Technical Manual

3000/01
8-Channel
Counter Cards
© 2002 - 2016 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: 8/26/2016

2
CONTENTS
INTRODUCTION ........................................................................................ 4
SPECIFICATIONS ..................................................................................... 6
FAILURE RATES IN ACCORDANCE TO IEC 61508 ............................... 9
CABLING................... .............................................................................. 11
REDUNDANT I/O CARDS PLACEMENT ................................................ 17
3000 Series System with I/O Cards.............................................................. 17
3100 Series System with I/O Cards.............................................................. 17
SOFTWARE CONFIGURATION ............................................................. 18
Firmware Upgrades ..................................................................................... 18
Editing the Configuration File ....................................................................... 19
NetArrays Configuration ............................................................................... 20
Redundant Card ID ................................................................................ 21
Distributed Logic .................................................................................... 21
Scan Rate .............................................................................................. 21
Integer Error Detection ........................................................................... 21
Integer Readback Status ........................................................................ 22
Integer Line Fault Status ........................................................................ 22
Integer Switch Fault Status .................................................................... 22
Counter Channel (Input 00 - Input 07) .................................................... 23
I/O Tag ................................................................................................... 23
Reset Tag .............................................................................................. 23
Filter ....................................................................................................... 23
Type ....................................................................................................... 23
Direction ................................................................................................. 24
Channel (Output 00 - Output 07) ............................................................ 24
I/O Tag Output ....................................................................................... 24
Channel (Input 08 - Input 15).................................................................. 24
I/O Tag Input .......................................................................................... 24
Comment ............................................................................................... 24
Distributed I/O Card Programming ......................................................... 25
Node Info ............................................................................................... 26
COMPLIANCE WITH CE MARK ............................................................. 28
ENVIRONMENTAL CONDITIONS .......................................................... 30
REFERENCED COMPANIES .................................................................. 31
DEFINITIONS........................................................................................... 31

3
Introduction

The 8-Channel Counter Card provides and interfaces to eight pulsed input signals. The card
model number defines if it is SIL rated or not:
3000/01-028 8-Channel Counter Card (Non-Interfering)
3000/01-029 8-Channel Counter Card (SIL-2)
Each channel may be programmed for pulse counting or frequency measurement; a pair of
adjacent channels may be programmed for quadrature counting. Pulse rates of up to 30 kHz may
be applied. Inputs should be driven by an active source (active pull up and pull down), not by a
passive device such as a relay.
This card also provides eight sinking digital input and eight sourcing digital output channels with
optional line monitoring. The digital output channel can be wired to the Servo Controller card if
desired (In this case the servo controller application logic should filter out the test pulses). This
card also includes a Watchdog Timer, which can disable the outputs in the event of a detected
failure.
In Pulse Counter mode, the channel counts pulses on the leading edge of the input signal. In
Frequency Measurement mode, the channel calculates the frequency from the number of
complete cycles of the input signal during a time interval, which is determined by the actual
frequency range. For quadrature counter mode operation, the phase difference between two
adjacent channels is measured. The counter increments on each transition of each signal or
decrements on each transition of each signal:

4
 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:

