High I/O Expansion Card

P/N: PC90-00021-00

High I/O Expansion

Technical Data Sheet
Table of Contents

Introduction and Overview....................................................................... 1

Board Power .............................................................................................1

Hookup Instructions ................................................................................. 3

Digital Input Hookup for High Side Switch.....................................................3
Digital Output Hookup for High Side Load .....................................................4
Digital Input/Output Hookup When Used As An Input .....................................5
Analog Input Hookup for 4-20mA Transmitter ...............................................6
Analog Input Hookup for Voltage Transmitter ................................................7
Analog Output 4-20mA Transmitter Hookup for Low Side Load.........................8
Analog Output 1-5V Hookup for Low Side Load ..............................................9
Load Cell Hookup .................................................................................... 10
Analog Output Hookup for Positive Ground System ...................................... 11

High I/O Expansion Card Specifications ................................................. 12

List of Figures
Figure 1: High I/O Expansion Board ................................................................ 2
Figure 2: Typical Digital Output/Input Hookup for High Side Switch Using on Board
Loop Power (Digital Input DI 1 Shown)................................................... 3
Figure 3: Typical Digital Output Hookup for High Side Load Using on Board Loop
Power (Digital Output DO5 Shown) ........................................................ 4
Figure 4: Typical Digital Input/Output Hookup when used as Input (Digital Input
DI5 Shown) ........................................................................................ 5
Figure 5: Typical Analog Input (4 to 20mA) Hookup Using on Board Loop Power
(Analog Input AI 1 Shown) ................................................................... 6
Figure 6: Typical Analog Input (1 to 5V) Hookup Using on Board Loop Power
(Analog Input AI 1 Shown) ................................................................... 7
Figure 7: Typical Analog Output (4 to 20mA) Hookup for Low Side Load Using on
Board Loop Power ............................................................................... 8
Figure 8: Typical Analog Output Hookup for 1 to 5V Output ................................ 9
Figure 9: Typical Load Cell Hookup ................................................................10
Figure 10: Typical Analog Output Hookup for External Positive Ground System ....11

January 2002 i
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
List of Tables
Table 1 High I/O Expansion Card Specifications ............................................... 12

ii January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Introduction and Overview
The I/O contained on the base Model 2000 Rod Pump Controller (RPC) is
specifically designed for pump off applications. If additional I/Os are required, one
of four expansion boards must be used. The high I/O expansion card provides the
maximum expansion capacity. Although the original model firmware can support
the small I/O expansion card, PC90-00019-00, it is not capable of supporting the
higher count I/O expansion boards. Therefore, the user should confirm that the
firmware to be utilized has this support. Eight digital I/Os are provided. Four of
the digital I/Os are dedicated as digital inputs and four are individually
configurable for use as digital inputs or digital outputs. Therefore the mix of digital
inputs and digital outputs can range from eight digital inputs and zero digital
outputs to four digital inputs and four digital outputs. There are eight single ended
analog inputs on the board that can be used as either 4-20mA or 1-5V inputs. A
single analog output is provided that can be used either as an optically isolated 4-
20mA output or a single ended 1-5V output.

Board Power
Board power of 10-15V DC is supplied to P4. The RPC power supply is normally
used to supply this input. This power is also used to supply the 24V DC loop power
from P5. Internal circuitry is used to boost the input power to the 24V DC level
needed for loop power.

January 2002
1
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

Figure 1: High I/O Expansion Board

2 January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Hookup Instructions
Digital Input Hookup for High Side Switch
Connect the High Side Switch as shown in Figure 2 . Loop power is provided by
this board.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

SW1

Figure 2: Typical Digital Output/Input Hookup for High Side Switch Using on Board
Loop Power (Digital Input DI 1 Shown)

January 2002
3
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
Digital Output Hookup for High Side Load
Connect the High Side Load as shown in Figure 3. Loop power is provided by this
board.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

– – – – – – – –
AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

– – – – – –
– – – – – – Analog Analog Load Load
Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

