Messung Systems NEXGEN PLC I/O Modules

NEXGEN - 4000 PLC

4 Channel, 16 bit Analog Voltage

Output Module (Ordering Code – 4334)

User Manual

Document No.:ED-2002-019

Version: 1.0

Published July 2002

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

Tel: (+91) – 020 – 712 0807, 712 2807.

Email : marketing@ms.messung.com
Web: www.messung.com

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Revision

Version Date Description

4 Channel, 16 bit Analog Voltage Output Module
1.0 5 August 2002 User Manual (Ordering Code – 4334)

Published July 2002 4 CH AO Manual(4334)

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INDEX
1. MODULE OVERVIEW ....................................................................................................... 5
1.1 ANALOG VOLTAGE 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 ................................................................................... 10
2.3 I/O AND MEMORY MAPPING ......................................................................................... 12
2.4 COMMANDS FOR CHANNEL ON/OFF............................................................................ 13
2.5 MODULE STATUS BITS ................................................................................................ 14
3. INSTALLATIONS AND WIRING..................................................................................... 15
3.1 MODULE INSTALLATION ............................................................................................... 15
3.2 CONNECTION DETAILS ................................................................................................ 15
3.3 PRECAUTIONS TO BE TAKEN......................................................................................... 17
4. CONFIGURATION AND PROGRAMMING .................................................................... 18
4.1 MODULE CONFIGURATION ........................................................................................... 18
4.2 PROGRAMMING ........................................................................................................... 19
5. APPLICATION EXAMPLE .............................................................................................. 22
5.1 EXAMPLE .................................................................................................................... 22
6. TROUBLESHOOTING .................................................................................................... 26
6.1 LED INDICATIONS FOR TROUBLESHOOTING.................................................................. 26
6.2 FAULT DIAGNOSTIC OF MODULE .................................................................................. 26

INDEX OF FIGURES
FIGURE 1 : FRONT VIEW OF ANALOG VOLTAGE OUTPUT MODULE ................................................. 6

FIGURE 2 :4-CHANNEL ANALOG VOLTAGE OUTPUT MODULE BLOCK DIAGRAM................................ 8

FIGURE 3 : DATA RANGE OF ANALOG OUTPUT VOLTAGE SIGNAL .......................................................... 10

FIGURE 4 : MEMORY MAPPING ................................................................................................... 12

FIGURE 5 : CONNECTION DIAGRAM OF ANALOG OUTPUT VOLTAGE MODULE ........................................... 16

FIGURE 6 :DIAGNOSTIC FLOW CHART CONTINUE .......................................................................... 27

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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 Output Module Overview
• LED Indications
• General Specifications

1.1 Analog Voltage Output Module Overview

This analog voltage output module takes digital value data from CPU module
and output an equivalent analog output voltage. This is R – 2R type D/A
conversion. It provides four non- isolated channels with 16-bit resolution (15
bits + 1 sign bit). The channels provide -10 to +10 VDC output for a load of 1
K Ohms and above.

The resolution is 312.5 µV.

The module also provides channel ON/OFF switches for each channel, which
clamp output voltage signals to ground whenever required.

This is register type of module and data transfer with CPU module takes
place by 'WRITE_W' function. The module has four DAC registers. Module
status is available in input image and user commands can be issued through
output image.

The figure 1 on next page shows the front view of 4-channel analog voltage
output module.

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4334
ANALOG OUTPUT
4 CH - VOLTAGE

NO 24V SUPPLY Module

Status
Front Shield LED
Plate

Terminal Block
Fixing Screw

CH 1
CH 2 Channel
01 VOUT1
Status
CH 3
02 GND1 LEDs
CH 4
03 SHIELD1
VOUT2
04
GND2
05
SHIELD2
06
20 Pin VOUT3
07
Removable GND3
08
SHIELD3
Terminal Block 09
VOUT4
10 IO Label
GND4
11
SHIELD4
12
13
14
15
EARTH
16
FG
17
18
0V
19
+24 V.
20

Terminal Block
Fixing Screw 4 CH
ANALOG OUTPUT
VOLT AGE

LED Connection Front Door

Indications Details Label

Figure 1 : Front view of Analog Voltage Output Module

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The module provides five LED indications on the front side. 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.
The analog voltage output module can be configured in any slot of the PLC.

