Termination - Servo with 5/6 wire LVDT input,
3099/15-000 5.75 14.6 26 16
resettable fuses
Triple Termination - Servo with 3 wire LVDT input,
3099/15-001 5.75 14.6 26 16
resettable fuses
Triple Termination - Servo with 4 wire LVDT input,
3099/15-002 5.75 14.6 26 16
resettable fuses
Triple Termination - Servo Analog Voltage input,
3099/15-003 5.75 14.6 26 16
resettable fuses
Single Termination - Servo with 5/6 wire LVDT input,
3099/15-100 4.37 11.1 26 16
resettable fuses
Single Termination - Servo with 3 wire LVDT input,
3099/15-101 4.37 11.1 26 16
resettable fuses
Single - Termination Servo with 4 wire LVDT input,
3099/15-102 4.37 11.1 26 16
resettable fuses
Single Termination - Servo Analog Voltage input,
3099/15-103 4.37 11.1 26 16
resettable fuses

Module dimension values are ± 0.05 inches or ± 0.127 centimeters!

Failure Rates in Accordance to IEC 61508

The 3000/01-002 2-Channel Servo Control card cannot be used for safety-critical functions.
However, the module is non-interfering with other safety-critical modules and therefore can be
used for non-safety related functions.

8
Cabling
Table 1: Ethernet Cabling Matrix
Host 
Ethernet  Switch  I/O  I/O  I/O 
Description  Redundant ID  Port  A  Switch B  Switch C  Switch D 
Node  Single (Non‐redundant) J1 X   
Processor      J2 X   
   J3 X 
   J4    X
A  J1 X   
   J2 X   
   J3 X 
   J4    X
B  J1 X   
   J2 X   
   J3 X 
   J4    X
C  J1 X   
   J2 X   
   J3 X 
   J4    X
D  J1 X   
   J2 X   
   J3 X 
   J4    X
Chassis  Main (00‐15)  J1 X 
Processor     J2    X
   Redundant (00R ‐ 15R) J1 X   
  
      J2           X 
MODBUS  Main (32‐47)  J1 X 
TCP/IP     J2    X
   Redundant (32‐47)  J1 X 
  
      J2           X 
2‐Channel  Main (32‐63)  J1 X 
Servo     J2    X
   Redundant (32‐63)  J1 X 
  
      J2           X 
8‐Channel  Main (32‐63)  J1 X 
Counter     J2    X
   Redundant (32‐63)  J1 X 
   J2    X

9
 Power
ON Power on and within limits
Power Servo OFF Power off or error
Card Transmit/Receive
Status ON Message transmit/receive
OFF No link activity
Link Status
ON Link is functioning normally
Transmit/Receive OFF Link error
Link Status I/O Network C
Servo Card Status
Transmit/Receive ON Primary, no errors
I/O Network D
Link Status 1 Blink Primary, card error
2 Blinks Secondary, no errors
3 Blinks Secondary, card error
4 Blinks Bootloader mode
6 Blinks Chassis address error
OFF Servo card offline

Figure 1: Two Channel Servo Control Card Front Panel

The MAC address used for raw Ethernet communication with the node processor is determined
by an assigned “chassis number”. This value is determined by DIP switch settings on the card as
shown in Table 2.

Figure 2: Two Channel Servo Control Card configured for chassis address 33.

10
 Table 2: Chassis Address Selection Switch Positions
Chassis
Number SW1 SW2 SW3 SW4 SW5
63 OFF OFF OFF OFF OFF
62 ON OFF OFF OFF OFF
61 OFF ON OFF OFF OFF
60 ON ON OFF OFF OFF
59 OFF OFF ON OFF OFF
58 ON OFF ON OFF OFF
57 OFF ON ON OFF OFF
56 ON ON ON OFF OFF
55 OFF OFF OFF ON OFF
54 ON OFF OFF ON OFF
53 OFF ON OFF ON OFF
52 ON ON OFF ON OFF
51 OFF OFF ON ON OFF
50 ON OFF ON ON OFF
49 OFF ON ON ON OFF
48 ON ON ON ON OFF
47 OFF OFF OFF OFF ON
46 ON OFF OFF OFF ON
45 OFF ON OFF OFF ON
44 ON ON OFF OFF ON
43 OFF OFF ON OFF ON
42 ON OFF ON OFF ON
41 OFF ON ON OFF ON
40 ON ON ON OFF ON
39 OFF OFF OFF ON ON
38 ON OFF OFF ON ON
37 OFF ON OFF ON ON
36 ON ON OFF ON ON
35 OFF OFF ON ON ON
34 ON OFF ON ON ON
33 OFF ON ON ON ON
32 ON ON ON ON ON

In normal operation, SW 6, SW 7 and SW 8 are in ON position.

