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Reference Guide
278596 Rev. A7
Refer to this publication for complete and accurate information that helps you better operate and service Metso
Automation equipment. Your comments and suggestions are welcome.
Metso Automation
1180 Church Road
Lansdale, PA 19446
Attention: Manager, Technical Publications
Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305 ................................... 3-1
Overview .................................................................................................................................................................. 3-1
LED Indication ..................................................................................................................................................... 3-1
Bus Address .......................................................................................................................................................... 3-2
Jumper Configuration ........................................................................................................................................... 3-2
Module Operation................................................................................................................................................. 3-2
Diagnostics ........................................................................................................................................................... 3-4
Module Specifications .......................................................................................................................................... 3-4
Field Wiring for IOP302....................................................................................................................................... 3-5
Field Wiring IOP 305 Analog Input Module..................................................................................................... 3-6
Field Wiring For Redundant Modules with Common Transmitter....................................................................... 3-7
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331..................7-1
Overview ...................................................................................................................................................................7-1
LED Indication ......................................................................................................................................................7-1
Bus Address...........................................................................................................................................................7-2
Module Operation..................................................................................................................................................7-2
Module specifications............................................................................................................................................7-3
Field Wiring...........................................................................................................................................................7-4
Field Wiring For Redundant Modules with Common DI......................................................................................7-5
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332
240V AC/DC Isolated Input Module IOP333 ...........................................................................................................8-1
Overview ...................................................................................................................................................................8-1
LED Indication ......................................................................................................................................................8-1
Bus Address...........................................................................................................................................................8-2
Jumper Configuration ............................................................................................................................................8-2
Module Operation..................................................................................................................................................8-2
Module Specifications ...........................................................................................................................................8-3
Field Wiring...........................................................................................................................................................8-4
Field Wiring For Redundant Modules with Isolated DI ........................................................................................8-5
Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350 ..............................10-1
Overview .................................................................................................................................................................10-1
LED Indication ....................................................................................................................................................10-1
v
maxPAC Hardware Reference Guide
Diagnostics ..........................................................................................................................................................12-8
Module Field Connections...................................................................................................................................12-9
Termination Field Connections Channels 1-2 ...................................................................................................12-10
Termination Field Connections Channels 3-4 ...................................................................................................12-11
Group1 Analog I/O Configuration ....................................................................................................................12-12
Group2 Analog I/O Configuration ....................................................................................................................12-13
Digital I/O Configuration Channels 1-2 ............................................................................................................12-14
Digital I/O Configuration Channels 3-4 ............................................................................................................12-15
Digital I/O Configuration - DC Power Switches ...............................................................................................12-16
Specifications.....................................................................................................................................................12-17
vii
maxPAC Hardware Reference Guide
Specifications.................................................................................................................................................... 14-12
maxPAC
Input/Output Subsystem
Overview
The maxPAC Input/Output System links the maxDNA Distributed Control
System to real world process control inputs and outputs. The Input/Output
system uses a compact design to provide the system with greatly enhanced
I/O capacity in relatively little space. A close relationship exists, in turn,
between this I/O system and the maxDNA Distributed Processing Unit
(DPU) which it serves.
The DPU and the I/O modules mount in an I/O chassis assembly. The
backplane in the chassis assembly provides the I/O bus connection between
the DPU and the I/O modules. It also provides the system power and field
power connections to the modules. Multiple I/O chassis that share the I/O bus
can be installed in a cabinet.
The following figure shows a typical cabinet arrangement with I/O in both
the front and rear of the cabinet.
Chassis Assembly
Three chassis assembly types are available for the installation of the I/O
module as follows:
The rack assemblies contain an I/O backplane featuring edge connectors for
I/O modules and connectors for 24V system supply and 24V and 48V loop
power supplies. Input/Output modules connect to the I/O bus through four to
eight connectors on the backplane, depending on chassis style.
System 24V
I/O Bus
I/O Bus
Connector
Connectors
Field 48V
Field 24V
DPU Mounting
DPU4E mounts in the right most position of the six-pack chassis assembly. It
occupies the equivalent of two I/O modules. Refer to Publication 278590 for
DPU4E information. DPU4F mounts in the left most position of the eight-
pack chassis assembly. It occupies the equivalent of one I/O module. Refer to
Publication 278705 for DPU4F information.
I/O Modules
The I/O modules are rugged enclosed printed circuit board assemblies. The
edge connection at the rear of each module provides the interface to the
backplane and the I/O bus. System power and field power, when applicable, is
also available through this connection.
While I/O modules vary by type, they may include one or more of the
following:
A color bar on the module faceplate identifies the module type. Each
module type has a unique color.
Euro-style terminal connector blocks for field wiring; each block contains
16 connectors;
All the modules that require field power include a front mounted fuse
disconnect and a LED fuse status indication;
All discrete modules include front mounted LEDs for input/output logic
state;
The I/O modules may be inserted and withdrawn safely with 24 Vdc and field
power applied.
Analog Input
Part Number Description
IOP301 Isolated analog input; 16 channels
IOP302 4-20mA common input; 16 channels
IOP303 3-wire RTD input; 8 channels
IOP304 Thermocouple/emf input; 16 channels
IOP305 Voltage common input; 16 channels
IOP306 Kit with sixteen 100 Ohm resistors
Analog Output
Part Number Description
IOP320 4-20 mA common output, 8 channels
Other
Part Number Description
IOP371 Optical bus extender
IOP336 QuadPAT, 4 channels
IOP341 Turbine Valve Positioner
IOP345 Turbine Overspeed
Power Supply
The maxDNA Input/Output System uses the Model APS Power Supply
Assembly, which provides 24V dc power for Distributed Processing Units
and I/O. This Power Supply Assembly consists of a 19-inch rack mount or
flush mount chassis accommodating up to six independent 10 amp power
supply modules. Metso Automation typically installs the power supply
modules in an N + 1 redundancy configuration. Because each module is
individually isolated, the chassis can be split to provide both system power
and loop power.
The types of terminal blocks installed in the termination facility are too
numerous to list; typically these terminations are DIN rail style. The cabling
back to the I/O module is typically made using two multi-conductor cables,
one to each of the Euro-Style plugs supplied with the individual I/O module.
Termination Assemblies
Part Number Description
IOP337 QuadPAT Termination Assembly
IOP342 Turbine Valve Termination Assembly
IOP346 Turbine Overspeed
CTO301 QuadPAT Module to Termination Assembly Cable
CTO302 Turbine Valve Module to Termination Assembly Cable
CTO303 Turbine Overspeed Module to Termination Assembly
Cable
Screwdriver
Hex Key Wrench, Metso Part No. 064598
Mounting Screws, Metso Part No. 030162 (8 per unit supplied)
Nut Retainers, Metso Part No. 003530 (8 per unit supplied)
Crimp Tool for field connectors, Weidmuller Part No. 906480
Crimp Contact Removal Tool, Weidmuller Part No. 906481
Before mounting any hardware, see "Cabling, Power, and Ground Wiring."
If your field wiring enters through the bottom of the cabinet, mount the
Model IOP I/O units from top to bottom. This will make wiring of future
units easier, since you will not have to pull wires from the bottom of the
cabinet past existing Model IOP I/O units. This same reasoning applies to
field wiring entering the top of the cabinet. Here you mount the Model IOP
units from bottom to top.
Usually, the Model IOP I/O units are supplied already mounted in cabinets,
but if you are mounting them yourself, follow this procedure.
