Product Description #

The RevPi AIO is an expansion module of the Revolution Pi product family with 4 analog inputs, 2 analog outputs and 2 RTD channels.

Components #

revpi-aio-aufbau
Position Component Application

1

3 × status LED

LEDs

2

6 × analog input,
2 × analog output

Pinout,
Parameterization

3

X4 connector

Connecting the Power Supply

4

Locking clamps

Mounting the Device on a DIN Rail

5

Ventilation Slots

Mounting the Device on a DIN Rail

6

2 × PiBridge

Connecting Expansion Modules

Pinout #

The RevPi AIO has

  • 2 analog outputs for current or voltage

  • 4 analog inputs for current and voltage

  • 2 RTD channels for resistance temperature sensors (Pt100/1000)

The pins on the connector are assigned as follows:

revpi-aio-pinout
Assignment to parameters and usage:
Pin Assignment Symbols Application

1

Output 1

 V

Positive voltage output channel 1

2

Output 2

 V

Positive voltage output channel 2

3

Output 1

I

Positive current output channel 1

4

Output 2

I

Positive current output channel 2

5

Output 1

-

Common ground for both output channels (current and voltage)

6

Output 2

-

Common ground for both output channels (current and voltage)

7

Output 1

-

(same as pin 5)

8

Output 2

-

(same as pin 6)

9

RTD 2

white (-)

Negative measuring current, 3-/4-wire; with 2-wire wire jumper to pin 18[1]

10

RTD 1

white (-)

Negative measuring current, 3-/4-wire; with 2-wire wire bridge to pin 12[1]

11

Input 4

-

Negative input current/voltage channel 4

12

RTD 1

white (-)

Negative measuring input, 2-/3-/4-wire, channel 1

13

Input 4

*

Wire bridge to pin 15 required for current measurements

14

RTD 1

red ()

Positive measuring input, 2-/3-/4-wire, channel 1

15

Input 4

Positive input current/voltage channel 4

16

RTD 1

red ()

Positive measuring current, 4-wire only, channel 1

17

Input 3

-

Negative input current/voltage channel 3

18

RTD 2

white (-)

Negative measuring input, 2-/3-/4-wire, channel 2

19

Input 3

*

Wire bridge to pin 21 required for current measurements

20

RTD 2

red ()

Positive measuring input, 2-/3-/4-wire, channel 2

21

Input 3

Positive input current/voltage channel 3

22

RTD 2

red ()

Positive measuring current, 4-wire only, channel 2

23

Input 2

-

Negative input current/voltage channel 2

24

Input 1

-

Negative input current/voltage channel 1

25

Input 2

*

Wire bridge to pin 27 required for current measurements

26

Input 1

*

Wire bridge to pin 28 required for current measurements

27

Input 2

Positive input current/voltage channel 2

28

Input 1

Positive input current/voltage channel 1

For details on configuration, see Parameterization.

LEDs #

The LEDs indicate different device statuses.

Power #

Signal Function

Green

The connection to the RevPi base module is established.

Flashes red

The connection to the RevPi base module is being established (initialization phase).

Red

The connection to the RevPi base module is interrupted.

OUT #

Signal Function

Off

The connection to the RevPi base module is not yet established (initialization phase).

Green

Outputs are ready for operation.

Flashes red

Range error. The values of the RevPi base module are too high or too low.

Red

Error at the outputs.

IN #

Signal Function

Off

The connection to the RevPi base module is not yet established (initialization phase).

Green

Inputs are ready for operation.

Flashes red

Range error. The voltage or current applied to one or more outputs is too high.

Compatible Base Modules #

Left side only:

See also Rules for the Arrangement of Devices.

Scope of Delivery #

The scope of delivery includes

  • RevPi AIO (expansion module)

  • PiBridge plug connector

  • X4 connector

  • 2 × 14-pin I/O connector

  • Product insert

Mounting and Connecting #

The RevPi was developed for use in a control cabinet. Observe the specifications for Intended Use and all Safety Instructions.

Warning
Danger to life due to electrical shock

There is a risk of fatal electrical shock when working on devices in the switch cabinet with 230 V mains voltage.

▷ Operations in the switch cabinet may only be carried out by qualified electricians.