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

Figure 1: 8-Channel Counter Card Front Panel

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

5
Specifications
Module Safety Integrity Level: SIL-2 for 3000/01-029 model only. Digital Inputs on the
module are not safety critical and are non-interfering with
safety functions. 3000/01-028 is non-interfering with safety
functions.
Card Address: Determined by onboard switch settings
Number of Channels: 8 Pulse Counter mode or Frequency Measurement mode
inputs; Quadrature mode requires 2 input channels per
measurement.
8 isolated sinking digital inputs.
8 sourcing digital output channels with line monitoring.
Isolation: 500 V AC/DC to RTP system
100 Volts DC maximum input channel to input channel.
Type of protection: Digital isolators (optical)
Outputs are also short-circuit proof (fuse protected on each
output channel)
Output Over-current Protection: Channel shutdown @ 1.4 A
Maximum permanent allowed
voltage (no damage)
For counting inputs: 10 Volts
For digital inputs: 40 Volts
For digital outputs: 30 Volts
Maximum Closed Circuit Current
For Digital Outputs: 0.5 A per channel, fuse protected to 1 A slow acting
Output Voltage Drop: 0.95 V @ 500 mA
Total Output Current per Card: 4A
Floating-Point Counter Resolution: For highest resolution, pulse counters should be reset at a
count less than 1.677721E+07 (or less than ±8,388,607 for
quadrature counters). The truncation of floating-point
numbers will produce lower resolution counts above these
limits.
To prevent rollovers, pulse counters should be reset at a
count less than 4.294966E+09 (or less than ±2.147483E+09
for quadrature counters).
Input Voltage:
Digital Inputs: 0 to 24 Volts
Pulse Inputs: 0 to 3 Volts
Type of Digital Input: IEC 61131-2 Type 1
Logic 1 Signal Detection:
Digital Inputs: Larger than 13.2 Volts
Pulse Inputs: Larger than 1.8 Volts
Logic 0 Signal Detection:
Digital Inputs: Less than 5.8 Volts
Pulse Inputs: Less than 1.3 Volts
Minimum Input Frequency: 0.5 Hz
Maximum Input Frequency: 30 kHz
Minimum Input Pulse Width: 8333 ns
Sample Repetition Rate: Samples are updated after each pulse
6
Output Configuration: Every channel has an independent non-latching channel
FET
Maximum Power per Channel: 15 Watts
Output ratings for other loads
such as incandescent lamps: Supported with same ratings
Minimum Load per Channel: 6 mA single configuration
12 mA dual redundant configuration
18 mA triple redundant configuration
Maximum Leakage Current
per Channel: 500 A
Channel Self Tests: All output channels are pulse-tested within 32 Node Processor
scan cycles.
Maximum time for testing: < 500 µs for outputs.
Output Delay Time: < 175 microseconds (ON to OFF or OFF to ON)
Watchdog Timers:
Fixed 3.4 s maximum
Windowed 0.3 ms minimum, 26.6 ms maximum

Suppressor networks for

inductive kickback: Diode protected
Programming Tools: NetArrays Developer Studio
Programming Languages: Flow Charts, Objects, Structured Text, C/C++, Fuzzy Logic
Processor Utilization: Processor can be configured for cyclic execution: 1 ms, 1.5
ms, 2 ms, 2.5 ms, 3 ms or 3.5 ms. Processor 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 Node Processor sends outputs each scan cycle to the
3000/01 Counter Card via CO_ variables. Field inputs are
acquired onboard by the 3000/01 Counter 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 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 @ 150 mA
External Power to Termination: 24 VDC nominal (20 to 30 VDC) at 4.1 A maximum
Termination Module Connectors: One D-Sub connector, 37 pins for use with the 3055/00
Power Digital 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 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:
7
 Width Width Minimum Maximum
Model # Description
(") (cm) AWG AWG
3099/37-000 SIL-2 Triple Termination - 8 channel counter 6.42 16.3 28 16
3099/37-100 SIL-2 Single Termination - 8 channel counter 5.00 12.7 30 12
*Module dimension values are ± 0.05 inches or ± 0.127 centimeters
User Replaceable Fuses: Littelfuse type 0665 001.HXSL or
Wickmann type 3741100041
Effect of Incorrect Field Wiring: Shorted input connections cause counts to freeze. Shorted
digital inputs will produce an OFF state. Open input
connections cause counts to freeze. Open digital inputs will
produce an OFF state. Reverse input connections cause
counts to freeze. Shorted output connections will de-
energize and shut down the output. Open output
connections will be annunciated in the error status word.
Reversed output connections apply reverse voltage to the
load.

8
Failure Rates in Accordance to IEC 61508
The following table summarizes the failure rates of the modules, which were calculated from
Failure Mode and Diagnostic Effects in accordance to standard IEC 61508. The information can
be used in calculating probability of dangerous failures using Reliability Block Modeling or Markov
Modeling. Such modeling should consider redundant 3000/01 counter card counting channels in
a 1oo2 or 2oo3 configuration and the digital output channels in a 2oo2 or 2oo3 configuration.

