DC 32-Circuit Source/Sink I/O Blocks

November, 2002 GFK-2197

Description _______________________________________________ Specifications __________________________________

Catalog Numbers
A DC 32-Circuit Source/Sink I/O Block is an intelligent, configurable 32 Circuit 12/24 VDC Source I/O Block IC66*BRD024
module that interfaces the controller to devices that provide or accept a
binary signal. The blocks are compatible with a wide range of input Terminal Assembly IC66*TBD024
devices, including both 2-wire and 3-wire electronic proximity switches. Electronics Assembly IC66*ERD024
Outputs may be low-power control and indicating devices such as relays, 32 Circuit 5/12/24 VDC TTL Sink I/O IC66*BRD025
contactors, and lamps. Two models are available: Block

12/24 VDC 32- Circuit Source block (IC66*BRD024), which Terminal Assembly IC66*TBD025
provides current to field output devices. Electronics Assembly IC66*ERD025
Block Specifications

5/12/24 VDC 32-Circuit Sink block (IC66*BRD025), which
Size (height x width x depth) 8.83" (22.43 cm) x 3.58" (9.1 cm)
receives current from field output devices. x 4.7" (11.94 cm)
Weight 4 lbs. (1.8 kg)
LEDs (I/O Block) Unit OK, I/O Enabled
LEDs (each circuit) Individual logic side indicators
Block to block Isolation 850V
Heat Dissipation 11W minimum with 8 inputs
5/12/24 VDC
Sink In/Out 18W maximum with 32 outputs at .5 Amp
Operating voltage (one source) 10 to 30 VDC (12/24 V supply)
4.9 to 5.3 VDC (5 V supply) (sink only)
absolute instantaneous limit
Ripple (maximum) 10% (12/24 volts) , 1% (5 volts)
Required DC power 150 mA typical/300 mA maximum
Power supply dropout time 4 ms at 12 volts, 20 ms at 24 volts
Input Specifications
Input voltage relative to DC- Source Blocks Sink Blocks
Input ON 5 VDC supply not applicable 0-0.8 VDC
12 VDC supply 8-12 VDC 0-4 VDC
24 VDC supply 18-24 VDC 0-6 VDC
Input OFF 5 VDC supply not applicable 2-5 VDC
12 VDC supply 0-6 VDC 6-12 VDC
Features 24 VDC supply 0-12 VDC 12-24 VDC
Input impedance (typical) 3.3K Ohms

Source and Sink versions each operate at nominal 12 to 24 volts
DC Input processing time (typical) 1.4 ms (plus selectable filter delay)

Sink version is also +5 volt TTL-compatible Selectable input filter times 1, 2, 3, 4, 5, 10, 20, 30, 40, 50, 60, 70, 80,

Thirty-two configurable I/O circuits, inputs and outputs can be mixed 90, or 100ms
on block Output Specifications

Resettable self-protecting circuits Maximum output current (steady state) 0.5 Amps per circuit

Software configurable Maximum inrush current 4 Amps up to 10ms (once every .5 sec.

Advanced diagnostics maximum)

Short circuit protection Block output current (total) 16 Amps

Failed Switch detection Output OFF leakage current 10µA, maximum

Blocking diodes and feedback resistors for redundancy applications Output turn-on delay 0.5 ms, maximum
These blocks have 32 identical discrete I/O circuits, each easily Output voltage drop 4.0 volts maximum at 4 Amps inrush
configured to be an input, an output, or an output with feedback. This Output Diagnostics Switch Fault
flexibility provides maximum design and application efficiency. Environmental Specifications
Operating Temperature -0° to +60°C (32° to +140°F)
Each circuit contains built-in protection when used as an output, Storage Temperature -40 °C (-40° to +212°F)
protecting the driver while allowing short-time surges. It also protects Humidity 5% to 95% (non-condensing)
against shorted loads caused by wiring errors. Vibration 5-10 Hz 0.2” (5.08mm) displacement,
Block LEDs verify proper block operation and CPU communications. 10-200 Hz at 1G
Individual circuit LEDs on the logic side indicate voltage present on Refer to GFK-0867 for product standards and general specifications.
inputs and outputs.: Compatibility ____________________________________________
Using this Datasheet ________________________________________ These blocks are compatible with Hand-held Monitor model
This datasheet summarizes information about block installation, IC66*HHM501 only. Note that Hand-held Monitor IC66*HHM501 version
configuration, and diagnostics. A (an older version) will only display all references for a 32-circuit block if
it is made the “Active Block”.
Your primary reference should be the Discrete and Analog Blocks User’s
Manual. It includes detailed instructions for block installation and For an IC600 series PLC, the Bus Controller may be model
configuration. IC66*CBB902 or CBB 903, any version; or model IC66*CBB900 or
CBB901 version 1.3 or later.
For additional information about systems and communications, including
bus specifications, refer to the I/O System and Communications Manual. If used to control operation of a Bus Switching Module, BSM
IC66*BSM021 is required. The block must operate at 18 volts or above.