▷ Before carrying out any operations in the switch cabinet, switch off the power supply properly.
Caution
Damage to the device due to overheating

The ambient temperature in the switch cabinet must not exceed the maximum permissible operating temperature.

▷ Keep ventilation slots clear.

▷ Observe the installation clearances.

▷ Mount the device in the intended orientation.

▷ Do not place appliances with high input power directly next to each other.

▷ Regularly remove dust and dirt from the area around the appliance.

Carry out the mounting and connection in the following order:

  1. Mount the RevPi base module and all expansion modules on a DIN Rail.

  2. Connect the expansion module via PiBridge plug connector.

  3. Connect all other devices such as sensors and actuators.

  4. Finally, connect the power supply.

Configuration #

An expansion module is configured as part of the module configuration of the Revolution Pi system, i.e. a RevPi base module with expansion modules. This is possible via the application PiCtory or, if applicable, directly in the development environment, e.g. via CODESYS.

Note

CODESYS and PiCtory cannot be used in parallel for configuration. An existing configuration via PiCtory will be overwritten by a configuration via CODESYS.

The virtual devices OPC UA Server and MQTT Client can only be used via PiCtory.

Parameterization #

The following parameters, inputs (INP), outputs (OUT) and memory variables (MEM) can be configured:

InputValue_1 … 4 (INP) #

These inputs can be set as either voltage or current inputs.

See also: Pinout

InputStatus_1 … 4 (INP) #

Displays the current status of the inputs 1 … 4.

In the event of an error, status messages are output:

Bit position LED Meaning

Bit 0 (LSB)

Flashes red

Input value is at least 24 mV or 20 µA below the configured input range.

Bit 1

Flashing red

Input value is at least 24 mV or 20 µA above the configured input range.

RTDValue_1 … 2 (INP) #

The temperature of connected Pt100 and Pt1000 sensors can be determined via the RTD channels.

RTDStatus_1 … 2 (INP) #

Displays the current status of RTD channels 1 … 2.

In the event of an error, status messages are output:

Bit position Meaning

Bit 0 (LSB)

Temperature below -200 °C or short circuit in the sensor or cable.

Bit 1

Temperature above 850 °C or no sensor connected or cable break.

OutputStatus_1 … 2 (INP) #

Displays the current status of the outputs 1 … 4. In the event of an error, status messages are output:

Bit position LED Meaning

Bit 0 (LSB)

red on

Temperature error from the output module. The output module is overheated due to prolonged overload (short circuit).

Bit 1

red on

Open load error of the current output. The connected circuit has too high an impedance, e.g. because the line is interrupted.

Bit 2

red on

Internal CRC error of the output module, e.g. hardware defect or serious external interference signals.

Bit 3

red flashing

Range error: Output value in the process image is outside the configured output range.
The output is set to the maximum or minimum permissible value.

Bit 4

-

Reserved for internal purposes

Bit 5

red on

Supply voltage of the expansion module is below 10.2 V.
The outputs are switched off.

Bit 6

red on

Supply voltage of the expansion module is above 28.8 V.
The outputs are switched off.

Bit 7 (MSB)

red on

Timeout during connection to the RevPi base module, e.g., PiBridge malfunction or piControl malfunction.
The outputs are switched off.

If the outputs are switched off, the outputs are re-available only after a restart of the device or a reset of the PiBridge (e.g. piTest -x).

OutputValue_1 … 2 (OUT) #

These outputs can be set as either voltage or current outputs.

See also: Pinout

Input1Range … Input4Range (MEM) #

Defines the input range for voltage or current measurement according to the connected sensor:

  • -10 … 10 V

  • 0 … 10 V

  • 0 … 5 V

  • -5 … 5 V

  • 0 … 20 mA

  • 0 … 24 mA

  • 4 … 20 mA

  • -25 … 25 mA

Scaling of the Inputs (MEM) #

  • Input1Multiplier … Input4Multiplier (MEM)

  • Input1Divisor … Input4Divisor (MEM)

  • Input1Offset … Input4Offset (MEM)

Scales the inputs 1 … 4.

Is determined by the three configuration values and calculated from the original value in mV or µA with:
Y = Multiplier/Divisor*X + Offset

ADC_DataRate (MEM) #

Frequency for data rate on the analog converter for all 4 inputs.