11
Adhere to the specified insulation strip length of 0.26 inches (6.5 mm) when you connect field
wiring to the terminal modules; excessive insulation strip lengths causes an electrical hazard. Do
not exceed the specified torque when you secure the wires into the terminal module; maximum
torque is 2.2 inch-pounds (0.25 N-m).

Standard cables to termination modules are minimum 5 feet in length.

You must disable (offline) an I/O card before you can hot-swap it. After you replace an I/O card,
you must enable it to return it to operation. While NetArrays is operating in Debug mode, use the
I/O Configuration Form to disable or enable I/O cards. To hot swap an I/O card, first display the
card’s icon in the I/O Configuration Form. If the I/O card’s icon is red, you can remove it. If the
I/O card’s icon is yellow or green, select the icon and disable it before you remove the card. After
you replace the I/O card, select the card’s icon and re-enable it. The color of the icon changes to
yellow or green to indicate the card is online.

Warning! Dangerous high voltages may be present at the cards’ terminal blocks during
normal operation. When you service these cards, avoid contact with exposed voltages
on the card while you connect the field cabling. The field cabling terminal block
connectors also may have high voltages when disconnected from the card.

Warning! Never remove the card from the chassis with the termination cables
connected and the field power applied. Always disconnect the field power and cables
before removing the card from the chassis. Always insert the card into the chassis with
the cables and field power disconnected.

12
 Pin Signal
Servo 1 Top Analog Output Channel 0+
1 Middle Analog Output Channel 0-
1 Bottom Ground
2 Top LVDT Excitation Output 0+
2 Middle LVDT Excitation Output 0-
LVDT 2 Bottom Ground
3 Top VA Channel 0
3 Middle VB Channel 0
3 Bottom Ground
Servo 4 Top Analog Output Channel 1+
4 Middle Analog Output Channel 1-
4 Bottom Ground
5 Top LVDT Excitation Output 1+
5 Middle LVDT Excitation Output 1-
LVDT
5 Bottom Ground
6 Top VA Channel 1
6 Middle VB Channel 1
6 Bottom Ground
7 Top Digital Input Channel 0+
7 Middle Digital Input Channel 0-
7 Bottom Ground
8 Top Digital Input Channel 1+
8 Middle Digital Input Channel 1-
8 Bottom Ground
9 Top Digital Input Channel 2+
9 Middle Digital Input Channel 2-
9 Bottom Ground
10 Top Digital Input Channel 3+
10 Middle Digital Input Channel 3-
10 Bottom Ground
11 Top Digital Input Channel 4+
11 Middle Digital Input Channel 4-
11 Bottom Ground
12 Top Digital Input Channel 5+
12 Middle Digital Input Channel 5-
Ground 12 Bottom Ground
13 Top Digital Input Channel 6+
13 Middle Digital Input Channel 6-
13 Bottom Ground
14 Top Digital Input Channel 7+
14 Middle Digital Input Channel 7-
14 Bottom Ground

13
 Pin Signal
- + Field Power +
VS 15 Top
15 Middle No Connection
24 VDC Nominal
15 Bottom Field Power -

Figure 3: Field connections on the 3099/15-X00 Termination Module with 5/6-Wire LVDT’s.

14
 Pin Signal
Servo 1 Top Analog Output Channel 0+
1 Middle Analog Output Channel 0-
1 Bottom Ground
2 Top LVDT Excitation Output 0+
2 Middle LVDT Excitation Output 0-
LVDT 2 Bottom Ground
3 Top VA Channel 0
3 Middle VB Channel 0
3 Bottom Ground
Servo 4 Top Analog Output Channel 1+
4 Middle Analog Output Channel 1-
4 Bottom Ground
5 Top LVDT Excitation Output 1+
5 Middle LVDT Excitation Output 1-
LVDT
5 Bottom Ground
6 Top VA Channel 1
6 Middle VB Channel 1
6 Bottom Ground
7 Top Digital Input Channel 0+
7 Middle Digital Input Channel 0-
7 Bottom Ground
8 Top Digital Input Channel 1+
8 Middle Digital Input Channel 1-
8 Bottom Ground
9 Top Digital Input Channel 2+
9 Middle Digital Input Channel 2-
9 Bottom Ground
10 Top Digital Input Channel 3+
10 Middle Digital Input Channel 3-
10 Bottom Ground
11 Top Digital Input Channel 4+
11 Middle Digital Input Channel 4-
11 Bottom Ground
12 Top Digital Input Channel 5+
12 Middle Digital Input Channel 5-
Ground 12 Bottom Ground
13 Top Digital Input Channel 6+
13 Middle Digital Input Channel 6-
13 Bottom Ground
14 Top Digital Input Channel 7+
14 Middle Digital Input Channel 7-
14 Bottom Ground