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 DC 32-Circuit Source/Sink I/O Blocks
November, 2002 GFK-2197

Block Operation ____________________________________________ Diagnostics ______________________________________________

These blocks provide 32 identical circuits, each configurable as an input The block monitors outputs for overload conditions, and checks the
or output. For both types of blocks, output circuits can be directly actual state of the switch against the commanded state. In case of
connected to input circuits without the use of other components or overload or wrong switch state, the block reports: FAILED SWITCH.
inversion of logic states. Short Circuit/Overcurrent Protection: diagnostics protect individual
output circuits against excess current. For Source blocks, the load
Source Block usually gets short-circuited to the DC- side of the supply. For Sink
A DC source block has all output devices connected to the negative (-) blocks, the load usually gets short-circuited to the DC+ side.
side of the power supply. Inputs control the positive (+) side. For If the output is commanded to go on and current exceeds 5 Amps for 1
outputs, an ON condition is logic 1 and an OFF condition is a logic 0. ms, the circuit is automatically turned off and the FAILED SWITCH
message issued. The circuit must be reset by cycling power to the
DC+
DC+ block, or by sending a CLEAR FAULTS command from the Hand-held
Configured Input Monitor or the Bus Controller.
as an Device Control
Smart Switch,
Input Blocking diode
Logic Surge Currents: Both Source and Sink blocks handle steady-state
I/O
and Feedback
resistor
loads of 0.5 Amps during normal operation. Surge current protection
determines conditions for safely switching loads between 0.5 Amps and
* To/From
4 Amps. The following chart shows allowable surge transients.
Configured Other
Output
as an Device Circuits CURRENT (AMPS)
Output 3.3K
5.0

4.0
DC-
Field DC- Terminal Electronics 3.0
Connections Assembly Assembly
2.0

* 39V Zener Diode 1.0

0.5

Sink Block 10 20 30
TIME (mS)
A DC sink block has all output devices externally connected to the
positive (+) side of the power supply. Inputs control the negative (-) side. CAUTION
For outputs, an ON condition is logic 0 and an OFF condition is a logic 1. Failure to operate a circuit within these limits may result in
thermal overload and damage to the block.
DC+
DC+ Configuration ____________________________________________
Configured To/From
Output .1µF First, the block must be configured with a Hand-held Monitor to:
as an 3.3K Other
Output
Device *
Circuits
Enter its Device Number (serial bus address).
Smart Switch,
Blocking diode

Enter its Reference Number (required only for IC600 and IC550
I/O and Feedback
resistor
series PLCs only).
Configured Control
Input In addition, unless all circuits on the block will be inputs, the Block I/O
as an Logic
Device
Input Type must be set to either Outputs or Combination on the Program Block
DC- ID screen.
DC-
Field Terminal Electronics Note: If a block is configured offline, it must be properly grounded and
Connections Assembly Assembly have a 75 Ohm resistor installed across its Serial 1 and Serial 2
* 39V Zener Diode
terminals.
The rest of the features can be configured either using a Hand-held
Blocking Diodes and Feedback Resistors for Redundancy Monitor, or by sending a Write Configuration datagram to the block from
Each I/O point on these blocks has a blocking diode and feedback the host.
resistor that facilitate redundancy when two or four points, each from a Feature Circuit or Factory Selections
different block, are used to drive the same load in a GMR T-output group Block Setting
or GMR H-output group. Below is an example of a GMR H-output group.
Baud Rate B 153.6 std 153.6 std, 153.6 ext, 76.8, 38.4
GMR 2-Block T and 4-Block H Output Groups Block I/O Type B input input, output, combination
An H-output group consists of two *BRD024 blocks connected in parallel Pulse Test B enabled enabled, disabled
on one side of the load, and two *BRD025 blocks connected in parallel to Input Filter Time B 20ms 1-100ms
the other side of the load. Note the assignment of the communications Circuit I/O Type C input input, output
busses.
Report Faults C yes yes, no
Bus A Bus B Hold Last State C no yes, no
Output Default State C off on, off
A B
BSM Present B no yes, no
BSM Controller B no yes, no
Source Blocks:
A and B Output Timeout B 2.5 sec. 2.5, 10 seconds
Redundancy Mode B none none, standby, duplex, GMR
C D
Load Duplex Def. State B off on, off
Sink Blocks: Config. Protect B disabled enabled, disabled
C and D