Note: before you mount an I/O chassis, it should contain the I/O backplane.
2. The holes in the maxDNA cabinet rear mounting rails are arranged in a
repeating pattern of two holes close together separated by a single hole.
To make sure all chassis assembly mounting screw cutouts line up to
corresponding mounting rail holes, you must align the top mounting
screw cutouts (left and right) of the chassis assembly with the top holes
(left and right) of two hole pair.
3. Position the chassis assembly (two ribbon connectors to the right) so that
the screw slots align with the nut retainers. Insert eight 10-32 mounting
screws (Metso Part No. 030162) and tighten securely.
Cables used in the maxDNA Distributed Control Systems are labeled at both
ends with the device and connector number. Interconnecting ribbon cables
are designed for specific orientation, however, the connectors still prohibit
wrong electrical connection.
Caution: The +24 Vdc power supply used to power any maxDNA hardware
should never be used for external relay contact wetting or to power any other
field equipment. Use a separate supply for contact wetting to provide noise
and interference protection for the maxDNA hardware.
Notice that the bottom rack of cabinet #1 is connected to the bottom rack of
cabinet #2 by a cable that runs from P11 to P9. This is because that results in
a shorter cable length than it would be had it run from P11 to P11. It is also a
much shorter cable length than if it had been run from the bottom of cabinet
1 to the top rack in cabinet 2.
To reiterate, when cabling the I/O racks together, the goal is to keep the I/O
bus length as short as possible. Connecting the cables on alternate sides of
the racks so that the I/O bus flows through from one rack to the next does
this.
Note that the ribbon cable connectors are keyed. The color stripe on the
ribbon cable should match pin 1 on the backpanel connector. Connector pin
1 is indicated by a white triangle symbol on the backpanel adjacent to the
connector.
A bus terminator (CPO402) must be installed at the end of the I/O bus
farthest from the DPU. The bus terminator is a small PC card assembly that
is designed to plug in to the I/O bus connector. When installing a terminator,
be sure to match its pin 1 indication to the pin 1 indication on the backpanel.
In Figure 1-5a, the terminator is shown inserted into connector P9 of the top
rack in cabinet 2. That is the point on the bus that is farthest from the DPU.
If you add I/O racks to your system at a later date, remember to move the
terminator from its old location to the new end of the bus.
I/O Bus Terminators are not used to provide impedance matching. They are
simply pull-up resistors that are used to improve the rise time of the open
collector I/O bus signals. For that reason, in some instances (e.g., a system
with both maxPAC and 564-style I/O connected with long cable runs), an
additional terminator at the DPU end might be required. Monitor the I/O Bus
Errors and, if your system seems to have an excessive amount, try adding the
additional terminator.
Refer to the Bus Extender Module chapter in this manual for information on
how to install terminators when BEMs are present in the system.
Cabinet #2 Cabinet #1
Terminator
D
P9 P P9
P11 P11
P10 U P10
D
P9 P P9
P11 P11
P10 U P10
P9 P9
P11 P11
P10 P10
P9 P9
P11 P11
P10 P10
Redundant I/O P9
P11 DPU
Primary
P10
Redundant I/O P9
P11 DPU
Secondary
P10
I/O Bus Cable
Terminator
Redundant I/O P9
P11 Primary
P10
Terminator
Redundant I/O P9
P11 Secondary
I/O Backup Cable
P10
(047472)
Redundant P9
P11 DPU
I/O - Primary
P10
Redundant P9
P11 DPU
I/O - Secondary
P10
I/O Bus Cable
Terminator
Redundant P9
P11 I/O - Primary
P10 Pri
Com
Terminator
Redundant P9
P11 Sec
I/O - Secondary
Y-Cable
P10
Terminator
Shared P9
P11
I/O
P10
Notes:
1. Keep the redundant I/O racks close to the DPUs that drive them.
2. Place the Y-Cable close to the I/O bus connectors (P10) on the redundant racks.
Put the DPU at one end of the I/O bus. Never put the DPU in the middle.
Terminate the far end of the I/O bus (the end farthest from the DPU).
The limit of 60 modules per bus segment is based upon the electrical
characteristics of the bus drivers. Other considerations such as the
types of modules used, the use of BEMs and the availability of DPU
resources may change the number and types of modules permitted.
Thus, it is very important that the user verify the correctness of the
proposed configuration by running the I/O Configuration Tool. Refer
to Publication 278609 for more information on the tool.
For I/O bus connections to a cabinet outside the cabinet group, use the
following cables:
For applications that require I/O bus connections between maxPAC racks
and Model 564 I/O racks, the following cables are available. Note that
Model 564 I/O racks do not support flow through cabling so they will
connect to the I/O bus as stubs.
DPU Modules
The DPU4E requires the use of the six-wide chassis and is mounted in the
right most position. DPU4F is mounted in the left most position of the 8-
wide chassis to take advantage of the airflow. Likewise, when using a
second DPU for backup, it is mounted on a second chassis beneath the
primary DPU.
Before mounting I/O modules, you should complete power and grounding
and field wiring and any I/O module preparation and adjustment. See
appropriate chapters in this publication to check correct addressing and
jumper selection on the modules.
Model IOP I/O is designed to allow module installation and removal with the
+24Vdc power supply ON.
To mount modules:
2. When the contacts are engaged and resistance is felt, firmly press on the
front panel of the module front plate to make the simultaneous
connections at the front and rear. Apply pressure to the left of the LEDs
to place the force directly in line with the printed circuit card of the
module.
3. Secure module to chassis assembly with the top and bottom lock-down
screws on the front of the module.
Module Addressing
You must set addresses for each I/O module using rotary switches mounted
in the lower or upper right corner of the printed circuit board of the module,
depending on module type. These hexadecimal switches permit 255 logical
addresses (hexadecimal FF is not available). The lower switch is the low
order address and the upper switch is the high order address.
maxPAC modules use one, two, four or eight addresses. The address set on
the module is its base address. For the eight-address module the base address
is the address of channel 1. The module will automatically occupy an address
for each of its channels, starting with its base address.
1. Multiply the low order switch setting by 1 to get the decimal equivalent,
where switch positions A to F correspond to 10 to 15, respectively.
3. Add the two decimal equivalents for logical (decimal) module address.
Shared Configuration
A shared I/O configuration uses a primary DPU, a secondary DPU, and one set
of Model IOP parallel modules. See Figure 1-6. Both DPUs share the I/O bus
but only the active DPU (primary or secondary) receives data from, and sends
data to, the set of common I/O modules.
Redundant network
D D
P P
U U
I/O Bus
I I I I I I I I I I
O O O O O O O O O O
Redundant Configuration
A redundant I/O configuration uses a primary DPU, a secondary DPU, and
two identical sets of Model IOP parallel modules. See Figure 1-7. The
primary and secondary DPUs receive data from, and send data to, their set of
I/O modules. Outputs from the inactive string of modules are inhibited until
they become active. It is necessary to install a Part No. CPO309 cable
between the two I/O strings as shown; this cable inverts the output-enable
signal so that outputs of the inactive I/O string are disabled.
D D
P P
U U
I/O B us
I I I I I I I I I I
O O O O O O O O O O
C P O 3 09
Mixed Configuration
A mixed configuration uses a primary DPU, a secondary DPU, a Y adapter,
two identical sets of redundant Model IOP parallel modules, and various other
common Model IOP modules. See Figure 1-8. The primary and secondary
DPUs receive data from, and send data to, the redundant modules. The active
DPU (primary or secondary) also receives data from, and sends data to, the
common set of I/O modules.