Load

Figure 3: Typical Digital Output Hookup for High Side Load Using on Board Loop
Power (Digital Output DO5 Shown)

4 January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Digital Input/Output Hookup When Used As An Input
Connect the switch as shown in Figure 4. Loop power is provided by this board.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

SW1

Figure 4: Typical Digital Input/Output Hookup when used as Input (Digital Input
DI5 Shown)

January 2002
5
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
Analog Input Hookup for 4-20mA Transmitter
Connect the 4-20mA Transmitter as shown in Figure 5. Loop power is provided by this board.
Ensure that the jumper is in place for the input you are connecting.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

–
Jumper must be installed for
Transmitter 4- to 20-mA input
4- to 20-mA

Figure 5: Typical Analog Input (4 to 20mA) Hookup Using on Board Loop Power
(Analog Input AI 1 Shown)

6 January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Analog Input Hookup for Voltage Transmitter
Connect the Voltage Transmitter as shown in Figure 6. Loop power is provided by this board.
Ensure that the jumper is removed for the input being connected.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

Signal
+ –
Voltage
Transmitter

Figure 6: Typical Analog Input (1 to 5V) Hookup Using on Board Loop Power
(Analog Input A11 Shown)

January 2002
7
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
Analog Output 4-20mA Transmitter Hookup for Low Side Load
Connect the 4-20mA Transmitter as shown in Figure 7. Loop power is provided by this board.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

RL

Figure 7: Typical Analog Output (4 to 20mA) Hookup for Low Side Load Using on
Board Loop Power

8 January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Analog Output 1-5V Hookup for Low Side Load
Connect the 1-5V Output as shown in Figure 8. Loop power is provided by this board.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

RL
RL must be greater
than 100k Ohms

Figure 8: Typical Analog Output Hookup for 1 to 5V Output

January 2002
9
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
Load Cell Hookup
Connect the Load Cell as shown in Figure 9.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts

R
R
R = 300 Ohms or greater R
R

Figure 9: Typical Load Cell Hookup

10 January 2002
MS-2000TDS-05 / Rev. A
 High I/O Expansion Card
P/N: PC90-00021-00
Analog Output Hookup for Positive Ground System
Connect the external positive ground output as shown in Figure 10.

1A
F1 P1

CAC INC.
PC90-00021-

F2

JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8

RP1
JP9
REV.

S/N

AI1 AI2 AI3 AI4 AI5 AI6 AI7

D22 D23 D24

Analog Analog Load Load

Output Output Cell Cell
4 to 20 1 to 5 Input Exc.
DI1 DI2 DI3 DI4 DI5/DO5 DI6/DO6 DI7/DO7 DI8/DO8
ma. volts
RL

+
12- to 36-V
External Positive
Ground System Vs
–

RL Min = 052
RL Max = (Vs - 5V)
Ohms
.025A

Figure 10: Typical Analog Output Hookup for External Positive Ground System

January 2002
11
MS-2000TDS-05 / Rev. A
High I/O Expansion Card
P/N: PC90-00021-00
High I/O Expansion Card Specifications

Table 1: High I/O Expansion Card Specifications

PC90-00021-00 High I/O Expansion Unit Card
Hardware Specifications
Digital Inputs 8 optically isolated 5K input impedance
Digital Outputs 4 optically isolated 1A @ 30V max (may optionally be used
as digital input)
Analog Input 8; 4-20mA / 1-5V single ended
Analog Output 1 Optically isolated 4 to 20mA
1 single ended 1 to 5V
Load Cell Input 1 differential input 10M input impedance
Load Cell Excitation 1; 10V @ 30mA max
Electronic Specifications
Power Supplied by main board (adds 520mW)
Loop Power On board DC/DC converter 12V in 24V out @ 200mA (add
175mW base plus 0.85 ∗ load)
Ambient Specifications
Operating -40°C to 85°C
Storage -85°C to 100°C

12 January 2002
MS-2000TDS-05 / Rev. A