1.2 LED Indications

The following table explains significance of five LEDs provided on the

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
OFF Channel OFF
Channel ON Green
(One for each channel) ON Channel ON

1.3 General Specifications

The general specifications of analog voltage output module are given below

Number of output channels 4 non-isolated channels with 16 bit resolution

Conversion method R – 2R ladder
Input range - 32,000 to + 32,000
Output voltage range -10 to 10 V DC
Resolution 312.5 µV
Load resistance > 1 KΩ
Load current 10 mA max.
Output short circuit protection Yes
Accuracy 0.5 % of full scale reading
Maximum conversion time 50 µsec irrespective of number of ON channels
isolation Channel to Internal circuit 1.5 KV optical
Channel to channel Nil
24 VDC, 300 mA
External supply requirement
(18 - 30 V DC including ripple)
• 315 mA miniature glass fuse on module
External supply protection
• Reverse polarity protection
• No 24 V Supply
Indications
• Channel ON (One for each channel)
Back-plane current (5 V consumption) 300 mA
IO points consumed 8 input bits and 8 output bits
Termination / connection 20-pin removable terminal block
Ordering code 4334

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2. Module Operation

This chapter helps in getting started with the analog voltage 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
• Commands for channel ON/OFF
• Module Status bits

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 analog voltage output module

Serial
Data DAC1 Channel 1
Opto Serial R-2R
Isolation Interface 0 to ± 10 VDC
Output 1 Output Signal
Driver
Control
Opto
Isolation

CPU

Channel
ON/OFF
Module DAC4 Channel 4
Interface Opto R-2R
Circuit Isolation 0 to ± 10 VDC
Output 4 Output Signal
Driver

No 24 V
Supply
Signal
Opto Miniature
Isolation Glass Fuse
+12 V + 24 VDC
+5V -12 V 24 V GND
+5 V DC to DC
Supply for Earth
Converter
GND DAC Circuit -5 V
GND

Figure 2 :4-Channel Analog Voltage Output Module Block diagram

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The module provides four digital to analog channels. CPU bus is optically
isolated from DAC circuit. The digital to analog converter operates on serial
data from CPU module. The data for four channels is stored inside DAC
registers one by one. DAC registers hold the data till module is powered
'ON'. DAC (R–2R type) converts binary data inside the register to an
equivalent analog output voltage. 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.

Independent set of two switches is provided for a channel, one in series with
output driver and another between output and ground for every channel.
When series switch is ON, ground switch is OFF and channel is active i.e.
output signal is available at output terminals. When series switch is OFF,
ground switch is ON and output terminal is held at ground level. The switch
positions can be changed through application program by setting
corresponding bit of corresponding output byte.

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
m Amp.) for external 24 VDC supply is provided on module.

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2.2 Data Range and Resolution

This section describes data ranges as applicable to voltage output.

-10.24 VDC -312.5 µV +312.5 µV +10.24 VDC

$ 8001 $ FFFF $ 1 $ 7FFF

-10VDC +10 VDC

$ 8300 0 VDC $ 7D00
$0000

Figure 3 : Data Range of Analog Output Voltage Signal

The module provides 16-bit resolution (15 bit + 1 sign bit). The figure above
shows digital data and associated output voltage values.
For voltage range of –10 V to +10 V, the digital value ranges from -32,000 to
+32,000 through 0.
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 64,000
(15 bits) equal steps. Each step corresponds to –

20 V / 64,000 = 312.5 µV

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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)
-10.24 V -32767 8001 0 0 0
-10 V -32000 8300 312.5 µV 1 1
-9 V -28800 8F80 1V 3200 C80
-8 V -25600 9C00 2V 6400 1900
-7 V -22400 A800 3V 9600 2580
-6 V -19200 B500 4V 12800 3200
-5 V -16000 C180 5V 16000 3E80
-4 V -12800 CE00 6V 19200 4B00
-3 V -9600 DA80 7V 22400 5780
-2 V -6400 E700 8V 25600 6400
-1 V -3200 F380 9V 28800 7080
-312.5 µV -1 FFFF 10 V 32000 7D00
0 0 0 10.24 V 32767 7FFF

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2.3 I/O and Memory Mapping

IO and memory mapping related to analog voltage output module is shown in

figure below.