Redundant network
D D
P P
U U
I I I I I I I I I I
O O O O O O O O O O
Backup
Adapter
I I I I I
O O O O O
Remote I/O
A Bus Expander Module (BEM) permits the I/O bus to be extended up to
2,000 meters using highly reliable and noise immune fiber optic cables.
BEMs, configured in pairs, support both locally and remotely mounted I/O
cards. In a typical configuration using redundant Distributed Processing
Units (DPUs), an I/O cabinet installed locally in a control room contains I/O
modules, a DPU pair, and a BEM pair. This is connected via I/O optical
cable to a ruggedized remote cabinet containing I/O modules, and a second
BEM pair. The optical link is established between the local and remote
expander modules. Any DPU or redundant pair of DPUs, can communicate
with I/O that are locally and/or remotely mounted. Figure 1-9 shows a
typical configuration with both redundant and common local I/O and
common remote I/O. The Y adapter would also be required at the remote
end to support both common and redundant remote I/O.
redundant network
D D
Y
P ADAPTER P
U U
B B
E E
M M Control
backplane backplane
Room
I I I I I I I I
O O O O O O O O
Optical
Cable
Remote
B B location
E E
M M
I I I I I I
O O O O O O
I I I I I I I I
O O O O O O O O
Specifications
Environment
The Model IOP I/O operates in the temperature range of 0C to 60C at a
relative humidity range of 0 to 90%, noncondensing.
I/O Bus
The Model IOP I/O uses an 8-bit parallel asynchronous I/O bus, capable of
10 microsecond transfers. The I/O bus interface uses LSI circuitry for better
reliability. Parity checks are performed on all inputs and outputs, with
additional security provided for outputs using a check-before-execute control
strategy.
Inputs/Outputs
All modules, both analog and digital types, withstand the normal or common
mode connection (IEEE-472, ANSI c37.90) and still maintain correct
operation. Common mode transients are bypassed to chassis metal work. All
points are optically isolated from the maxDNA I/O bus. Channel to channel
isolation allows series or parallel connection between channels or external
relay systems. All digital modules have logic state indication on the front
panel, one indication per point.
Overview
This module, featuring 16 isolated input channels, can be configured for any
mix of voltage or current inputs. The current loop can be powered from a
field supply or from a system loop supply provided via the backplane edge
connector. For current inputs, this module is pin and function compatible
with the IOP302 input module.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the
DPU. This LED blinks on and off when the module is not being scanned by
the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For
use as a replacement for a Model 564 module this module requires 16 bus
addresses and provides 15 channels. The addressing rules specified in the
Model 564 manuals still apply.
When used as a maxPAC module, the module only requires two bus
addresses and provides 16 channels. Each module address must be on an
even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to
31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers, located near the address switches. Refer
to the following table for jumper setting information.
In addition, five jumpers per channel determine the type of input connected
to the channel.
Input Type A B C D E
4-20 mA powered by Metso IN IN IN IN OUT
Automation
4-20 mA powered by user IN IN OUT OUT IN
Voltage input OUT OUT OUT OUT IN
Program Resistors
Jacks are provides at the front of the module for the installation of a pair of
resistors per channel. These resistors can be used to scale a voltage input to
the 2.4V span of the A/D measurement. These resistors are identified as
follows:
Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Series R 1 7 26 32 51 57 78 85 113 120 142 148 175 193 211 233
Shunt R 3 10 29 35 53 60 80 88 115 123 144 151 177 196 215 234
The input circuit configuration for each type of input is shown in the
following sketch. An electronic fuse protects the 24-volt loop power to the
transmitter. A 200-Ohm thermistor in series with the 4-20 mA input provides
current limiting for voltages up to 100 Volts. The 24-volt loop supply is
available to the module from the backplane. For current inputs with external
shunt the channel is configured for voltage input and Rs = 0.
24V(+)
24V(-)
From backplane
1A 1B
200
2
Rs
+
100 A/D
Xmitter Rp
1
1D -
24V 1E
1C
4-20 ma powered by system
200 1A 1B
2
+ +
Rs 100 A/D
Voltage Rp
1D -
- 1
1E
1C
Voltage input
200 1A 1B
+ Rs
+
A/D
100
Xmitter Rp
1 1D -
-
1E
1C
4-20 ma powered externally,
internal shunt
Module Operation
This microprocessor-based module supports up to 16 isolated high level
inputs. A sigma delta A/D and precision reference is provided for each pair
of inputs. The A/D reads the voltage generated by the selected input and
converts the differential measurement to a 15-bit plus sign binary value
5V - logic
Regulator 24V
DC/DC
REF FLASH
Channel 1
Multiplexer OPTO
A/D 1
Channel 2
uC
FPGA
Optical isolation I/O Bus
between each pair
of channels
DC/DC
REF
Channel 15
Multiplexer
OPTO
A/D 8
Channel 16
optical isolation
field to logic
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
Module specifications
Resolution 15 bits plus sign
Scan Rate 100 msec.
Temperature Sensitivity 0.004% of reading/oC 1.5uv/oC RTI
Accuracy 0.1% of full scale at 25oC
Source Impedance Effect 10 Mohm operational, 20K Ohms on loss of power
Conversion method Sigma Delta oversampling. Single A/D per
channel
Span 4 to 20 mA, 0-2.4V
Calibration Self-calibration on power up. Periodically on line
to compensate for temperature effects
Input Impedance - 4-20 mA input 300 Ohms
- voltage input 1 Mohm
Normal Mode Voltage 50 Volts
Normal Mode Rejection 60db @ 50/60 Hz
Common Mode Voltage 500 Volts dc or peak ac
Common Mode Rejection 120db @ 50/60 Hz, 100 Ohm imbalance
Isolation 1500 Vac (field to logic)
500 Vac (channel to channel)
Input Power 400 mA
(from 24V system supply)
Field Wiring
P2 P3
1 1
24V,In(-) 24V,In(-)
Channel 1 Channel 9
2 2
In(+) In(+)
3 3
24V,In(-) 24V,In(-)
4
Channel 2 Channel 10
4
In(+) In(+)
5 5
24V,In(-) 24V,In(-)
6 Channel 3 6 Channel 11
In(+) In(+)
7 7
24V,In(-) 24V,In(-)
8 Channel 4 8 Channel 12
In(+) In(+)
9 9
24V,In(-) 24V,In(-)
10 Channel 5 10 Channel 13
In(+) In(+)
11 11
24V,In(-) 24V,In(-)
12 Channel 6 12 Channel 14
In(+) In(+)
13 13
24V,In(-) 24V,In(-)
14 Channel 7 14 Channel 15
In(+) In(+)
15 15
24V,In(-) 24V,In(-)
16 Channel 8 16 Channel 16
In(+) In(+)
The connection to the (-) terminal of the 24v supply must be made at the (-)
side of the shunt resistor. The voltage that is developed across each 100-Ohm
shunt by the 4-20 mA signal from the transmitter is wired to the AI module
using twisted pair cables. A PTC thermistor is recommended between the
transmitter output and the 100-Ohm shunt. This protects the 100-Ohm shunt
against over voltage and provides additional resistance to increase the
transmitter load to 250 Ohms. Kit IOP306 supplies 16 pairs of 100-Ohm
shunts and thermistors to support two IOP301 analog input modules.