15
 Pin Signal
- VS + 15 Top Field Power +
15 Middle No Connection
24 VDC Nominal
15 Bottom Field Power -

Figure 4: Field connections on the 3099/15-X01 Termination Module with 3-Wire LVDT’s.

16
 Pin Signal
Servo 1 Top Analog Output Channel 0+
1 Middle Analog Output Channel 0-
1 Bottom Ground
2 Top LVDT Excitation Output 0+
2 Middle LVDT Excitation Output 0-
LVDT 2 Bottom Ground
3 Top VA Channel 0
3 Middle VB Channel 0
3 Bottom Ground
Servo 4 Top Analog Output Channel 1+
4 Middle Analog Output Channel 1-
4 Bottom Ground
5 Top LVDT Excitation Output 1+
5 Middle LVDT Excitation Output 1-
LVDT
5 Bottom Ground
6 Top VA Channel 1
6 Middle VB Channel 1
6 Bottom Ground
7 Top Digital Input Channel 0+
7 Middle Digital Input Channel 0-
7 Bottom Ground
8 Top Digital Input Channel 1+
8 Middle Digital Input Channel 1-
8 Bottom Ground
9 Top Digital Input Channel 2+
9 Middle Digital Input Channel 2-
9 Bottom Ground
10 Top Digital Input Channel 3+
10 Middle Digital Input Channel 3-
Ground 10 Bottom Ground
11 Top Digital Input Channel 4+
11 Middle Digital Input Channel 4-
11 Bottom Ground
12 Top Digital Input Channel 5+
12 Middle Digital Input Channel 5-
12 Bottom Ground
13 Top Digital Input Channel 6+
13 Middle Digital Input Channel 6-
13 Bottom Ground
14 Top Digital Input Channel 7+
14 Middle Digital Input Channel 7-
14 Bottom Ground

17
 Pin Signal
- VS + 15 Top Field Power +
15 Middle No Connection
24 VDC Nominal
15 Bottom Field Power -

Figure 5: Field connections on the 3099/15-X02 Termination Module with 4-Wire LVDT’s.

18
 Pin Signal
Load 1 Top Analog Output Channel 0+
1 Middle Analog Output Channel 0-
1 Bottom Ground
2 Top No Connection
2 Middle No Connection
- 2 Bottom Ground
+
VS 3 Top Analog Input Channel 0+
3 Middle Analog Input Channel 0-
3 Bottom Ground
Load 4 Top Analog Output Channel 1+
4 Middle Analog Output Channel 1-
4 Bottom Ground
5 Top No Connection
5 Middle No Connection
5 Bottom Ground
-
VS + 6 Top Analog Input Channel 1+
6 Middle Analog Input Channel 1-
6 Bottom Ground
7 Top Digital Input Channel 0-
7 Middle Digital Input Channel 0+
7 Bottom Ground
8 Top Digital Input Channel 1+
Ground 8 Middle Digital Input Channel 1-
8 Bottom Ground
9 Top Digital Input Channel 2+
9 Middle Digital Input Channel 2-
9 Bottom Ground
10 Top Digital Input Channel 3+
10 Middle Digital Input Channel 3-
10 Bottom Ground
11 Top Digital Input Channel 4+
11 Middle Digital Input Channel 4-
11 Bottom Ground
12 Top Digital Input Channel 5+
Middle Digital Input Channel 5-
12 Bottom Ground
13 Top Digital Input Channel 6+
13 Middle Digital Input Channel 6-
13 Bottom Ground
14 Top Digital Input Channel 7+
14 Middle Digital Input Channel 7-
14 Bottom Ground

19
 Pin Signal
- VS + 15 Top Field Power +
15 Middle No Connection
24 VDC Nominal
15 Bottom Field Power -

Figure 6: Field connections on the 3099/15-X03 Termination Module with Analog I/O.

3000/01 3000/01
Counter Servo
Card Card

Figure 7: Interconnection of digital I/O between the 3000/01 Counter and 3000/01 Servo
cards.