CPU module Analog voltage output module

1.1.1.1.1Input Image Input Scan

Logic Scan
No 24 V Supply Ix.4 IMM_IN
EN ENO

SLOT

Output Scan
Output Image Channel 1
Channel 1 ON/OFF Qx.0
Channel 2 ON/OFF Qx.1
Channel 3 ON/OFF Qx.2 Logic Scan
Channel 4 ON/OFF Qx.3 IMM_OUT Module Channel 2
EN ENO Interface
SLOT circuit
Channel 3

Memory Variables Channel 4

Channel 1 Data MW10
Channel 2 Data MW12 Logic Scan
Channel 3 Data MW14
Channel 4 Data MW16 WRITE W
EN ENO
SLOT

DATA

LEN
ADDR

Figure 4 : Memory Mapping

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The module consumes 8 input bits (1 byte) of input image and 8 output bits
(1 byte) of output image in the CPU module. CPU reads the status of module
in input scan. For the details, refer chapter 2.5. CPU writes user commands
to module in output scan. User can issue command to switch ON/OFF
channel through output image. For the details, refer chapter 2.4. For
immediate updation of input and output image in application program,
IMM_IN and IMM_OUT functions can be used whenever required.

Data from PLC variable area of CPU module e.g. memory or page is
transferred to module memory when 'WRITE_W' function gets executed in
application program i.e. in logic scan. This data in turn is transferred to DAC
registers addressed from # 0. Data for channel 1 is transferred to register
address # 0 while data for channel 2 is transferred to register address # 2
and so on. DAC converts this binary data to an equivalent analog output
voltage. To get analog output voltage, channel should be ON. When
corresponding output bit is set, channel is ON and analog output is available
at output terminal as per data.

2.4 Commands for Channel ON/OFF

As explained earlier in chapter 2.1 and 2.3, independent set of switches is

provided to make channel ON/OFF. The switch isolates the output driver and
connects output terminal to ground, whenever required. When CPU is in
'STOP' mode, all the four channels are OFF isolating output signal. In this
case, DAC registers on module are cleared. After power ON, all four
channels are OFF. User switches them ON through application program. The
individual channel can be turned ON through application program by setting
corresponding bit of corresponding output byte. If CPU does not service
module due to some problems like identity error, all the four channels remain
OFF ensuring analog voltage output at zero.

CPU writes user commands to module in output scan. User can issue
command to ON/OFF channels individually through output image. When
Qx.0 bit is set, channel 1 gets ON and when Qx.3 bit is set, channel 4 gets
ON. Thus connecting analog output signal from output driver stage to output
terminal. The table below shows relevance of channels and output image
bits.

Output Image bit Channel ON/OFF

Qx.0 Channel 1
Qx.1 Channel 2
Qx.2 Channel 3
Qx.3 Channel 4

Note - 'x' is output byte number which is consumed by the module

The status of individual channel ON/OFF is indicated by 'Channel ON' green

LEDs on front side of the module. Four LEDS are provided for four channels.

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When channel is ON, (i.e. Qx.n is ON, n - 0 to 3) corresponding green LED is

ON indicating channel is active.

This feature is useful especially when analog outputs are used as speed
reference to the drives.

Normally output image is updated during output scan. For immediate

updation, 'IMM_OUT' function can be used in application program if required.

2.5 Module Status Bits

CPU reads the status of module in input scan. The information of availability
of 24 VDC signal is provided to CPU by module in the input image. The input
bit 4 is set if 24 VDC to module is not available or 315 mA glass fuse in DC-
to-DC converter is blown. In this case, analog voltage output remains at
zero. The specified range of 24 VDC supply to module is 18 to 30 VDC
including ripple. As long as 'No 24 V Supply' bit is ON, channel output
remains to be zero.

Input Image bit Status Indication

Ix.4 No 24 V Supply

Note - 'x' is input byte number which is consumed by the module

Normally input image is updated during input scan. For immediate updation,
'IMM_IN' function can be used in application program if 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.
1. Put the module in to the desired slot of the PLC
2. Tighten the screw provided at the top of the module
3. Connect the terminal block at the front of the module and tighten it.

3.2 Connection Details

The figure shows the connection diagram of 4-channel analog voltage output
module

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Voltage
Output
01 VOUT1
02 GND1
03 SHIELD1
Earth VOUT2
04
05 GND2
SHIELD2
Connect this shield to Connect this shield 06
Earth busbar or to shield VOUT3
to ‘SHIELD’ 07
terminal on external GND3
terminal. 08
SHIELD3
Electronic controller to 09
VOUT4
which output signal is 10
GND4
connected. 11
SHIELD4
12
13
14
15
EARTH
16
FG
17
18
0V
19
+24 V.
20

GND + 24 V 4 CH
Earth Earth ANALOG O UT PUT
VOLT AGE

Figure 5 : 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.
Being susceptible to industrial noise, analog signal is to be carried out on the
field through shielded cable. Connect one end of shield (towards analog
voltage 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)

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to Earth busbar in control panel or this end can be connected to shield

terminal of respective external device.