Twisted pair
(-)
4 wire
Transmitter 100
(+)
thermistor Primary
IOP301
AI Module
(-)
(+)
Secondary
IOP301
AI Module
(-)
(+)
Secondary
IOP301
AI Module
Overview
The IOP302 module features sixteen 4-20 mA common input channels. The
IOP305 module features 16 voltage input (not current input) channels.
Transmitter loop power is available to the module via the backplane,
providing individually fused 24V transmitter power for each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the
DPU. This LED blinks on and off at a constant rate when the module is not
being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For
use as a replacement for a Model 564 module this module requires 16 bus
addresses and provides 15 channels. The addressing rules specified in the
Model 564 manuals still apply.
When used as a maxPAC module, the module only requires two bus
addresses and provides 16 channels. Each module address must be on an
even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to
31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers. Refer to the following table for jumper
setting information.
Module Operation
This microprocessor-based module supports up to 16 4-20 mA inputs, all
powered from a local 24V loop supply. A sigma delta A/D and reference are
provided for each input. Each A/D constantly reads the voltage generated by
the input and converts the differential measurement to a 15-bit plus sign
binary value, which is read by the microcontroller.
The microprocessor provides the input data to the DPU on demand via the
bus FPGA. The FPGA provides the I/O bus interface logic; its program is
loaded from the FLASH on power up. Module calibration is done
automatically at power up following startup diagnostics. Calibration is
repeated periodically online to compensate for temperature effects.
5V - field 5V - logic
DC/DC Regulator 24V
REF FLASH
Signal
Channel 1 Conditioning A/D
OPTO uC
FPGA
I/O Bus
Signal
Channel 16 Conditioning A/D
The input circuit for each channel of the 4-20 mA input module is shown in
the following sketch. An electronic fuse protects the 24V loop power to the
transmitter. A 200-Ohm thermistor in series with the input provides current
limiting for overvoltage conditions up to 100 Volts. The 24-volt supply is
available to the module from the backplane.
Current Limit
200
100 A/D
24V(-)
From backplane
24V(+)
Fuse
The following sketch shows the input circuit for the voltage-input module.
A/D
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
Module Specifications
Resolution 15 bits plus sign
Scan Rate 20 msec.
Temperature Sensitivity 0.004% of reading/oC 1.5uv/oC RTI
Accuracy 0.1% of full scale at 25oC
Source Impedance Effect 10 Mohm operational, 20K Ohms on loss of power
Conversion method Sigma Delta oversampling. Single A/D per channel
Span 4 to 20 mA, 0-2.4V.
Calibration Self-calibration on power up. Periodically on line to
compensate for temperature effects
Input Impedance IOP302, 300 Ohms; IOP305, 1mOhm
Normal Mode Voltage IOP302, 50 Volts; IOP305, 24 Volts
Normal Mode Rejection 60db @ 50/60 Hz
Common Mode Voltage 100 volts dc or peak ac for the group
Common Mode Rejection 120db @ 50/60 Hz, 100 Ohm imbalance
Isolation 1,500 Vac field to logic
Input Power 125 mA
(from 24V system supply)
1 1
24V 24V
Channel 1 Channel 9
Transmitter 2 Transmitter 2
Iin Iin
3 3
24V 24V
Channel 2 Transmitter
Channel 10
Transmitter 4 4
Iin Iin
5 5
24V 24V
Transmitter 6 Channel 3 Transmitter 6 Channel 11
Iin Iin
7 7
24V 24V Channel 12
Channel 4
Transmitter 8 Transmitter 8
Iin Iin
9 9
24V 24V
Channel 5 Transmitter
Channel 13
Transmitter 10 10
Iin Iin
11 11
24V 24V
Channel 6 Transmitter
Channel 14
Transmitter 12 12
Iin Iin
13 13
24V 24V
Transmitter Channel 7 Transmitter 14 Channel 15
14
Iin Iin
15 15
24V 24V
Transmitter 16 Channel 8 Transmitter 16 Channel 16
Iin Iin
P2 P3
1 1
(-) (-)
Channel 1 Channel 9
0-2.4V 0-2.4V 2
2
(+) (+)
3 3
(-) (-)
0-2.4V Channel 2 0-2.4V
Channel 10
4 4
(+) (+)
5 5
(-) (-)
0-2.4V Channel 11
0-2.4V 6 Channel 3 6
(+) (+)
7 7
(-) (-)
Channel 4 Channel 12
0-2.4V 0-2.4V 8
8
(+) (+)
9 9
(-) (-)
0-2.4V Channel 5 0-2.4V 10 Channel 13
10
(+) (+)
11 11
(-) (-)
Channel 6 0-2.4V Channel 14
0-2.4V 12 12
(+) (+)
13 13
(-) (-)
0-2.4V Channel 7 0-2.4V 14 Channel 15
14
(+) (+)
15 15
(-) (-)
0-2.4V Channel 8 0-2.4V 16 Channel 16
16
(+) (+)
The recommended maximum distance between the shunt resistor and the I/O
module is 10 meters. The +24V connection is independently fused to each
transmitter. The voltage that is developed across each 100-Ohm shunt by the
4-20 mA signal from the transmitter is wired to the AI module using twisted
pair cables.
The (-) terminal of the loop supply is connected to the (-) side of the shunt
resistors so that the 4-20 mA current does not flow through the twisted pairs
wires. A PTC thermistor is recommended between the transmitter output and
the 100-Ohm shunt. This protects the 100-Ohm shunt against over voltage
and provides additional resistance to increase the transmitter load to 250
Ohms. Kit IOP306 supplies 16 pairs of 100-Ohm shunts and thermistors to
support two IOP305 analog input modules.
(+)
DCS 24V
Loop Supply
(-)
Twisted pair
(-)
100
Transmitter
(+)
2-wire
thermistor
Primary
IOP305
AI Module
(-)
(+)
Secondary
IOP 305
AI Module
Overview
This module features 8 isolated 3-wire RTD input channels.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the
DPU. This LED blinks on and off when the module is not being scanned by
the DPU. It is also used to display errors detected by diagnostics.
Bus Address
This module supports two modes of operation selected by jumper setting. For
use as a replacement for a Model 564 module this module requires 8 bus
addresses and provides 7 channels. The addressing rules specified in the
Model 564 manuals still apply.
When used as a maxPAC module, the module only requires two bus
addresses and provides 8 channels. Each module address must be on an
even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to
31 are reserved for digital input modules.
Jumper Configuration
The module contains three jumpers. Refer to the following table for jumper
setting information.
Module Operation
This microprocessor-based module supports up to 8 RTD inputs, which can
be independently configured. A reference excitation current is provided for
each input. A sigma delta A/D reads the voltage generated by one of the eight
inputs and converts the differential measurement to a 15-bit plus sign binary
value representing the millivolt input, which is read by the microcontroller.
Multiple readings are done for each channel to compensate for the error
introduced by the field wiring in 3-wire RTDs. The microcontroller initiates
the conversion and waits for the conversion to complete. The digital filter in
the oversampling A/D provides excellent 50/60 Hz normal mode rejection.
The A/D also provides a variable gain amplifier function. Prior to starting
each conversion, the microcontroller sets the gain required in the A/D and
selects the RTD excitation current based on the configuration for that input.
It also selects the input channel by means of four solid-state optically
coupled relays.