20
Software Configuration
Firmware Upgrades
Firmware updates are required when you upgrade to a new version of NetSuite. The required
files are included in the NetSuite distribution CD. You must follow this procedure in the order
presented to successfully update the firmware.

Firmware Upgrade Order

When upgrading firmware, the following order should be followed:

1. Upgrade 3019 MODBUS Serial card firmware and PLD.

2. Upgrade 3018 HART card firmware and PLD.
3. Upgrade 3000/01-0YZ Counter card firmware and PLD.
4. Upgrade 3000/01-0YZ Servo card firmware and PLD.
5. Upgrade 3000/01 Chassis Processor firmware and PLD.
6. Upgrade 3000/02 Node Processor firmware.
7. Lastly, power cycle in order for the new firmware and PLD to take effect.

If the order is not followed, then you might not be able to communicate to the cards intermittently
as a result of firmware incompatibilities. In this case, the firmware of any card can still be
updated by means of setting it into Bootloader mode.

Firmware Upgrade Procedure

1. Turn the power ON at all chassis within the target node.
2. From the Windows StartPrograms menu, launch the RTPNC utility.
3. In the Devices pane of the RTPNC utility window, select the node that corresponds to the
target node you are updating.
4. In the Files menu, select Download Card File…
5. Navigate to the NetSuite distribution CD and open the Firmware folder.
6. To upgrade the Distributed Card, open the Distributed IO folder corresponding to the
RTP3000 or RTP3100 system.
7. Open the appropriate revision level folder, select the binary engine file (iocard.bin), and click
on the Open button. You will need to enter the download password to perform the operation.
The engine is downloaded to all Distributed IO Cards.
8. If applicable, the PLD can be upgraded, following above-described procedures steps 4 to 8.
The PLD file would reside in the same directory as the iocard.bin file.
Note: In the Device Status window, verify that all distributed cards received the
downloaded engine (iocard.bin) file. If some cards do not show the firmware
update to have received:
a. Repeat the procedure.
b. If some of the cards still do not receive the firmware update, then
i. Set switch 8 on the distributed card to OFF position
ii. Connect the J1 I/O Ethernet port to the host network switch
iii. Follow the chassis processor firmware upgrade procedure for default IP
address 89.89.89.89.
iv. Set switch 8 on the distributed card to ON position
v. Connect the J1 I/O Ethernet port to the I/O network switch C.

21
NetArrays Software Configuration
This card operates in a distributed intelligence mode, executing its own portion of the control
program, which is downloaded directly to the card. The Distributed Servo Card must be linked to
the Distributed I/O program in NetArrays in the card’s configuration. See Distributed I/O User
Application Logic Programming for more details.

Adding a Distributed Servo Card to the IOC

Adding a 3000/01-002 Two-Channel Distributed Servo Controller Card to the I/O Configuration
Form differs from adding other I/O cards because this card can be placed only on empty chassis
slot with chassis numbers 32 to 63.
To display the Property Manager window for the Distributed Servo Card, right-click on the
(3000/01) 2-Channel Distributed Servo Card icon in the IOC.

Configuring Redundant Distributed Servo Controllers

Adding a redundant pair of 3000/01 2-Channel Distributed Servo Controllers to the IOC is slightly
different from the procedure for adding other redundant I/O Cards. The first step is to drag and
drop a (3000/01) 2-Channel Distributed Servo Controller icon onto empty chassis slot (32-63).
Access the Property Manager of the Distributed Servo Controller and configure the parameters,
making sure to set the Redundant Card ID to a non-zero value.

22
To add the redundant card, select (3000/01) 2-Channel Distributed Servo Controller icon, click on
right mouse button and select Copy As Redundant option in popup menu, then select empty
chassis slot (32-63) and paste redundant card to it. Access the Property Manager of this
Distributed Servo Controller and verify that Distributed Form selected for the Distributed Logic
parameter of the redundant card is the same as in the first Distributed Servo Controller card.

Card Properties

Redundant Card ID
If the inputs of two or three of these cards are connected in a parallel redundant input
configuration, a unique Redundant Card ID must be assigned to the cards to identify them as
being part of the same parallel redundant group. These cards are considered to be connected in
a parallel redundant input configuration if a single input is connected to channel 0 of each card,
another input is connected to channel 1 of each card, and so on for every configured channel on
the cards.

The Redundant Card ID number assigned to one group must not be assigned to any other group
of redundant cards. If the card's inputs are not connected in a redundant configuration, the
Redundant Card ID must be 0.