Safe Failure Fraction: 99.56%

Diagnostic Coverage: 99.13%
Failure Rates In Common Circuitry:
Safe Detected 4.4166E-07
Safe Undetected 1.0461E-08
Dangerous Detected 5.4781E-07
Dangerous Undetected 2.8865E-09
Don't Care
2.0786E-07
Ethernet Counting
Failure Rates In Per Channel Circuitry: DO Channel
Channel Channel
Safe Detected 1.3522E-07 0.0000E+00 5.6361E-08
Safe Undetected 1.3659E-09 0.0000E+00 5.6930E-10
Dangerous Detected 5.9702E-08 3.8735E-08 1.3480E-08
Dangerous Undetected 5.7760E-11 1.9465E-10 2.6200E-09
Don't Care 4.1450E-08 9.6700E-09 1.3570E-08
Average Frequency of a Dangerous Failure per Hour (Single): 5.7589E-09
Average Frequency of a Dangerous Failure per Hour (Dual Redundant): 5.2731E-09
Average Frequency of a Dangerous Failure per Hour (Triple Redundant): 7.8966E-09
Mean Time to Restoration: ≤ 9 days

The 3000/01-029 counter card also provides eight sinking digital input channels that may be used
for external manual controls as determined by the user. The digital inputs channels are not safety
critical and shall be non-interfering with the safety operation of the input / output channels.

If using the digital outputs as part of the SIF, the outputtest parameter in the card’s configuration
file must be enabled (1). When the 3000/01-029 counter card’s outputs are used for low-demand
mode, readback (loopback) failure indications from the card shall be monitored by operators /
users. Such failure annunciation shall initiate replacement of the module within the MTTR
because the card’s ability to fail-safe might have been lost.

Alternatively, the 3000/01-029 counter card can be used in high demand mode or continuous
mode in which failure annunciation shall be monitored within the user application logic utilizing the
card’s error status words. The user application logic in turn shall de-energize the power to the
field termination module 3099/35-000 or 3099/35-001 using an independent digital output (card &
channel) which is marked for safety. This solution provides an independent automatic means of
fail-safe action.

The counting inputs shall be verified by user application logic. For example, a turbine which is
running at normal operating conditions won’t produce a sudden zero speed, or it won’t produce a
speed more than what is physically possible. Therefore, it shall be expected that the frequency
measurement be within a certain range (e.g. 50 Hz ± 5 Hz). Likewise, when a channel is
configured in counting mode or in quadrature mode, receiving no counts shall be verified for
reasonability (e.g. if receiving no counts is the safe state of a turbine, then an independent
verification shall be programmed to assure that the rotation is stopped. Such reasonability
9
checks must be implemented in the user application logic to cover failures in the counting
functionality.

10
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) J3 X
TCP/IP J4 X
Redundant (32-47) J3 X

J4 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

11
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 Figure.

Figure 2: 8-Channel Counter Card addressed for 33.

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.
12
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.

13
 Terminal Pin Signal
- VS + TB 1 1 Top Counter Input 0+
Count /
TB 1 1 Bottom Counter Input 0-
Frequency
TB 1 2 Top Counter Input 1+
Input
TB 1 2 Bottom Counter Input 1 -
TB 1 3 Top Counter Input 2+
TB 1 3 Bottom Counter Input 2 -
TB 1 4 Top Counter Input 3+
TB 1 4 Bottom Counter Input 3 -
- VS + TB 1 5 Top Counter Input 4+
A TB 1 5 Bottom Counter Input 4 -
Quadrature
Input - VS + TB 1 6 Top Counter Input 5+
B TB 1 6 Bottom Counter Input 5 -
TB 1 7 Top Counter Input 6+
TB 1 7 Bottom Counter Input 6 -
TB 1 8 Top Counter Input 7+
TB 1 8 Bottom Counter Input 7-
TB 1 9 Top Voltage Out 0
TB 1 9 Bottom Digital Input 0
TB 1 10 Top Voltage Out 1
TB 1 10 Bottom Digital Input 1
TB 1 11 Top Voltage Out 2
TB 1 11 Bottom Digital Input 2
TB 1 12 Top Voltage Out 3
TB 1 12 Bottom Digital Input 3
TB 1 13 Top Voltage Out 4
TB 1 13 Bottom Digital Input 4
TB 1 14 Top Voltage Out 5
TB 1 14 Bottom Digital Input 5
TB 1 15 Top Voltage Out 6
TB 1 15 Bottom Digital Input 6
TB 1 16 Top Voltage Out 7
TB 1 16 Bottom Digital Input 7
TB 1 17 Top No Connection
24 VDC Nominal
TB 1 17 Bottom No Connection
- VS + TB 1 18 Top Digital Input Field Power +
TB 1 18 Bottom Digital Input Field Power -
TB 2 1 Top Digital Output Field Power +
- VS + TB 2 1 Bottom Digital Output Field Power -
TB 2 2 Top Digital Output 7+
24 VDC Nominal TB 2 2 Bottom Digital Output 7-
TB 2 3 Top Digital Output 6+
TB 2 3 Bottom Digital Output 6-
TB 2 4 Top Digital Output 5+
TB 2 4 Bottom Digital Output 5-
TB 2 5 Top Digital Output 4+
TB 2 5 Bottom Digital Output 4-
14
 Terminal Pin Signal
- VS + TB 2 6 Top Digital Output 3+
TB 2 6 Bottom Digital Output 3-
Load TB 2 7 Top Digital Output 2+
TB 2 7 Bottom Digital Output 2-
TB 2 8 Top Digital Output 1+
TB 2 8 Bottom Digital Output 1-
TB 2 9 Top Digital Output 0+
TB 2 9 Bottom Digital Output 0-
Figure 3: Field connections on the 3099/37-100 Termination Module shown with examples.