The inputs are multiplexed with optical relays to provide channel to channel
isolation. Immediately following each measurement, open RTD and over
range conditions are checked. A DC/DC converter provides isolated power to
the field side of the measuring circuit. Communication between the
microcontroller and the A/D is serial at 100kHz.
Optical isolators provide the isolation between the A/D and the serial logic
circuits. The microprocessor provides the input data to the DPU on demand
via the bus FPGA. The FPGA provides the I/O bus interface logic; its
program is loaded from the FLASH on power up.
5V - logic
5V - field DC/DC Regulator 24V
Excitation
FLASH
Current
Channel 1 REF
Channel 8
optical isolation
field to logic
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
Module Specifications
Resolution 15 bits plus sign
Scan Rate 8 points converted in 1.6 seconds
Input Type 10 ohm Cu, 10 ohm Pt, 25 ohm Pt, 100 ohm Cu,
100 ohm Pt, 100 ohm Ni, 1000 ohm Pt
Input Range 0 1000 ohms
Temperature Sensitivity 0.004% of reading/oC 1.5uv/oC RTI
Accuracy 0.15% of reading 0.5oC
Input Multiplexer Solid-state FET, optical isolation
Conversion method Sigma Delta oversampling
Linearization Digital in DPU. RTD ranges may be randomly
mixed.
Calibration Self-calibration on power up. Periodically on
line to compensate for temperature effects.
Maximum Lead Resistance 5 Ohms each lead
Compensation
Backup Conversions disabled if common RTD is
connected to redundant modules.
Conformity Error 0.3oC, 0.5oF
Normal Mode Rejection 60db @ 50/60 Hz
Common Mode Rejection 120db @ 50/60Hz, 100 Ohm imbalance
Common Mode Voltage 240V rms, 350V dc peak
Input Power 125 mA
(from 24V system supply)
Field Wiring
P2 P3
1 1
2 2
3 Channel 1 3 Channel5
4 4
5 5
6 6
7 Channel 2 Channel 6
7
8 8
9 9
10 10
11 Channel 3 11 Channel 7
12 12
13 13
14 14
Channel 4 Channel 8
15 15
11
16 11
16
(-)
Primary
IOP303
RTD Module
Ret
W2 not installed
(+)
(-) Secondary
IOP 303
RTD Module
Ret
W2 - not installed
Overview
This module features 16 isolated thermocouple of emf input channels
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the
DPU. This LED blinks on and off at a constant rate when the module is not
being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For
use as a replacement for a Model 564 module this module requires 16 bus
addresses and provides 15 channels. The addressing rules specified in the
Model 564 manuals still apply.
When used as a maxPAC module, the module only requires two bus
addresses and provides 16 channels. Each module address must be on an
even boundary (i.e. 32, 34, 50 etc.) in the range of 32 to 252. Addresses 0
to 31 are reserved for digital input modules.
Jumper Configuration
The module contains three jumpers. These jumpers are located at the rear of
the module above the edge connector. Refer to the following table for jumper
setting information.
Module Operation
This microprocessor-based module supports up to 16 TC or emf inputs,
which may be independently configured. A sigma delta A/D reads the
voltage generated by one of the 16 TC or emf inputs and converts the
differential measurement into a 15 bit plus sign binary value representing the
millivolt input, which is read by the microcontroller. The microcontroller
initiates the conversion and waits for the conversion to complete.
The inputs are multiplexed with optical relays to provide channel to channel
isolation. Immediately following each measurement, open TC and over range
conditions are checked. A DC/DC converter circuit provides isolated power
to the field side of the measuring circuit. Communication between the
microcontroller and the A/D is serial at 100kHz. Optical isolators provide the
isolation between the field side and the serial logic circuits. The
microprocessor provides the input data to the DPU on demand via the bus
FPGA. The FPGA provides the I/O bus interface logic; its program is loaded
from the FLASH on power up.
5V - logic
5V - field DC/DC Regulator 24V
FLASH
Channel 1 REF
A/D OPTO uC
Field Interface FPGA
Circuits I/O Bus
OPEN
TC
Channel 16
optical isolation
field to logic
Diagnostics
Module Specifications
Resolution 15 bits plus sign
Scan Rate 16 points converted in 1 seconds
Input Type Types B, D, E, G, J, K, N, R, S, T, Platinell II
Input Range +/-10mv, +/-25mv, +/-60mv, +/-100mv,
+/-250mv, +600/-250mv
Temperature Sensitivity 0.004% of reading/oC 1.5uv/oC RTI
Accuracy 0.15% of reading 0.5oC
Input Multiplexer Solid-state FET, optical isolation
Conversion method Sigma Delta oversampling
Linearization Digital in DPU. RTD ranges may be randomly
mixed.
Calibration Self-calibration on power up. Periodically on
line to compensate for temperature effects
RJ Compensation Digital in module
Open TC Detection Performed each reading (1,000 0hm
threshold)
Backup Conversions disabled if common TC is
connected to redundant modules
Conformity Error 0.3oC, 0.5oF
Reference Junction Error 0.25oC
Normal Mode Rejection 60db @ 50/60 Hz
Common Mode Rejection 120db @ 50/60 Hz, 100 Ohm imbalance
Common Mode Voltage 240V rms, 350V dc peak
Input Power 125 mA
(from 24V system supply)
Field Wiring
P2 P3
1 1
+ +
Channel 1 Channel 9
2 2
- -
3 3
+ +
4 Channel 2 4 Channel 10
- -
5 5
+ +
6 Channel 3 6 Channel 11
- -
7 7
+ +
8 Channel 4 8 Channel 12
- -
9 9
+ +
Channel 5 Channel 13
10 10
- -
11 11
+ +
12 Channel 6 Channel 14
12
- -
13 13
+ +
14 Channel 7 14 Channel 15
- -
15 15
+ +
11
16 Channel 8 11 Channel 16
16
- -
(+)
(-)
Primary
IOP304
TC Module
(+)
(-)
Secondary
IOP 304
TC Module
This module, featuring eight 4-20 mA output channels, receives power from
the 24V-system supply via the backplane edge connector. Loop power is also
available to the module via the backplane and is individually fused 24V for
each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the
DPU. This LED blinks on and off when the module is not being scanned by
the DPU. A second green LED provides the status of the loop power fuse
disconnect.
Bus Address
This module requires eight bus addresses and provides eight channels. Each
module address must be on a 0 or eight boundary (i.e. 32, 40, 48, etc.) in the
range of 32 to 240. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains four jumpers. Refer to the following table for jumper
setting information. Note: this is for the newer modules that have two rotary
address switches.
Module Operation
This microprocessor-based module supports up to eight 4-20 mA output
channels. Communication between the microcontroller and each output is
serial. The output request received from the I/O bus is translated by the
microcontroller into a pulse width modulated signal, which is transmitted to
each output circuit via a high-speed optical isolator. This optical isolator
provides the isolation between the logic and the field.
The duty cycle of the serialized output is proportional to the output level. The
output circuit converts this signal into 4-20 mA. Open load is detected and
reported to the DPU.
The FPGA provides the I/O bus interface logic; its program is loaded from
the FLASH on power up.
The 24-Volt loop supply is available to the module from the backplane. All
the outputs are connected to the loop supply.
AO Module
5V - logic
Regulator 24V
FLASH
4-20 ma
Channel 1 out D/A 1 OPTO
uC
Powered from field FPGA
24V supply I/O Bus
4-20 ma
Channel 8 out D/A 8 OPTO
optical isolation
field to logic
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
Module Specifications
Resolution 12 bits
Rise Time 750 msec.