Distributed Logic
The Distributed Logic Tag is the Tag name of the Distributed Form (.dis) created in NetArrays
specifically for this Distributed Servo Card. This will be the part of the project program that will be
downloaded directly to this Distributed Servo Card for execution.

Scan Rate
The Scan Rate Property determines how fast the user logic and I/O will be executed. Available
parameters are 1.0 ms, 1.5 ms, 2.0 ms, 2.5 ms, 3.0 ms and 3.5 ms. The scan rate should be at
least 1.5 ms for dual and 2.0 ms for triple redundant configurations and should be verified by
using the Node Info object’s Scan Cycle and Scan Reserve variables: If the object reports
insufficient Scan Reserve time, then a larger Scan Rate should be selected.

Integer Error Detection

The Error Detection input is an Int Variable that can be used to detect an I/O card failure. It is
resides in the project program running in the Node Processor. NetArrays assigns a Tag to this
property when the card is added to the I/O configuration. Reconfigure the Tag as required to
match the Module Form Int Variable object that is used to monitor the card’s Error Detection
input. Note that in redundant configurations, the Tag of this variable must be unique in each card.

The Error Detection input is an Int Variable that provides I/O card status information within the
user application program. The format of this variable is common to all RTP I/O cards. A Card
Timeout Error (Bit 0) will set the Error Latch bit (Bit14), which will remain set until this bit is
cleared to zero by an operator. While the Error Latch is set, the card will be offline and the target
node will not attempt to communicate with it. Note that most cards do not use all the status bits
shown. Any unused bits will always equal zero.

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
ERR DATA DATA CARD CBL LOOP CH TIME
LTCH ERR INV ID ERR BACK FAIL OUT

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Bit 14 Card Error Latch
This status bit indicates that a Card Timeout Error occurred on the I/O card, and that it
has been taken offline. The card will not be initialized or placed online until this bit is
cleared in the project program or operator intervention.
Note: If this bit is set, it must be cleared to return the card to operation. The
correct way to clear this bit is to select the card’s icon in the I/O configuration
Form while NetArrays is operating in Debug mode and answer “Yes” to the
prompt. See I/O Card Status and Control. (It is also possible to change the
value of this variable by forcing an Integer Bit Variable object, with Bit 14
selected in the object's properties, to zero. Do not clear the entire Error
Detection Integer Variable to zero.)

Bit 9 Backplane Bus Data Error

This status bit is applicable only to I/O cards with Backplane Bus data checking
capability. It indicates that a data error was detected in a data or command transfer to or
from an I/O card.
Bit 8 Data Invalid
For a 3000 system, this status bit indicates that the I/O card is not ready to send valid
data.
Bit 7 Card ID Does Not Match I/O Configuration
This bit indicates that the ID code read from the I/O card does not match the card type
specified in the NetArrays I/O configuration.
Bit 5 Cable Detect Error
This bit indicates that one or more of the cables are not connected to the I/O card or
between the I/O card and the termination block.
Bit 4 Loopback Error
This bit indicates that an output card has failed a loopback test. The actual output from
the card does not equal the expected output.
Bit 1 Channel Failure
This bit indicates that the card has a failure on one or more of its channels. Examine the
channel specific error status word to isolate the failed channel(s).
Bit 0 Card Timeout Error
This bit indicates that there was no response from the I/O card. The card is not returning
a ready test signal, is offline, or has been removed from the chassis. This bit sets the
Card Error Latch (Bit 14).

Float Cal High Input

The Fixed Gain Cal High input is a floating-point voltage equal to 10.0 volts (100% of full scale
input). It is derived from a fixed calibration voltage source on the card. This input can be used to
test the card’s calibration and performance. NetArrays assigns a Tag to this input when the card
is added to the I/O configuration. Reassign this Tag as required to access this calibration voltage
in the project program.

Integer Channel Error Status

The Channel Error Status is an Int Variable that can be used to detect out-of-range errors on the
analog inputs channels. NetArrays assigns a Tag to each channel when the card is added to the
I/O configuration. Reconfigure the I/O Tag as required to match the Module Form Variable object
that is used to monitor out-of-range inputs.

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I/O Channel Properties
Output Channel (Output 00 – Output 01)
Both channels are Float outputs, and cannot be disabled. Each channel requires a floating-point
value.

I/O Tag
Each Float output channel is controlled by a Float Variable object. NetArrays assigns a Tag to
each channel when the card is added to the I/O configuration. Reconfigure the I/O Tag as
required to match the Module Form Float Variable object that is used to control the channel
output.