15
 Terminal Pin Signal
- VS + TB 1 1 Counter Input 0+
Count /
TB 1 2 Counter Input 0-
Frequency
Input TB 1 3 Counter Input 1+
TB 1 4 Counter Input 1 -
TB 1 5 Counter Input 2+
TB 1 6 Counter Input 2 -
TB 1 7 Counter Input 3+
TB 1 8 Counter Input 3 -
- VS + TB 1 9 Counter Input 4+
A TB 1 10 Counter Input 4 -
Quadrature
Input - VS + TB 1 11 Counter Input 5+
B TB 1 12 Counter Input 5 -
TB 1 13 Counter Input 6+
TB 1 14 Counter Input 6 -
TB 1 15 Counter Input 7+
TB 1 16 Counter Input 7-
TB 1 17 Not Connected
TB 1 18 Not Connected
TB 2 1 Voltage Out 0
TB 2 2 Digital Input 0
TB 2 3 Voltage Out 1
TB 2 4 Digital Input 1
TB 2 5 Voltage Out 2
TB 2 6 Digital Input 2
TB 2 7 Voltage Out 3
TB 2 8 Digital Input 3
TB 2 9 Voltage Out 4
TB 2 10 Digital Input 4
TB 2 11 Voltage Out 5
TB 2 12 Digital Input 5
TB 2 13 Voltage Out 6
TB 2 14 Digital Input 6
TB 2 15 Voltage Out 7
24 VDC Nominal
TB 2 16 Digital Input 7
- VS + TB 2 17 Digital Output Field Power +
TB 2 18 Digital Output Field Power -
TB 3 1 Digital Output 0+
TB 3 2 Digital Output 0-
TB 3 3 Digital Output 1+
TB 3 4 Digital Output 1-
TB 3 5 Digital Output 2+
TB 3 6 Digital Output 2-
TB 3 7 Digital Output 3+
TB 3 8 Digital Output 3-
TB 3 9 Digital Output 4+
TB 3 10 Digital Output 4-
16
 Terminal Pin Signal
- VS + TB 3 11 Digital Output 5+
TB 3 12 Digital Output 5-
Load TB 3 13 Digital Output 6+
TB 3 14 Digital Output 6-
TB 3 15 Digital Output 7+
TB 3 16 Digital Output 7-
- VS + TB 3 17 Digital Output Field Power + (Redundant)
TB 3 18 Digital Output Field Power - (Redundant)
24 VDC Nominal
Figure 4: Field connections on the 3099/37-000 Termination Module shown with examples.

Redundant I/O Cards Placement

3000 Series System with I/O Cards
Redundant I/O cards may be located in any chassis; there are no restrictions.

3100 Series System with I/O Cards

Redundant I/O cards in non-safety 3100 systems have the following chassis placement
restrictions. All Redundant I/O Cards may be located in the same chassis or in a single other
redundant chassis.
There can be multiple pairs of redundant chassis, but all redundant I/O cards must stay within the
same chassis pair as the other cards in the chassis pair.