Temperature Sensitivity 0.004% of reading/oC
1.5uv/oC RTI
Accuracy 0.1% of reading .05% of
span at 25oC
Span 4 to 20 mA.
Calibration Self-calibration on power up
with calibration jumper set
Load Impedance 0 800 Ohms
Input Power 175 mA
(from 24V system supply)
Field Wiring
P2
1
Iout
Channel 1
Load 2
Return
3
Iout
Channel 2
Load 4
Return
5
Iout
Load 6 Channel 3
Return
7
Iout
Channel 4
Load 8
Return
9
Iout
Load
Channel 5
10
Return
11
Iout
Load
Channel 6
12
Return
13
Iout
Load 14 Channel 7
Return
15
Iout
Load 16 Channel 8
Return
Current (+)
Loop
Controlled (-)
Device Primary
IOP320
AO Module
W2 not installed
W3 not installed
W4 - not installed
(+)
(-)
Secondary
IOP 320
AO Module
W2 not installed
W3 installed
W4 not installed
Overview
These modules feature 16 digital common inputs.
LED Indication
Individual red front-panel LEDs provide the input status indication for each
channel. A green LED, labeled Active at the bottom of the module front
panel, is on when system power is present and the module is communicating
with the DPU. This LED blinks on and off when the module is not being
scanned by the DPU. A second green LED provides the status of the loop
power fuse disconnect.
Bus Address
This module requires one bus address. The address range for digital input
modules is 0 to 31 (0 1F). The address range for digital input modules
configured as slow DIs is 32 to 254.
Module Operation
The following is a simplified sketch of the circuit for one channel. The
signal-conditioning block provides filtering, current limiting circuit, and an
input threshold. It also includes the input status LED. The optical isolator
provides isolation between the field circuits and the logic circuits. The input
status is buffered and latched in the I/O bus interface circuit. The data is
presented to the I/O bus as a 16-bit word when the module is scanned by the
DPU. A watchdog timer in the I/O bus interface circuit controls the operation
of the active LED, causing it to blink when the module is not scanned for 0.7
seconds.
The 24V/48V(+) and 24V/48V(-) loop power signals are connected to all the
channels. They are routed to the module from the backplane via a fuse
disconnect which is accessible from the front of the module.
24V/48V(-) 24V/48V(+)
Fuse disconnect
To other channels
Module specifications
IOP 330 24V IOP331 48V
Rated Input Voltage 24Vdc nominal, 40 Vdc 48Vdc nominal, 60V dc
maximum maximum
Input current per point 5 mA @ 24 Volts 5 mA @ 48 Volts
On-State Voltage 8.5 Volts 22 Volts
Isolation 250 VAC continuous, 1,500 VAC for 1 minute
User input to logic
Indicators 1 LED per point provides status indication.
LED provides power and communication indication.
LED provides loop power disconnect status
I/O Bus Address One address
Input Power 50 mA
(from 24V system supply)
Field Wiring
P2 P3
1 1
Channel 1 Channel 9
2 2
3 3
4 Channel 2 Channel 10
4
5 5
6 Channel 3 6 Channel 11
7 7
Channel 4 Channel 12
8 8
9 9
Channel 5 Channel 13
10 10
11 11
12 Channel 6 12 Channel 14
13 13
14 Channel 7 14 Channel 15
15 15
11
16 Channel 8 11 Channel 16
16
(+)
(-)
Primary
IOP30,331
DI Module
(+)
(-)
Secondary
IOP 330,331
DI Module
Overview
These modules provide16 isolated digital inputs
LED Indication
Individual red front-panel LEDs provide the input status indication for each
channel. A green LED, labeled Active at the bottom of the module front
panel, is on when system power is present and the module is communicating
with the DPU. This LED blinks on and off when the module is not being
scanned by the DPU.
Bus Address
This module requires one bus address. The address range for digital input
modules is 0 to 31 (0 1F). The address range for digital input modules
configured as slow DIs is 32 to 254.
Jumper Configuration
For IOP332 and IOP333, jumpers (W1W16) must be installed for AC
inputs.
Module Operation
The following is a simplified sketch of the circuit for one channel. The
signal-conditioning block provides filtering, current limiting circuit, and an
input threshold. It also includes the LED. The optical isolator provides
isolation between the field circuits and the logic circuits. The input status is
buffered and latched in the I/O bus interface circuit. The data is presented to
the I/O bus as a 16-bit word when the module is scanned by the DPU. A
watchdog timer in the interface circuit controls the operation of the active
LED, causing it to blink when the module is not scanned for 0.7 seconds.
Module Specifications
IOP 332 120V IOP333 240V IOP334 24V
Rated Input 120 Volts ac/dc nom. 240 Volts ac/dc nom. 24V dc nominal,
Voltage 180 Volts max 280 Volts max 40V dc max
Input current per 5 mA @ 120 Volts 5 mA @ 240 Volts 5 mA @ 24Volts
point
On-State Voltage 48 Volts dc 70 Volts dc 8.5 Volts dc
100 Volts ac
Isolation 60 VAC; 250 VAC continuous, 125 VAC; 1500 VAC for 1 minute
User input to
logic
Isolation 350 VAC continuous
Channel to
channel
Indicators 1 LED per point provides status indication
LED provides power and communication indication
Field Wiring
P2 P3
1 1
3 3
5 5
7 7
9 9
11 11
13 13
15 15
AC/DC 11
16 Channel 8 AC/DC 11
16 Channel 16
(-)
AC/DC
Primary
DI Module
(+)
(-)
Secondary
DI Module
This module provides eight isolated digital input channels. Each channel
provides a pair of digital inputs, which can be individually programmed to
support 24, or 48 Volt inputs.
Features
LED Indication
A red status LED is provided for each input. A green LED, labeled Active on
the module front panel, is on when system power is present and the module is
communicating with the DPU. This LED blinks on and off when the module
is not being scanned by the DPU.
Bus Address
This module only requires two bus addresses and provides 8 channels.
Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the
range of 32 to 252. Addresses 0 to 31 are reserved for digital input
modules. This module is compatible with DPU4E and DPU4F only.
Jumper Configuration
A two-position jumper is used to select the input voltage for each input. The
input number identifies the jumpers. The two positions are A and B as
follows:
Mode 7 Period
Time duration between the last onset of input1and the previous onset
of input1. The timebase frequency (0.5 usec/count) is counted
during this time. Input2 is not used. The measurement is updated at
the end of each detected period. Counts read by DPU represent the
average of the last four measurements.
Module Operation
This microprocessor based module supports up to 16 digital inputs. As
shown in the functional block diagram, the field circuits are used to detect
and optically isolate the digital inputs. High-speed optical isolators support
higher frequency inputs. The processor circuits implement the configured
timing functions and provide the interface to the I/O bus FPGA. The Time
Processor Unit (TPU) included in the 68332 processor is used to process the
timing functions. The TPU operates from microcode masked in 68332 ROM.
The 16 DI inputs are debounced in an FPGA and are available individually to
the processor TPU inputs.
Diagnostics
The module executes diagnostics on power up. To indicate any errors
detected during power-up or on-line operation the LED labeled active blinks
the first digit at a slower rate and the second digit at a faster rate.