Connect terminal number 16 (EARTH) to earth busbar in control panel and

connect frame ground terminal number 17 (FG) to earth busbar
independently.
For functioning of analog voltage output module, external 24 VDC supply is
required. Connect 24 VDC supply between terminals 20 (24 V) and 19 (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.

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 analog voltage output module. This information is useful for application
program development. This is explained in following sections
• Module Configuration
• Programming

4.1 Module Configuration

The analog voltage output module provides 4 non-isolated channels, which

can be independently operated.

The configuration consists of configuring the slot for analog voltage output
module (like any other discrete IO module) only. The Programming and
Documentation software is used for configuration and programming.

The module consumes 1 byte of input image and 1 byte of output image. The
input image is used for reading status of module. The output image is used
for writing user commands to module. The corresponding output bit can be
set to switch ON the channel. Refer to Chapter 2.4 for more information.

The IO byte consumption along with configuration of Nexgen PLC is shown

below

Power CPU Slot 0 Slot 1 Slot 2 Slot 3

Supply Module
Module 32 DC Input 32 DC Input 4 Ch Analog 16 DC Output
Module Module Voltage Module
Output
Module
I0.0 to I0.7 I4.0 to I4.7 Q9.0 to Q9.7
I1.0 to I1.7 I5.0 to I5.7 I8.0 to I8.7 Q10.0 to Q10.7
I2.0 to I2.7 I6.0 to I6.7 Q8.0 to Q8.7
I3.0 to I3.7 I7.0 to I7.7

Input module in first two slots consumes IB0 to IB7 of input image. 4 channel
analog voltage output module in slot 2 consumes one byte i.e. IB8 of input
image and one byte i.e. QB8 of output image. 16 DC output module in slot 3
consumes QB9 and QB10 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 the analog voltage output module when 'WRITE_W' function is executed.
The data in the PLC variables 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.

The WRITE_W function below shows data transfer from the CPU module’s
memory to analog voltage output module’s registers. The details of transfer
are –

• Analog voltage output module is configured in slot 2 of PLC

• Start address of memory on the CPU module is MW100
• Length of data area to be transferred is 4 words
• Address on the analog voltage output module in slot 2 is # 0

WRITE_W function gets executed when condition for enable 'EN' is ON.
ENO bit becomes ON when function is enabled and executed. If function
parameters are invalid e.g. address is above # 6, length is greater than 4,
etc or slot number is wrong, etc. then function is not executed.

M0.0 ------ WRITE_W ---- M0.1

+---| |---+--------- |EN ENO|-+---------+---( )---
| |
#2 -|SLOT |
| |
MW100 -|DATA |
| |
#4 -|LEN |
| |
#0 -|ADDR |
| |
-------------------

So 4 words (MW100 to MW106) are transferred to the DAC registers at

address # 0 onwards ( # 0, # 2, # 4, #6 ) of the analog voltage output module
in slot 2.

Example of basic application program is given below. For the same, refer
Nexgen PLC configuration shown in chapter 4.1.

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In this configuration, following points are to be noted.

I8.4 is a module status bit as 'No 24 V Supply' bit. I8.4 is set if 24 VDC supply
to 4-channel analog output module is absent or on board glass fuse is blown.

Q8.0 is a command bit to switch ON channel 1. When Q8.0 is set in

application program, channel 1 is ON and analog voltage output is available
at output terminals. When Q8.0 is 0, analog voltage output gets disconnected
from output terminal and output terminal gets connected to ground through
100 K resistor.

Similarly, Q8.1 to Q8.3 corresponds to channel 2 to channel 4 of analog

voltage output module configured in slot 2.The status of channels is indicated
by green LEDs provided on front side of module.

S4.2 is a Module Error bit for module in slot 2. This is indication of error in IO
configuration in slot 2.

While developing application program, first check whether the module is

healthy. For the same, check 'Module Error' bit S4.2 and 'No 24 V Supply' bit
I8.4. If any one bit is set, declare respective fault. In this case, analog voltage
output is not available. If both are OFF, switch ON channel. Here we are
referring to channel 1 and hence Q8.0.

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S4.2 I8.4 M0.7

+---|/|---+---|/|---+---------+---------+---------+---( )---

M0.7 Q8.0
+---| |---+---------+---------+---------+---------+---( )---

M0.0 is channel 1 enable bit in application program.