This is an example of a good redundant configuration. All Redundant I/O cards are within two
chassis only:
Rack0 Slot0 is redundant with Rack0 Slot1 (OK-Redundant cards in same Rack)
Rack0 Slot2 is redundant with Rack1 Slot5 (OK-Redundant cards in one Rack and second Rack)
Rack0 Slot3 is redundant with Rack1 Slot10 (OK-Redundant cards in one Rack and second Rack)

This is an example of a bad redundant configuration. The redundant cards are distributed over
three chassis:
Rack0 Slot0 is redundant with Rack0 Slot1 (OK-Redundant cards in same Rack)
Rack0 Slot2 is redundant with Rack1 Slot5 (OK-Redundant cards in one Rack and second Rack)
Rack0 Slot3 is redundant with Rack2 Slot5 (Not OK-Redundant cards in one Rack and third Rack)

17
Software Configuration
Firmware Upgrades

To update firmware of the 3000/01 Counter cards follow this 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 A 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 A I/O Ethernet port to the I/O network switch C.

18
Editing the Configuration File
Line supervision on the digital outputs can be configured to be enabled (factory default) or
disabled. To change the configuration:
1. Set DIP SW1-8 to OFF position, which is shown in Figure.
2. Unplug the J2 Ethernet port cable and connect the J1 Ethernet port to the host network.
3. Use the Project Tag Database Manager (PTDBM.exe) and configure the default IP.

4. Turn on the 3000/01 Counter Card. Ensure that the PC’s network interface is configured
in the same IP domain as 89.89.89.89. Issue a ping command from the PC to the
configured IP address 89.89.89.89 to verify connectivity.
5. Run the Node Configuration program (RTPNC.exe) and select the device created in step
1.
6. Right click on the file name IOCARD.CFG and select Upload from the pull-down menu.
7. To enable line supervision on the digital outputs, change the outputtest parameter to 1.
To disable line supervision on the digital outputs, change the outputtest parameter to 0.
8. Click the Download button to write the configuration to the card.
9. Reconnect all Ethernet cables to the I/O network as shown in Table 1 and set DIP SW1-8
on the card (see Figure) back to its ON position. Power-cycle the 3000/01 Counter Card.

19
NetArrays Configuration

The 3000/01 Eight-Channel Distributed Counter Card provides an interface to eight high-speed
pulsed input signals. Each channel may be configured for pulse counting or frequency
measurement; two adjacent channels may be configured for quadrature counting. Pulse rates of
up to 1 MHz may be applied to the card. The 3000/01 card also provides eight digital input and
eight digital output channels.

In Pulse Counter mode, the channel counts on the leading edge of the input signal. In Frequency
Measurement mode, the channel calculates the frequency from the number complete cycles of
the input signal during a specific time interval, which is determined by the actual frequency range.
For Quadrature Counter mode operation, the phase difference between two adjacent channels is
measured. The counter increments if the first channel leads the second channel, or decrements
if the first channel lags the second channel.

The channel input data can be accessed as a floating-point engineering units count or frequency
(Float Variable). NetArrays also returns an error detection status word for the card.

Adding a 3000/01 8-Channel Distributed Counter Card to the I/O Configuration Form differs from
adding other I/O cards because this card can be placed only on empty rack slot with rack
numbers 32 to 63. This card operates in a distributed intelligence mode, executing its own
20
portion of the control program, which is downloaded directly to the card. The Distributed Counter
Card must be linked to the Distributed I/O program in NetArrays in the card’s configuration.

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 Counter Card. This will be the part of the project program that will
be downloaded directly to this Distributed Counter Card for execution. See section Distributed
I/O Card Programming for programming the Distributed Form.

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 CARD CBL LOOP TIME
LTCH ERR INV ID ERR ERR BACK OUT

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

21
 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 6 Card Specific Error
This bit indicates that a card-specific error occurred: Load Fault or Proof Test Error
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 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).

Integer Readback Status

The Readback Status is an Int Variable that can be used to access the actual output signals from
all eight channels. 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 Readback Status.