Readback Tag
The Readback Tag column specifies the Tag assigned to the readback input of the channel
output. NetArrays assigns a Tag to each Readback input when the card is added to the I/O
configuration. Reconfigure the Readback Tag as required to match the Module Form Float
Variable object that is used to read this input.

Channel (Input 00 – Input 01)

Both channels are Float inputs, and cannot be disabled. The channels can return a floating-point
values of LVDT inputs from the device or any other user defined analog inputs.

I/O Tag
Each input channel is accessed by a Float Variable object. NetArrays assigns a Tag to each
channel when the card is added to the I/O configuration. Reconfigure the I/O Tag as required to
match the Module Form Float Variable object that is used to access the channel.

Filter
If required, recursive filtering is available for Frequency Measurement inputs. A filter weight must
be assigned to enable the filter. Enter a weight factor of 10 through 2000. The filtering effect
increases as the weight value increases. The filtering can be expressed as:

Where: Xn is the input to the filter

Yn is the output from the filter
Yn-1 is a weighted portion of the previous output
A filter parameter of “0” disables recursive filtering of the channel’s input.

25
Threshold
This is the value which the filter will reset to the input value. The units are in mV.

Type
This parameter determines the input range used in the Input Out-of-Range testing. The Type
selected must agree with the type of analog input signal physically connected to the channel.
Select voltage 0-10V, voltage +/-10V, current 4-20mA, or current 0-20mA to match the channel’s
input configuration.

Channel (Input 02 – Input 07)

Each input channel can be enabled (Bool) or disabled (Disabled). You can disable any unused
channel to avoid scanning unconnected inputs, and to free up the Tag assigned to the channel.

I/O Tag
Each input channel is accessed by a Bool Variable object. NetArrays assigns a Tag to each
channel when the card is added to the I/O configuration. Reconfigure the I/O Tag as required to
match the Module Form Bool Variable object that is used to access the channel.

Distributed I/O User Application Logic Programming

Distributed Intelligent I/O Cards execute a part of the NetArrays project program, created
specifically for a particular card. During the project download operation, a part of the project
program is downloaded directly to the Distributed I/O Card for execution, and not to the Node
Processor.

The program for the Distributed I/O Card is created in NetArrays by selecting Add New
Distributed Form (.dis) from the Project menu.

This opens a new Distributed Main form named Dist1, which includes a Main object, a Scan
object, a Stop Scan object, and a Module object named Dist1_. (Subsequent distributed forms
created from the Project menu will be named Dist2, Dis3, etc.). Change Distributed Main form
name Dist1 to Distributed Logic Tag Name defined in appropriate Distributed Intelligent I/O Card.

Creating the rest of the Distributed I/O Card Program is the same as creating any other project
program in NetArrays, with one exception. You can add Sequence, Module, Ladder, Fuzzy, or
State form objects to the Main Form, and then progress to defining the function performed in
those forms. However, you must remember:

26
1 Data and status are passed between the Distributed I/O Card Program and the Main
Project Program by variables prefixed by the characters CI_ and CO_ only. The prefix CI_
defines a Card Input variable to the Main Project Program. The prefix CO_ defines a Card
Output variable from the Main Project Program. All other variables in the Distributed I/O
Card’s Program are seen only by the Distributed I/O Card.

2 Two separate Error Detection variables are provided for the card. The first Error Detection
integer variable listed in the card’s Property Manager is passed to the Main project program
without a CI_ prefix. The Main project program uses this variable to indicate timeout, card
ID error, and card latch error conditions. The second Error Detection integer variable listed
in the card’s Property Manager is for use in the Distributed I/O Card program.
For example, assume that the output channels on a Distributed I/O Card are assigned the
tag names Output_00 and Output_01, the input channels on the card are assigned the tag
names Input_00 and Input_01, and that the card’s error detection variable is assigned the
tag Card_Status. The following figure shows part of the Module Form Dist1_, which is part
of the Distributed I/O Card Program.