Module specifications
Input voltage 24V, 48V jumper selectable
Input thresholds 24V 10 Volts
48V 20 Volts
Debounce 0-255 msec dynamically configured per
channel
Accuracy 1 cycle or 0.15%, whichever is greater
Maximum frequency 32KHz
Minimum Pulse Width 10 usecs
Common Mode Voltage 240Vac rms, 350V dc peak
Input Power 150 mA
(from 24V system supply)
Field Wiring
P2 P3
1 1
+ +
Input 1 Input 9
2 2
- -
Channel 1 3 Channel 5 3
+ +
4 Input 2 Input 10
4
- -
5 5
+ +
6 Input 3 6 Input 11
- -
Channel 2 7 Channel 6 7
+ +
Input 4 Input 12
8 8
- -
9 9
+ +
10 Input 5 10
Input 13
- -
Channel 3 11 Channel 7 11
+ +
12 Input 6 12 Input 14
- -
13 13
+ +
14 Input 7 14 Input 15
- -
Channel 4 15 Channel 8 15
+ +
11
16 Input8 11 Input 16
16
- -
Overview
These modules provide 16 Form A relays or 10 form C relays. The form A
outputs can be converted to form B via on-board jumpers.
LED Indication
Individual red front-panel LEDs provide the output status indication for each
channel. A green LED, labeled Active at the bottom of the module front
panel, is on when system power is present and the module is communicating
with the DPU. This LED blinks on and off when the module is not being
scanned by the DPU.
Bus Address
This module requires one I/O one bus address.
This module requires one bus address. The address range for digital output
modules is 32 to 254. Addresses 0 to 31 are reserved for digital input
modules.
Jumper Configuration
Jumper W1 configures all the outputs to either reset or fail in place when
there is no communications in the I/O Bus for more than 0.7 seconds.
Configuration is as follows:
For the IOP351 module, each channel can be strapped in the printed circuit
assembly for form A or form B operation per the following table. The default
configuration is form A for all channels.
Module Operation
The following is a simplified sketch of the circuit for one channel. The relay
drivers energize the relay coils and control the operation of the output LEDs
to correspond to the data in the I/O bus interface circuit. A watchdog timer in
the interface circuit controls the operation of the active LED, causing it to
blink when the module is not scanned for 0.7 seconds. It also controls the
state of the outputs on loss of communications.
5V Reg 24V
Channel 1
Channel 16
PROM
optical isolation
field to logic
Module Specifications
IOP 350 Form C IOP351 Form A/B
Maximum Switching 5 amps @ 250 VAC
Capacity 3 amps @ 30 VDC
0.3 amps @ 110 VDC
Number of Channels 10 16
Expected Relay Life Mechanical @ 180cpm - 5X10^6
Electrical @ 20cpm (resistive load) 10^5
Maximum Operating Speed 20cpm
Operating Time 15 msec. Maximum (excluding bounce)
Release Time 5 msec. Maximum (excluding bounce)
LED Indication 1 LED per point provides output status indication
active LED provides power and communication indication
I/O Bus Address One address
Input Power 400 mA
(from 24V system supply)
5V Reg 24V
Channel 1
Channel 16
PROM
optical isolation
field to logic
1 1
Channel 1 Channel 9
2 2
3 3
Channel 2 4 Channel 10 4
5 5
Channel 3 6 Channel 11 6
7 7
Channel 4 Channel 12
8 8
9 9
Channel 5 10 Channel 13 10
11 11
Channel 6 12 Channel 14 12
13 13
Channel 7 14 Channel 15 14
15 15
Channel 8 11
16 Channel 16 11
16
Wiring IOP350
P2 P3
1 1
Channel 1 2 2
Channel 6
3 3
4 4
5 5
Channel 2 Channel 7
6 6
7 7
8 8
Channel 3 Channel 8
9 9
10 10
11 11
Channel 4 Channel 9
12 12
13 13
14 14
Channel 5 Channel 10
15 15
11
16 11
16
Power (+)
Source
(-)
Primary
Switched Relay Module
Device
W1 installed
(+)
(-)
Secondary
Relay Module
W1 installed
Overview
The Bus Extender Unit (BEM) provides a flexible way to distribute the
system throughout the plant, resulting in reduced cabling costs and
installation time. Placing I/O in remote cabinets closer to a given process
typically reduces tray loading and the number of required junction boxes
since remote I/O cabinets are substituted. It also shortens wiring distances to
field devices, such as thermocouples and RTDs.
LED Indication
Individual green front-panel LEDs provide status indication for each channel.
The lower LED, labeled Active at the bottom of the module front panel, is on
when the BEM and its associated DPU are active. The LEDs labeled link1
and link2 indicate which optical link is operational.
Link Test
A link test pushbutton is provided to switch operation between the two
optical links. This can be used to verify that the two links are operational.
Bus Address
This module does not require a bus address.
Jumper Configuration
The module contains two jumpers located in the bottom right corner of the
board. Refer to the following table for jumper setting information.
installed locally in a control room contains I/O modules, a DPU pair, and a
BEM pair. This is connected via I/O optical cables to a ruggedized remote
cabinet containing I/O modules and a second BEM pair. The optical link is
established between the local and remote Extender modules as shown in
figure 11-1.
D D
P P
U U
Y Cable
B I I B
E / / E
M O O M
I I
/ /
O O
Optical Links Optical Links
B B
E E
M M
I I
/ /
O O
Figure 11-1. Optical Link between Local and Remote Extender Modules
Multiple BEMs can be connected to the I/O bus to allow multiple remote
locations for I/O. When multiple BEM modules are connected to different
parts of the system, all BEMs connected to a DPU must share the same I/O
bus as the DPU, as shown in figure 11-2. See also, "Redundant Configuration
Approaches."
I I B B B D
/ / E E E P
O O M M M U
Remote I/O Bus Area 1 Remote I/O Bus Area 2 Remote I/O Bus Area 3
Up to 45 Modules Up to 45 Modules Up to 45 Modules
Figure 11-2. The DPU Supports up to 60 Modules Locally and Up to 45 per Remote Location.
DPU Compatibility
The Extender is compatible with 4A, 4B and 4E DPUs, but is not compatible
with the earlier DPU3, DPU4 or controller file models. To use a bus
Extender with DPU 4A and 4B, firmware EPLD may need to be updated.
Contact Metso Automation Customer Care for assistance.
Important: Remember other factors limit the number of modules you may
configure, such as I/O mix, DPU loading, application requirements, etc. Such
BEM Operation
Each Extender module is packaged in a Model IOP I/O style printed circuit
board. Each board contains a chipset that includes a transmitter, receiver and
an optical transceiver. The transmitter converts the parallel data into serial
data, appends encoded error checking bits and sends the data serially over a
very fast fiber optic link (160 MBaud). The receiver decodes the serial data,
does error checking and converts the data back to the original parallel form.
The Extender also includes the buffers/darlingtons associated with the Model
IOP bus, bosfet switches to disconnect the backup DPU Extender from the
bus, and a CPLD to provide some small additional logic required to support
the operation of the chip set. The MACK condition (multiple modules on the
bus) is detected by the remote Extender transmitted over the link and
simulated locally for interpretation by the DPU.
Figure 11-3 shows a functional block diagram of the Bus Extender Module.
Operation is as follows:
I/O Bus Interface Buffers to duplicate both the DPU and I/O module bus
interface. The ACK signal from the module is detected at the remote end
transmitted by the link and simulated at the DPU end.
CPLD provides all the logic resources required by the link. This includes
latching and synchronizing the bus data to the frame clock, error detection
and link failover.