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Chan Chan Chan Chan Chan Chan Chan Chan
7 6 5 4 3 2 1 0

Integer Line Fault Status

The Line Fault Status returns the results of the supervision tests on the eight loads connected to
the card if the outputtest parameter is enabled (1) in the cards’ configuration file. A 1 indicates an
open, or shorted, load condition. 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 Load Fault Status.

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Ch 7 Ch 6 Ch 5 Ch 4 Ch 3 Ch 2 Ch 1 Ch 0 Ch 7 Ch 6 Ch 5 Ch 4 Ch 3 Ch 2 Ch 1 Ch 0
Short Short Short Short Short Short Short Short Open Open Open Open Open Open Open Open

Integer Switch Fault Status

The Switch Fault Status returns the results of tests on the eight source switches and eight sink
switches. A 1 indicates a failed switch detected for the channel. 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 Switch Fault Status.

22
 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Chan Chan Chan Chan Chan Chan Chan Chan
7 6 5 4 3 2 1 0

I/O Channel Properties

Counter Channel (Input 00 - Input 07)
Each Input channel may be configured as a Float input or Disabled. If "Float" is selected, the
input channel returns an engineering units floating-point count or frequency. If "Disabled" is
selected, the input channel is disabled. You can disable any unused input channel to avoid
scanning unconnected inputs.

I/O Tag
Each enabled Input channel is accessed by a Float Variable object. NetArrays assigns a Tag to
each input 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 access the channel input.
Note! All unused un-terminated I/O points must be disabled in IO Configuration.

Reset Tag
This column specifies the Tag of a Bool Variable that can reset the accumulated pulse count or
quadrature count input value to zero. When the box is checked, this function is enabled.
NetArrays assigns a Tag to each entry in this column when the card is added to the I/O
configuration. Reconfigure the Reset Tag as required to match the Module Form Bool Variable
object that is used to reset the accumulated count. The accumulated count is cleared when the
controlling Bool Variable is True.

This reset feature can be disabled by un-checking the box.

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.

Type
This parameter selects the function performed by the input channel. Select Frequency
Measurement, Pulse Counter, or Quadrature Counter from the list as required.

Note: A Quadrature Counter requires two adjacent input channels (for example, channels 0 and
1, 2 and 3, 4 and 5, or 6 and 7). To configure two channels as a quadrature counter, select
“Quadrature Counter” as the Type for the first channel, and then disable the second channel by
selecting “Disable” in the Channel column.

23
Direction
This variable is used only in Quadrature Mode. When this variable is False, it indicates that the
counter increments because the first channel leads the second channel. If the variable is True,
the counter decrements because the first channel lags the second channel.

Channel (Output 00 - Output 07)

Each output channel can be enabled (Bool), or disabled (Disabled). You can disable any unused
channel to avoid scanning unconnected outputs.

I/O Tag Output

Each output channel is controlled by a Bool Variable. NetArrays assigns a Tag to each output
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 control the channel’s output point value.
Note! All unused un-terminated I/O points must be disabled in IO Configuration.

Channel (Input 08 - Input 15)

Each input channel can be enabled (Bool), or disabled (Disabled). You can disable any unused
channel to avoid scanning unconnected inputs.

I/O Tag Input

Each input channel is accessed by a Bool Variable. NetArrays assigns a Tag to each input
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 access the channel’s input point value.
Note! All unused un-terminated I/O points must be disabled in IO Configuration.

Comment
Enter up to 255 characters for comments associated with the corresponding tag. The comments
are informational only and are not required by any RTP NetSuite application.

24
Distributed I/O Card 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:

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.

25
 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.

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

26
Properties

Processor Select A, which will match the Distributed Counter Card to pull the
information.
Online This Bool variable will indicate if the selected Counter Card is
operational or not. If this variable is True, it indicates that the
selected Counter Card is online and operational.
Primary This Bool variable will indicate if the selected Counter Card is the
primary.
Scan Cycle For the Distributed Counter 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
Counter Card.
If reserve cycle time is not enough, then the scan cycle should be re-
configured.
All other properties are not applicable for the 300/01-029 Counter Card.

27
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
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.
28
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.

29
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.

30
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
MTTR Mean Time to Restoration
RF Radio Frequency
RFI Radio Frequency Interference

31