  • 5 Hz

  • 10 Hz

  • 20 Hz

  • 40 Hz

  • 80 Hz

  • 160 Hz

  • 320 Hz

  • 640 Hz

The rate, at which the values in the process image are updated, is approximately 1/5 of this ADC data rate.

Output1Range … Output2Range (MEM) #

Value range for current or voltage:

  • Off (Output inactive)

  • 0 … 5 V

  • 0 … 10 V

  • -5 … 5 V

  • -10 … 10 V

  • 0 … 5.5 V

  • 0 … 11 V

  • -5.5 … 5.5 V

  • -11 … 11 V

  • 4 … 20 mA

  • 0 … 20 mA

  • 0 … 24 mA

Output1EnableSlew … Output2EnableSlew (MEM) #

Determines whether the slew rate is used:

  • On

  • Off

Output1SlewStepSize … Output1SlewStepSize (MEM) #

Defines the increment of the slew rate:

  • 1

  • 2

  • 4

  • 8

  • 16

  • 32

  • 64

  • 128

Increment 1 corresponds smallest bit value (LSB) of the converter.

Output1SlewUpdateFreq … Output1SlewUpdateFreq (MEM) #

Defines the step frequency for the slew rate:

  • 258 kHz

  • 200 kHz

  • 154 kHz

  • 131 kHz

  • 116 kHz

  • 70 kHz

  • 38 kHz

  • 26 kHz

  • 20 kHz

  • 16 kHz

  • 10 kHz

  • 8.3 kHz

  • 6.9 kHz

  • 5.5 kHz

  • 4.2 kHz

  • 3.3 kHz

Scaling of the Outputs (MEM) #

  • Output1Multiplier … Output2Multiplier (MEM)

  • Output1Divisor … Output2Divisor (MEM)

  • Output1Offset … Output2Offset (MEM)

Scales the output channels.

Is determined by the three configuration values and calculated from the original value in mV or µA with:
Y = Multiplier/Divisor*X + Offset

  • 16 bit signed multiplier

  • 16 bit unsigned divisor

  • 16 bit signed offset

RTD1Type … RTD2Type (MEM) #

Selects the sensor type:

  • Pt100

  • Pt1000

RTD1Wiring … RTD2Wiring (MEM) #

Selects the measurement method:

  • 2-Wire

  • 3-Wire

  • 4-Wire

Scaling of the RTD Channels #

  • RTD1Multiplier … RTD2Multiplier (MEM)

  • RTD1Divisor … RTD2Divisor (MEM)

  • RTD1Offset … RTD2Offset (MEM)

Scales the RTD channels.

Determined by the three configuration values and calculated from the original value (given in 1/10 °C) using the following formula:
Y = Multiplier/Divisor*X + Offset

  • 16-bit signed multiplier

  • 16-bit unsigned divisor

  • 16-bit signed offset

RTD Channels #

The temperature of connected Pt100 and Pt1000 sensors can be determined via the RTD channels.

See Pinout.

revpi-aio-rtd-channels

The scaling can subsequently be used for conversion in other units or for a subsequent calibration of a temperature sensor. A 32-bit integer arithmetic is used for calculations in the RevPi AIO. The results are stored as 16-bit values in the process image. Should the result Y exceed the limits of a 16-bit signed value, the fault will be recognised and the value limited. The output values for scaling factor 1 always have to be stored in the process image in the unit mV or µA respectively.

Examples:

To have the temperature in °C without decimal places in the process image, the setting must look like this:

Multiplier = 1, Divisor = 10, Offset = 0

In order to manage the temperature in °F in the process image, the parameters have to be set like this:

Multiplier = 18, Divisor = 100, Offset = 32

For process data in °Kelvin you need these values:

Multiplier = 1, Divisor = 10, Offset = 273

Should an error occur, you receive error messages in the input values of the channels RTDStatus_1 and RTDStatus_2.

Should the recorded temperature be outside the range, the respective limit will be issued (-200.0 °C or 850.0 °C) and the respective status bit will additionally be set.

In the fields RTDValue_1 and RTDValue_2 you can define symbolic names for the 4 analog input values. With these names you can read out measured values of the connected sensors from the process image with piTest, a self-written program or an application software. The values are given there in 1/10 °C if you leave the scaling at 1.

