ADLINK HSL Distributed High Speed I/O System

ADLINK HSL Distributed High Speed I/O System

Overall Overview of HSL System

1. Core architecture: master-slave distributed RS-422 multipoint bus

Adopting single master multi slave command response polling communication, the host is plugged into an HSL master control card, various I/O slave modules are hung remotely, and standard Category 5e RJ45 Ethernet cables are used for wiring, replacing traditional RS485 multi node PLCs, to solve the problems of insufficient slots for centralized industrial control computers and complex on-site wiring.

2. Core product advantages

Deterministic high-speed scanning

The scanning period is linearly related to the number of slave indexes, with no random delay; Optional speed of 3/6/12Mbps (default 6Mbps), divided into full duplex/half duplex:

Full duplex single index time: 3M=60.67 μ s, 6M=30.33 μ s, 12M=15.17 μ s

Half duplex single index time: 3M=118 μ s, 6M=59 μ s, 12M=29.5 μ s

The maximum number of indexes for a single master is 63, and the 6M full duplex full configuration scan only takes 1.911ms, with a refresh rate of thousands of milliseconds.

Minimalist wiring

Universal Cat5 Ethernet cable+RJ45, supporting serial and star topologies; Under a single port of 6M, the maximum distance is 200m, and with HUB relay, the maximum distance is 2.4km.

Ultra large I/O expansion capability

A single industrial computer can have up to 8 main cards; Single PCI-7854 dual controller supports 126 indexes, and fully equipped DI16DO16 can achieve 24192 digital IO channels.

Multi type integrated substation

The unified bus integrates discrete DI/DO, relays, 16 analog signals, and 4-axis pulse motion modules, and a set of buses is used to achieve data acquisition and motion control.

Hardware hot plugging and self diagnosis

Terminal base separation design, module can be replaced without power failure; CRC12 verification, real-time statistics of the number of unresponsive slave stations, and automatic marking of communication anomalies.

Low development threshold

The main card has a built-in 32KB SRAM cache for all I/O states, allowing applications to directly read and write memory without the need to handle underlying communication protocols.

3. Typical application scenarios

Distributed replacement of traditional PLC: Single IPC unified control of all remote I/O, eliminating the need for multiple PLC networking;

Remote deterministic data collection: thermocouple, voltage/current sensor remote synchronous sampling;

Distributed motion control of equipment: multi axis pulse stepper/servo drive for assembly line;

Distributed digital signals and relay switch control for the production line.

4. Overall hardware composition of the system

HSL main control card (PCI/PMC interface, host side)

HSL slave station I/O module (DB/M/U three series, on-site side)

Supporting DIN rail terminal base (TB series, wiring carrier)

HSL-HUB/signal repeater (extended distance, star topology extension)

Cat5 shielded Ethernet cable (only using RJ45 3/4/5/6 four wire for transmitting and receiving)

Detailed specifications of HSL main controller (host control card)

1. Differentiation of Three Main Control Hardware Models

Model: Master Control ASIC Quantity: RJ45 Port Bus Maximum Support: Slave Index

PCI-7853 1 main control 2-port RJ45 standard PCI 2.1 63

PCI-7854 2 independent controllers 4-port RJ45 standard PCI 2.1 126

PMC-7852/G 2 independent main control 4-port RJ45 PMC embedded 126

2. General hardware parameters

Communication: Isolation transformer multi-point RS-422, full/half duplex optional, rate 3/6/12M software/dial-up switching;

Cache: Each master is equipped with 2KB SRAM to cache all slave IO in real-time;

Power supply:+5V typical 500mA; operating temperature 0~70 ℃;

Interface: RJ45 is only valid for TX+/TX -/RX+/RX - four wires, the rest are vacant;

Dial configuration: PMC card sets speed through SW1, JP jumper switches between full/half duplex; PCI card board S1 dial code setting card number.

3. Software architecture layering

Application → DLL library → underlying driver → PCI bus → main control ASIC → RS422 transceiver circuit, hardware automatically polls and refreshes memory, software only reads and writes cache.