To write data in analog output module, 'WRITE_W' function is to be used as

below.
Slot is # 2. The data is in memory variable MW100. Here, channel of interest
is one so length is 1 word. The address is # 0 for 4-channel analog voltage
output module. When 'WRITE_W' function is executed, data in MW100 is
transferred to channel 1 DAC register and equivalent analog voltage output is
generated. When 'WRITE_W' function is executed, ENO bit M0.1 is 1 till
enable condition of function is 1 and if all the parameters are valid and
function is executed.

M0.7 M0.0 ------ WRITE_W ---- M0.1

+---| |---+---| |---+---------|EN ENO|-+---( )---
| |
#2 -|SLOT |
| |
MW100 -|DATA |
| |
#1 -|LEN |
| |
#0 -|ADDR |
| |
-------------------
The status of ENO bit is to be checked in application program for execution
of 'WRITE_W' function. Other wise appropriate action is required.

If all the four channels are used in above case, set Q8.1, Q8.2,Q8.3. The
data in MW102 corresponds to channel 2.The data in MW104 corresponds to
channel 3. The data in MW106 corresponds to channel 4. In 'WRITE_W'
function, length should be 4 in this case.

For immdiate updation of input and output image, 'IMM_IN' and 'IMM_OUT'
functions can be used repectively,in application program when ever required.

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5. Application Example

In this chapter basic example is given to get started with analog voltage
output module. The example demonstrates how to configure the module and
develop application program. This example is discussed only for
understanding purpose.

5.1 Example
Drive speed control in forward / reverse direction as per speed setting from
MMI
This example illustrates how speed of motor in forward and reverse direction
is controlled using analog voltage output module and use of channel ON/OFF
switches to clamp analog output to exact zero.
Inverter is used for controlling speed of motor, which in turn controls speed of
line. Speed reference is given through analog voltage output module.
Operator sets speed on MMI as Meters per Minute. The setting of speed is
from 0 to 5.00 Meters per Minute.
Follow the steps below –
Step 1: Feasibility Study
It is necessary to carry out feasibility study. This helps to know – with what
precision control is possible. The useful things are -
• Range and resolution of analog output module. The range is –10 to +10
V. The resolution is 312.5 µV.
• Required precision. 0.000 to 5.000 meters per minute in steps of 0.001
meters per minute
Thus 0 to 5 meters per minute corresponds to 0 to 10 Volts. For 0 to 10 volts,
the steps are 32000 with resolution of 312.5 µV. Thus precision of control is
5 / 32000 = 0.00015 meters per minute. This is much more than required
(0.001 meters per minute). This is also applicable when motor rotates in
reverse direction.
Step 2: Ensure power connections
Ensure 24 VDC power connections to the analog voltage output module.
Connect 24 VDC to terminal number 20 and ground to terminal no.19.
Connect terminal 16 (Earth) and 17 (FG) to earth busbar in control panel
independently.
Step 3: Connect Analog Signals
While connecting analog signals, take precautions as explained in chapter 3.
Here channel 1 is used to provide speed reference to inverter.
Step 4: Configure the PLC
Configure the analog output module like any discrete IO module using
Programming and Documentation software.

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The figure shows slot number, type of module and its address.

Slot 0 Slot 1 Slot 2

Power CPU 32 DC 4 Channel 16 Relay

Supply Module Input Analog Output Module
Module Module Voltage
Output
Module Q5.0 to Q5.7
I0.0 to I0.7 Q6.0 to Q6.7
I1.0 to I1.7 IB4
I2.0 to I2.7 QB4
I3.0 to I3.7

Step 5: Define global variables

Define global variables used in application program. Define attributes like
symbol, address, data type, initial values, comment wherever applicable.
Step 6: Write application program
Details required for this application are mentioned below.
Operator sets speed on MMI as Meters per Minute. The setting of speed is
from 0 to 5.000 Meters/ Minute. Program MMI such that speed set value is
stored in memory word MW100. The display on MMI will show speed set in
format ##. ### Meters/ Minute. The contents of MW100 will be 0 to 5000.
So 5000 corresponds to analog voltage of 10 VDC.
Memory bit M0.1 decides direction of motor. If M0.1 is 0, motor will rotate in
forward direction and reference required is 0 to 10 VDC. If M0.1 is 1, motor
will rotate in reverse direction and reference required is 0 to -10 VDC.
Memory bit M0.0 is zero speed bit.
Write application ladder related to analog voltage output modules as given
below. The application program below is explained with reference to
Programming and Documentation software DOXMINI+.
To get analog output voltage, first switch ON channel 1. For the same, output
bit Q4.0 should be made 1.