Technical Data #

Item No.: 100250

Standard

EN 61131-2

Housing dimensions (H × W × D)

96 × 22.5 × 110.5 mm

Housing type

DIN rail housing for TH35 according toDIN EN 60715

Housing material

Polycarbonate

Weight

Approx. 115 g

Protection class

IP20 / NEMA Class 1

Power supply

12 … 24 V DC (-15 % / +20 %)

Power consumption

  • Max. 200 mA at 24 V (full load)

  • Max. 400 mA at 12 V (full load)

  • Max. 500 mA during start up

Approved operating temperature

-30 … +55 °C

Approved storage temperature

-40 … +85 °C

Max. relative humidity (at 40 °C)

93 % (non-condensing)

Voltage measuring ranges

±10 V | ±5 V | 0 … 10 V | 0 … 5 V

Current input ranges

0 … 20 mA | 0 … 24 mA | 4 … 20 mA | ±25 mA

Temperature input range

-200 … +850 °C

Voltage output ranges

±10 V | ±11 V | ±5 V | ±5.5 V | 0 … 10 V | 0 … 11 V | 0 … 5 V | 0 … 5.5 V

Current output ranges

0 … 20 mA | 0 … 24 mA | 4 … 20 mA

Input channels

  • Total: 6

  • Voltage: max. 4

  • Current: max. 4

  • RTDs: 2

Output channels

  • Total: 2

  • Voltage: max. 2

  • Current: max. 2

Galvanic isolation

  • Inputs to each other: no

  • Inputs to outputs: yes

  • Outputs to each other: no

  • System bus to inputs/outputs: yes

Type of analog inputs

  • Voltage/current: differential

  • Temperature sensor RTD (Pt100/Pt1000): 2-, 3-, 4-wire

Type of analog outputs

Single-ended, common ground, short-circuit proof

ADC type

Internal 24 bit | effective 16 bit

DAC type

16 Bit

Input resolution in process image

Voltage 1 mV | Current 1 μA | Temperature 0.1 K

Output resolution in process image

Voltage 1 mV | Current 1 μA

Max. overall input error (at 25 °C ambient temperature)

  • Voltage (all input ranges): ±10 mV (±5 mV at 0 … 5 V)

  • Current (all input ranges): ±20 μA (±24 μA at 0 … 24 μA)

  • Temperature (complete range): ±0.5 K

Max. overall input error (at -30 … +55 °C ambient temperature)

  • Voltage (all input ranges): ±10 mV

  • Current (all input ranges): ±72 μA

  • Temperature (complete range): ±1.5 K

Max. overall output error (at 25 °C ambient temperature)

  • Voltage (all input ranges): ±15 mV

  • Current (all input ranges): ±20 μA

Max. overall output error (at -30 … +55 °C ambient temperature)

  • Voltage (all input ranges): ±15 mV

  • Current (all input ranges): ±72 μA

Input conversion time (data rate in process image)

8 … 1000 ms (adjustable)

Output data rate

1 PiBridge cycle

Output slew rate, adjustable digital slew rate control

1 LSB at 3.3 kHz up to 128 LSB at 258 kHz

Input impedance Voltage

>900 kΩ

Output impedance Voltage

<16 Ω | maximum capacitive load 5 nF at 1 kΩ

Max. load resistance for current output

600 Ω

Min. load resistance for voltage output

1 kΩ

Further features

All inputs and outputs are linearly scalable; overtemperature monitoring; overcurrent monitoring; range monitoring

Optical display

3 status LEDs (bi-color)

EMC immunity

According to EN 61000-6-2; a shielded cable is required for the analog I/Os for cable lengths over 3 m.

Conformity

CE, RoHS, REACH, UKCA

UL certification

UL-File-No. E494534
NOTE: The device may only be supplied from circuits that comply with Class 2 or Safety Extra Low Voltage (SELV) according to Class 9.4 of UL 61010-1.
1. RevPi AIO uses the 3-wire measuring method for a 2-wire sensor. Therefore, the missing third wire must be simulated by a wire bridge on the RevPi AIO between pins 10 and 12 (RTD1) and 9 and 18 (RTD2) respectively.