Somewhere in the Main Project Program, the output variables CO_Output_00 and
CO_Output_01 are generated by the program's logic. Two Float variables with the same
tag names are added to a Module Form in the Distributed I/O Card’s Program. These
variables from the Main Project Program are renamed by adding the Float variables
Output_00 and Output_01 to the Module Form. Variables Output_00 and Output_01 can
drive the outputs from the Distributed I/O Card. (Note that in general, the data from the
Main Project Program will not be applied directly to the channel outputs as shown in this
example. The Distributed I/O Card Program will, in most cases, manipulate this data to
generate the channel outputs.)
The input data from channels 0 and 1 are accessed by the variables Input_00 and
Input_01 in the Distributed I/O Card's Program. These measurements are converted to
the variables CI_Input_00 and CI_Input_01, which will be transferred to the Main Project
Program. Variables with the same tag names in the Main Project Program may then
access the input data from the Distributed I/O Card. (Note that in general, the channel
input data will not be transferred directly to the Main Project Program as shown in this
example. The Distributed I/O Card Program will, in most cases, manipulate these inputs
before transferring the data to the Main Project Program.)
The Integer Error Detection variable Card_Status is accessed only by the Distributed I/O
card program. The Main project program accesses a separate card Error Detection
variable.

27
Node Info

The Node Info object reports diagnostic information for the Distributed Servo card
configured in its Property Manager display. Add the object to an MForm in the distributed
logic created for the servo card.

Properties

Processor Select A, which will match the Distributed Servo Card to pull
the information.
Online This Bool variable will indicate if the selected Servo Card is
operational or not. If this variable is True, it indicates that
the selected Servo Card is online and operational.
Primary This Bool variable will indicate if the selected Servo Card is
the primary.
Scan Cycle For the Distributed Servo Card, the scan cycle can be
configured in 1.0 millisecond, 1.5 milliseconds, 2.0
milliseconds, 2.5 milliseconds, 3.0 milliseconds or 3.5
milliseconds. This variable will show the real-time status of
the scan cycle in the distributed cards.
Scan Reserve The Reserve cycle time can also be obtained for the
Distributed Servo Card. If reserve cycle time is not enough,
then the scan cycle should be re-configured.
All other parameters and variables are not applicable for this card.

28
Compliance with CE Mark
This section describes how to install and operate RTP equipment for use in the European Union
(EU) to comply with the requirements of the CE Mark and its referenced standards. The
procedures in this section apply also to other environments where provisions of the EU’s EMC
and Low Voltage Directives are either required or desirable.
RTP Corporation has successfully tested and reviewed its products to the stringent requirements
of the European Union’s EMC Directives (2004/108/EC) and Low Voltage Directive (2006/95/EC).
In order for the equipment to meet the requirements of these directives, the equipment
must be installed and operated in accordance with these instructions.
These tests and reviews are in accordance to EN 61131-2:2007 as listed in the next section.
Information on the tests performed and the standards involved is available from RTP Corporation.
To comply with the requirements of the CE Mark and its referenced standards, the system
integrator, installer, and end user must store, integrate, install, and operate this equipment in
accordance with the following guidelines.
1. Compliance with all product specific instructions (including but not limited to storage
instructions, installation instructions, operating instructions, maintenance instructions,
disposal instructions, and specifications) is required.
2. RTP equipment is rated for use in Installation Category (Overvoltage Category) II and
Pollution Degree 2 environments in accordance with standard IEC 664.
3. To assure that an Operator is not exposed to electrical hazards, all equipment capable of
electrical hazards must be housed in a grounded enclosure (equipment cabinet/rack) that
limits access to the equipment only to Service Personnel. Limited access may include
enclosure doors and side panels, which are locked or require a tool to open. To assure
compliance with the EMC requirements, the equipment must be housed in an enclosure
(equipment cabinet/rack) that provides EMC shielding. Compliance testing was
performed in a shielded equipment rack provided by Hoffman Concept® Wall Mounted
Enclosure model number CSD242420. To assure compliance, the equipment must be
installed in this style cabinet, or one with similar or greater RF attenuation characteristics.
The cabinet should be outfitted with continuous copper finger gasketing and copper foil
along all seams and joints.
4. The Service Personnel must be trained to operate the equipment and must be aware of
the potential of electrical hazards of the equipment and of the field I/O signals connected
to the equipment.
5. Hazardous voltage warning labels must be applied to the enclosure doors adjacent to the
locking mechanisms to warn the Service Personnel that hazardous voltages are
contained within the enclosure, if modules carrying 120 V and above are used.
6. Hazardous voltage warning labels also must be applied to the termination modules
(which carry 120 V and above), adjacent to the external connectors, to warn the Service
Personnel that hazardous voltages are present at the module's terminal blocks.
7. To assure compliance with the EMC requirements, the equipment must have all
communications, power, and field signal cabling exiting the enclosure enclosed in metal
conduits or shielded wireways. These conduits must provide EMI/RFI shielding and must
be terminated at the enclosure shell. There must be no uncovered openings in the
cabinet. Connections between the cabinet and conduit must be made with conduit
connectors making good (low impedance) electrical contact to the enclosure. Input
mains power to the enclosure and mains power fed to switching digital output I/O cards
and modules must be filtered by AC mains filters with attenuation characteristics of