HSL slave station I/O module, terminal base, repeater

（1） Three major sub station series (DB/M/U)

DB series: Bare board card, requiring a base to support it; Representative: HSL-DI32-DB, HSL-DO32-DB (32 point IO occupying 2 indexes)

M series: metal shell industrial type, with isolation; Contains digital, relay, and analog modules. The key model in the document is HSL-DO32-M-N/P (32 channel digital output, occupying 2 slave indexes, 6-digit DIP dip to set the starting address, starting with odd numbers)

U series: ultra-thin and compact, DI16DO16 specifically designed for small devices.

1. Rules for Discrete Digital I/O Modules (including HSL-DO32-M-N/P)

Single index module (DI16DO16, R8DI16): DIP any 1-63 address, occupying only one index;

32 channel module (DI32/DO32, including DO32-M): must start with an odd number and occupy 2 consecutive indexes (such as dialing 3, occupying 3 and 4);

IO Electrical: Optocoupler isolation 2500VRMS, supports NPN current injection/PNP current pulling 24V signal; DO single channel maximum 50mA, U series 90mA; relay module supports AC/DC load of 2A.

2. Analog module (M series AI16AO2)

16 differential/single ended analog inputs+2 outputs, 16 bit ADC/DAC; Divided into VV voltage type and AV current type; Full duplex down hopping occupies 2 indexes (dialing 5 occupies 5, 7), supporting the calibration process in the document appendix.

3. 4-axis motion module HSL-4XMO

Pulse based stepper/servo control; Full duplex hop numbers occupy 4 indexes, and half duplex consecutive 4 indexes; Support downloading point tables and motion scripts to reduce host CPU usage.

4. Terminal Base TB Series

DIN rail installation, carrying modules, integrated RJ45 serial interface, wiring terminals; Key jumper: The bus terminal resistor is only turned on by the last base of the link, and the rest are turned off; Single slot TB32 and dual slot TB64, supporting different series of M/DB modules.

5. HSL-HUB repeater

1 in 3 out RJ45, can cascade up to 7 units with a maximum distance of 2.4km; jumper switching speed and duplex mode enable star shaped cabling, solving the problem of long attenuation in a single chain.

6. Specification for setting DIP addresses for slave stations

6-digit dip switch, ON=1、OFF=0； Address 0 is reserved for the controller and can be used from 1 to 63; Different modules occupy different numbers of indexes, so it is necessary to reserve skip space when networking, otherwise communication will be abnormal.

Bus communication mechanism and fault handling

1. Polling workflow

The main controller cycles from small to large according to the index: issuing output values → reading the current input status, completing one scan in one round, and storing the data in the onboard SRAM for software reading.

2. Communication error detection mechanism

Each slave station has an independent unresponsive counter:

Single failure count+1, successfully reset to zero;

If the count is ≥ 3, set the first level fault flag, and if it is ≥ 7, determine that the slave station is offline;

The driver interrupts and reports to the offline slave station every 20ms, and the software can read the fault register to troubleshoot disconnection and module power failure.

3. Topology and wiring requirements

Recommend serial daisy chain with dual RJ45 straight through base;

Open the 120 Ω terminal resistor at the end of the link base and close it in the middle;

Shielding the network cable throughout the entire process, reducing transmission speed in industrial strong interference scenarios (3M improves distance and anti-interference).

Supporting software system (debugging tools+development libraries)

1. LinkMaster Utility Debugging Tool (Windows specific)

Chapter 4 of the manual provides a complete explanation of the graphical debugging software and its core functions

Automatically scan all HSL master cards of the entire machine and identify all online slave station models and addresses;

Real time scanning of communication quality across the entire network, visualizing the number of errors in each index;

Module specific testing panel: DI32/DO32, DI16DO16, independent interface for analog and motion control;

Read and write digital output, real-time input acquisition, analog calibration, motion axis point testing;

Check the communication status bits of the slave station (Data request, 1/3/7 fault flags).

2. Bottom level function libraries (DLL/shared libraries)

The complete function list in Chapters 5 and 6 of the manual is divided into five categories of APIs:

System initialization/card information reading;

Timer control;

Discrete DI/DO read and write (adapted for batch operation of 32 point output modules such as DO32);

Analog AI/AO acquisition and output;

Special functions for pulse stretching and motion control;

3. Development environment support

Windows：2000/XP， Support VC/VB/Delphi, LabVIEW, MATLAB;

Linux: 2.4 kernel, GCC shared library development;

Programming process: Initialize HSL → Scan slave → Loop to read and write SRAM cache → Release resources.