M0.0 Q4.0
+---|/|---+---------+---------+---------+---------+---( )---

SCALE function converts speed setting to corresponding analog voltage

output. 0 to 5000 corresponds to 0 to +10 VDC reference for forward
direction. Scaled speed set count i.e. 0 to $7FFF is available in memory word
MW102.

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M0.0 ------- SCALE -----

+---|/|---+---------+---------+---------|EN ENO|-
| |
#0 -|X1 DOUT|- MW102
| |
#5000 -|X2 |
| |
#0 -|Y1 |
| |
$7FFF -|Y2 |
| |
MW100 -|DATA |
| |
-------------------

The scaled count is to be written to respective channel. This is for forward

direction operation. Before writing, check for 'Module Error bit'. System bit
S4.1 is set if module identity error is present. In this case declare fault. Also,
check for 24 V supply present. The I4.4 bit is set if 24 VDC supply to module
is absent. In this case declare module fault.

M0.1 M0.0 I4.4 S4.1 ------ WRITE_W ---- M0.2

+---|/|---+---|/|---+---|/|---+---|/|---|EN NO|---( )---
| |
#1 -|SLOT |
| |
MW102 -|DATA |
| |
#1 -|LEN |
| |
#0 -|ADDR |
| |
-------------------

The memory bit M0.2 is 1, if 'WRITE_W' function is executed clearly

indicating that data is transferred to module and to respective channel. If
M0.2 is 1, take further actions in application program.

If reverse direction is selected, content of MW102 is to be converted to 2's

compliment binary format. This is done using functions ‘CPL_W’ and
‘ADD_W’ functions.

M0.1 M0.0 ------- CPL_W -----

+---| |---+---|/|---+---------+---------|EN ENO|-
| |
MW102 -|DATA DOUT|- MW114
| |
-------------------

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M0.1 M0.0 ------- ADD_W -----

+---| |---+---|/|---+---------+---------|EN ENO|-
| |
#1 -|DAT1 DOUT|- MW116
| |
MW114 -|DAT2 |
| |
-------------------

M0.1 M0.0 I4.4 S4.1 ------ WRITE_W ---- M0.4

+---| |---+---|/|---+---|/|---+---|/|---|EN ENO|---( )---
| |
#1 -|SLOT |
| |
MW116 -|DATA |
| |
#1 -|LEN |
| |
#0 -|ADDR |
| |
-------------------

Step 7: Transfer the program to the PLC and test is as per requirement.

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6. Troubleshooting

In this chapter, following points related to analog voltage output modules are
discussed.
• LED Indications for Troubleshooting
• Fault Diagnostic of Module

6.1 LED Indications for Troubleshooting

The following table explains significance of LED provided on the front side of
module. These LEDs are very useful for diagnosis of module in case of any
fault condition.

LED Color Status Description

OFF 24 V supply present
No 24 V Supply Yellow 24 V supply not present
ON
On board fuse blown
OFF Channel OFF
Channel ON Green
(One for each channel) ON Channel ON

6.2 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
o DC voltage (with high precision)
o Continuity and resistance
• Set up for on line monitoring of application program as follows
o PC with Programming and Documentation software.
o 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 20 &19.

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? IO 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

Module Error
ON System bit Status? OFF

Replace Module
YES Module NO
working OK?

Diagnosis Over OFF Channel LED ON

Status?

Check application program.

Check channel ON/OFF bit Qx.n
for set.

OFF Channel LED ON

Status ?

Replace Module

Figure 6 :Diagnostic flow chart continue A

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NEXGEN PLC I/O Modules Messung Systems

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
YES as per binary data? NO

Diagnosis Over Contact MESSUNG

SYSTEMS

* The fuse should be replaced by same type strictly

Rating - 315 mA, 250 V
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, channels are in OFF condition with channel LED
indications OFF. In this case, channel output terminals are connected to
ground by channel switches.

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NEXGEN PLC I/O Modules Messung Systems

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 - 4000 PLC

4 Channel, 16 bit Analog Voltage Output Module (Ordering Code – 4334)
User Manual

Document No. ED-2002- 019

Published July 2002 4 CH AO Manual(4334)

Page 30 of 30 Document No.: ED-2002-019/V1.0