29
 Corcom VR series filters or with similar filters with equal or greater attenuation
characteristics.
8. DC input mains power to the enclosure and mains power must be filtered by a DC mains
filters with attenuation characteristics of Corcom 6EH1 series filters or with similar filters
with equal or greater attenuation characteristics.
9. Insulation strip length of 0.26 inches (6.5 mm) is required on all field wirings to the I/O
card termination modules.
10. The disposal of any electronic products must be in accordance with local regulations (e.g.
Directive 2002/96/EC of the European Parliament and of the Council on waste electrical
and electronic equipment). Some RTP Corporation products contain materials that may
be detrimental to the environment. These materials may include, but are not limited to
lead (in solder) and lithium (in batteries).
11. Prior to storage or shipping, the equipment must be packaged in accordance with the
following guidelines:
● Inventory all items and inspect all components for damage.
● Verify that all fasteners are properly tightened and that the chassis I/O module
retaining bar is properly installed.
● Wrap the chassis assembly in plastic bubble wrap.
● Select a suitable shipping box that provides at least 1½ inches of space between the
equipment and all sides of the box. This space shall be tightly packed with packing
peanuts or bubble wrap to protect the equipment during storage or shipping.
● Close and secure the box with suitable packing tape.
● Do not stack boxes more than three high. Store the boxes in a protected, dry
environment. Do not expose the boxes to rain or environmental conditions beyond
the ranges specified for the equipment in this document.

30
Environmental Conditions
The modules are rated for the following environmental conditions:

Specification Type Recommended Range Test Specification

IEC 60068-2-30, Db
Operating Temperature -20 ºC to 60 ºC
RTP Type Testing
Operating Temperature Change 10 ºC/minute IEC 60068-2-14 Test Nb
Operating Humidity 10% to 95% non-condensing IEC 60068-2-30, Db
IEC 60068-2-1 Tests Ab, Ad
Storage Temperature -40 ºC to 85 ºC IEC 60068-2-2 Tests Bb, Bd
RTP Type Testing
Storage Temperature Change 10 ºC/minute IEC 60068-2-14 Test Na
Storage Humidity 0% to 100% condensing IEC 60068-2-30, Db
Vibration 9 Hz to 150 Hz at 1 g IEC 60068-2-6, Fc
Mechanical Shock 15 g for 11 milliseconds IEC 60068-2-27, Ea
Electrostatic Discharge Immunity ±6 kV contact IEC 61000-4-2
80 MHz to 1 GHz at 20 V/m
1 GHz to 2.1 GHz at 10 V/m
Radiated E-Field Immunity IEC 61000-4-3
2.1 GHz to 2.5 GHz at 5 V/m
2.5 GHz to 2.7 GHz at 1 V/m
Ethernet Line Burst Immunity ±2 kV IEC 61000-4-4
Ethernet Line Surge Immunity ±2 kV IEC 61000-4-5
Ethernet Line Conducted RF
150 kHz to 80 MHz at 10 V IEC 61000-4-6
Immunity
Pulsed Magnetic Field 300 A/m IEC 61000-4-9

Modules can be ordered with optional HumiSeal© conformal coating. In this case, the modules
can be installed in G3 harsh environmental conditions as defined in standard ISA–S71.04–1985.

This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used
in accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause interference
in which case the user will be required to correct the interference at his own expense.

This Class A digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la Classe A est conforme à la norme NMB-003 du Canada.

31
Referenced Companies
Corcom Inc.; Libertyville, Illinois, USA; 708-680-7400
Hoffman; Anoka, Minnesota, USA; 763-422-2178

Definitions
OPERATOR is any personnel other than SERVICE PERSONNEL. Requirements
assume that the OPERATOR is oblivious to electrical hazards, but does not act
intentionally in creating a hazard.
SERVICE PERSONNEL are assumed reasonably careful in dealing with obvious
hazards.
CE Conformité Européenne
EMC Electro-Magnetic Compatibility
EMI Electro-Magnetic Interference
EC European Community
EN European Norm
ESD Electro-Static Discharge
EU European Union
IEC International Electrotechnical Commission
MPU Main Processing Unit
RF Radio Frequency
RFI Radio Frequency Interference

32