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 DC 32-Circuit Source/Sink I/O Blocks
November, 2002 GFK-2197

Field Wiring ______________________________________________ For 5 volt Sink applications only, jumper the +5V terminal to any DC+
Any circuit can be an input or output. Connect one terminal of a field terminal.
device to DC power and the other to the block (terminals 10-41). All I/O CAUTION
devices must return to the same power circuit.
For 12 or 24 volt sink applications do not jumper the +5V terminal
Connections for a DC Source Block
to DC+. It will damage the block. Leave the +5V terminal open.
For a Source block, connect outputs to the negative side of the power
supply and inputs to the positive side. DC Source and Sink Block, Power Disconnects
It is important to wire Block power disconnects so that power and input
5 DC+
6 DC+ power will be removed at the same time. Locate the power disconnect
DC+
7
8 DC+ as shown below.
9
N
DEVICE 1
DC+ DC SINK
10
H
11 BLOCK
12 DC SOURCE
13 BLOCK
SOURCE YES NO
14 DC+
15
16 DC+
17 FIELD OUTPUT DEVIDE LOAD
18
19
(10-41)
20 DC-
21 LOAD
22 TYPICAL OUTPUT
23 DEVICE WIRING
24 DC- DC-
25
26 YES NO
27 FIELD INPUT DEVICE
28
29 (10-41)
30 DC+ CAUTION
31
32 TYPICAL INPUT
33
34
DEVICE WIRING If circuit power is not removed at the same time as block power,
35
36
the block may power up when multiple inputs are activated, even
37
38
though one leg of power has been removed from the block.
39
N
DEVICE 32 41
40
If you want to disable the block without removing power from input
H DC-
43
42
DC- devices, use a Block Puller to unplug the Electronics Assembly. Do not
DC-
45
44
DC- disconnect H or N to remove power.
46 DC-
Wire sizes
Terminals 5 to 46 are for field devices. Each terminal accepts one AWG
Connections for a DC Sink Block #14 wire (avg 2.1mm2 cross section), two AWG #14 (2.1mm2 cross
For a Sink block, connect outputs to the positive side of the power supply section) solid wires, or two AWG #16 (each avg 1.3mm2 in cross section)
and inputs to the negative side. Connect a DC source to the DC+ stranded wires.
terminals (6-9) and the return to the DC- terminals (42-46). Bussing Power Connections
5 +5V Depending on layout and current loads, positive and negative
6 DC+ connections can be bussed and made by single wires to the block or
7 DC+
N
9
8 DC+
DC+
power source.
H
DEVICE 1 10 For TTL-Compatible
11
12
Applications Only
13
14
5 +5V LEDs ____________________________________________________
15
6 DC+
17
16
7
8
DC+
DC+
The block's Unit OK and I/O Enabled LEDs show its operating status:
9
18 DC+
19
20 Unit OK I/O Enabled Meaning
21 SINK
22
23
FIELD OUTPUT DEVICE
ON ON Block functioning, CPU communicating
24
(10-41)
25
26 DC+ ON OFF Block functioning, No CPU communications for 3 bus scans
27
TYPICAL OUTPUT
29
28
DEVICE WIRING
ON Blinking Block functioning, Circuit forced
30
31
32
Blinking ON Circuit fault, CPU communicating
FIELD INPUT DEVICE
33
34 (10-41) Blinking OFF Circuit fault, No CPU communications for 3 bus scans
35
DC+
37
36
TYPICAL INPUT
Alternate Blinking Circuit fault, Circuit forced
38
39
40
DEVICE WIRING
Synchronous Blinking No CPU communications - block number conflict
N
DEVICE 32 41
DC-
H
43
42
DC- OFF OFF No block power, or block faulty
44
DC-
45 DC-
46 DC-

Each circuit has its own LED. If the circuit is configured as an input, the
LED indicates the presence of threshold voltage at the input terminal. If
For correct 5 volt operation, power to the block, measured at the power
the circuit is configured as an output, the LED indicates the actual state
supply input terminals, must be within the range 4.9VDC to 5.3VDC.
of the load.
CAUTION

Do not apply more than 5.25 volts to the +5V terminal. Damage to
the block may result.

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 DC 32-Circuit Source/Sink I/O Blocks
November, 2002 GFK-2197

Installation Instructions ____________________________________ Grounding

Carefully inspect all shipping containers for damage. If any equipment is The block’s mounting screws must not be used as the only means of
damaged, notify the delivery service immediately. Save the damaged grounding the block. Connect the green ground screw on the block to a
shipping container for inspection by the delivery service. After unpacking reliable ground system using a short wire lead, minimum size AWG #12
the equipment, record all serial numbers. Save the shipping containers (avg 3.3mm2 in cross-section).
and packing material in case it is necessary to transport or ship any part
of the system. Grounding
Screw

Block Mounting
Genius I/O blocks are considered "open equipment" and therefore must
be installed within a protective enclosure. They should be located in an
area that is clean and free of airborne contaminants. There should be
adequate cooling airflow.
The block can be mounted right side up, or upside down. Leave at least Alternate Ground
Connection Point
2 inches of space between blocks. Mount the block by drilling two
screw or bolt holes for 8-32 hardware. Position the block so that the WARNING
notches in the upper and lower flanges line up with the mounting holes.
Mount the block using 8-32 screws. Use star washers to provide ground If mounting screws do not make good ground connection and
integrity. the ground screw is not connected to a reliable ground, the
Removing an Electronics Assembly block is not grounded. Electrical shock hazard exists. Death or
personal injury may result.
The block’s Electronics Assembly can be replaced with a compatible
model without removing field wiring or reconfiguring the block. Serial Bus Wiring
Do not overtorque the terminal screws. Recommended torque for all
Electronics terminals is 6 in/lb (.678 N/M).
Assembly
Retaining Terminals 1 to 4 are for the serial bus. They accept one AWG #12 wire
Screws
(Qty. 2)
(avg. 3.3mm2 in cross-section) or two AWG #14 wires (each avg
2.1mm2). The minimum recommended wire size is AWG #22 (avg
.36mm2).
Terminals 1 to 4 can also accommodate spade or ring lugs up to 0.27
Terminal
Assembly
inch (6.85 mm) in width with a minimum opening for a #6 screw, and up
to 0.20 inch (5.1 mm) depth from the screw center to the back barrier.
Be sure unshielded wire ends are not longer than 2 inches (5cm).
Connector
Pins Using one of the cable types recommended in the System and
Communications User’s Manual, connect the serial bus to terminals 1- 4.
(If a Bus Switching Module will be connected directly to the block, see
1. Unscrew the retaining screws at the top and bottom of the block. below instead).

2. Using a Block Puller (IC660BLM507), engage the tabs in the first

vent slots. Move the tool to the center of the block and squeeze the
handle.
1 SERIAL 1
3. Pull the Electronics Assembly upward. 2 SERIAL 2

3
WARNING SHIELD IN

4 SHIELD OUT

If power is applied to the field terminals, power is also exposed

on the connector pins at the base of the Terminal Assembly, and If the block is at either end of the bus, connect a terminating resistor of
electrical shock hazard exists. Do not touch the connector pins! the appropriate type (see the System and Communications User’s
Death or injury may result. Manual for details) across its Serial 1 and Serial 2 terminals.
Start End
Inserting an Electronics Assembly
of Bus of Bus
Terminating Terminating
1. Align the Electronics Assembly in the guides and push down firmly. Resistor Resistor

CAUTION Serial 1 Serial 1

Serial 2 Serial 2
Do not exert excessive force; it may damage the block. Shield In Shield In
Shield Out Shield Out
If unusual resistance is met, remove the Electronics Assembly. If
power is applied to the block, DO NOT TOUCH THE CONNECTOR
PINS! Inspect the Terminal Assembly, connector receptacle, and
Wiring for a Bus Switching Module
connector edge board (on the Electronics Assembly). Be sure the
keying matches. Remove any obstacles and reinsert the Electronics If the block will be a BSM Controller, attach the Bus Switching Module to
Assembly. Pay close attention to the alignment of the guide pins. the block’s serial bus terminals. Attach the serial bus cables to the BSM
as described in the Bus Switching Module datasheet. Wire the BSM like
2. Secure the Electronics Assembly with the screws on the top and a load to circuit 1. Connect either BSM pigtail wire to terminal 6. For a
bottom of the Terminal Assembly. DC Sink block, connect the other BSM wire to DC+. For a DC Source
block, connect the other BSM wire to DC-.