Receiver (Serializer) Converts the received TTL level serial stream into
parallel data.
Frame Clock 8 MHz clock initiates the serial conversion of the I/O bus
data. Thus a snapshot of the Model IOP bus is sent every 125 nsecs. This
corresponds to a serial speed of 160Mb of the optical transceivers.
Primary
DPU
OUT/IN
Local Bus Remote Bus
Expanders Fiber Expanders
LO/HI
ADDR Receiver
Transmitter
DATA B
u
LATCH f
f
INT
e Redundant Remote
Redundant CPLD
r CPLD Fiber Optic
Fiber Optic 564 Bus
s Transceiver B
Transceiver
DATA[8..0] u
M M
A
f
C
Fiber A
f
OUT/IN
C
K K e
Receiver LO/HI
ACK
Transmitter r
s ADDR
XACK
DATA
ALT_IN
LATCH
Status INT
Secondary
DPU
DATA[8..0]
OUT/IN Fiber
B
LO/HI u
Receiver f
ACK
ADDR B Transmitter f
u e XACK
DATA r
f s ALT_IN
LATCH f
INT
e Redundant
Redundant
Fiber Optic
r Transceiver
Fiber Optic CPLD
CPLD Transceiver
s
DATA[8..0]
Fiber M
M
A A
C C
K K
Receiver Transmitter
ACK
XACK
ALT_IN
Status
Optical Transceivers Convert the TTL level transmit serial data into an
optical signal and the received optical signal into a TTL level serial data. A
second transceiver supports redundant links for single DPU applications. The
transmitter/receiver chip pair detects the operational state of the active link.
Optical Cabling
The two front-accessible optical transceivers, designated Link 1 (top link)
and Link 2 (bottom link), each have two ST type connectors, one to transmit
(Tx) and the other to receive (Rx). The fiber optic cable connects the transmit
output of one BEM to the receive input of the other BEM.
Termination Requirements
Two terminations are required on each electrical I/O bus segment; one at
each end of the bus. This rule applies to the local I/O bus (the bus segment
that contains the DPU) as well as to all remote I/O busses (bus segments that
contain only the BEM and I/O modules).
The Remote BEM I/O bus segment does not contain a DPU. Thus, two
terminator cards (CPO402) are required one plugged in to each end of the
Remote BEMs electrical bus. See the figure titled Termination of Local
and Remote BEM Busses.
D
P P9 P9
P11 P11 Terminator
U P10 P10
D B
P P9 P9
P11 P11 E
U P10 M P10
B
P9
P11 E
M P10 Fiber Optic Cables
Terminator P9
P11
P10
connected to its associated BEM only. A special cable (Part No. 047374)
must be used to connect the local I/O bus between the racks housing each
DPU. When this cable is used, jumpers in the following module types must
be set up for common I/O as follows:
At the remote location, the I/O bus connections to the BEMs end must be
isolated only for redundant I/O applications. For common I/O applications
the two remote BEM modules, connected to primary and secondary DPUs,
are connected to the same Parallel I/O backplane or daisy chained Parallel
I/O backplanes.
D D
Y
P CABLE
P
U U
B B
E E
M M Control
backplane backplane
Room
I I I I I I I I
O O O O O O O O
Optical
Cable
Remote
B B location
E E
M M
I I I I I I
O O O O O O
I I I I I I I I
O O O O O O O O
Figure 11-5. Redundant DPUs with local common and remote common I/O configuration using Y cable.
backplane
D
P
U
B
I I
E
O O
M
Control
Room
B I I I I
E Optical
Cable O O O O
M
To other
Locations Optical Redundant Cable
B
I I I Remote
E
O O O location
M
I I I I
O O O O
Figure 11-6. Single DPU with common and remote I/O configuration. The redundant optical cables shown in this
illustration are optional but recommended.
Although the BEM extends the Model IOP I/O bus up to 2000 meters, a time
delay factor reduces the maximum number of I/O modules that may be
installed beyond 400 meters. The time delay in the Extender circuit is
minimal; however there is a delay in the optical cable, introduced by the
speed of light, which is proportional to distance (approximately 1 x 10-9
sec/ft).
In configurations using a cable link no more than 400 meters in length, I/O
module reduction is minimal. See "Calculating Link Capacities."
In a series link, the links can be configured such that one BEM and DPU
connects to a remote's BEM and its rack. This rack then contains another
BEM, which is then connected to a second remote's rack with its BEM. This
configuration approach introduces time delays, which will limit the number
of supported modules. Consult the factory if more than two links are on one
DPU.
In configurations using redundant DPUs, each DPU can have its own bus
Extender to the remote location. Any single failure of the Extender or cable
will not result in loss of operation, and the replacement of the failed
component can occur without loss of service.
A failure in the remote location will only affect the remote I/O modules
associated with the remote Extender.
Refer to the front-panel LEDs and digital output to identify fault conditions
detected by the link, specifically loss of lock and receive error.
Use a front panel pushbutton to test the redundant links. The pushbutton
initiates a failover between the two links.
Cabling Recommendations
To augment cable reliability, Metso Automation recommends the following
cabling practices:
For configurations using either single or redundant pairs of BEMs, use two
separate, four-fiber optical cables (Part No. CON064-LLLL). Attach one
cable to Link 1 and the other cable to Link 2. As noted, route cables
separately to minimize the possibility of damage to both cables.
For each link connect two of the four available connector ends to the optical
transceiver connectors. The two extra, unused fibers in each cable serve as
spares in the event that the active fibers are cut or damaged.
Specifications
Model:
IOP371 Bus Extender Module (Part No. 181500)
Distance:
Up to 2000 meters
Speed:
Maintain Model IOP I/O bus communications
I/O addresses:
Up to 255 unique I/O addresses per DPU
Power Requirements
24 Volts @0.5 amps
Environment
The module operates in the temperature range of 0oC to 60oC at a relative
humidity range of 0 to 90%, noncondensing.
Optical cable
62.5/125 m multimode fiber optic cable
CON062-LLLL Two- fiber optical cable
CON064-LLLL Four-fiber optical cable
Operating wavelength
1300 nm.
QuadPAT
Module IOP336
QuadPAT Termination
Module IOP337
Overview
The maxPAC Quad Position Adjusting (QuadPAT) module in combination
with the maxPAC Quad PAT termination assembly produces PAT increase
and decrease outputs (120V or open collector) for single phase AC drive
units or three-phase power switches. The module accommodates 1000-ohm
slidewires or two-wire rotary position sensors. In addition, the maxPAC
Quad PAT termination includes the DI circuits for sensing the drive unit
limit switches.
Features
Self-calibration on power up
Software stored in FLASH
Field to logic Isolation
Channel-to-channel Isolation
Fast scan time
Front Panel
The QuadPAT front panel contains bicolor LEDs to report the status of the
increase and decrease outputs and limit switch for each channel and also
LEDs for module status indication. It also includes the two I/O connectors.
The top connector includes all the digital I/O and the analog signals are
available at the bottom connector.
LED Indication
A pair of bi-color LEDs provides I/O state indication for each QuadPAT
channel. The DO is the first LED of the pair and the DI is the second LED.
For normally closed limit switches (open at a limit) the LED indication for
each digital input and digital output pair is as follows:
In addition, the lower green LED, labeled Active at the bottom of the front
panel, is on when power is on and the DPU is communicating with the
module. The upper green LED at the bottom of the front panel indicates that
loop power is turned on.
Jumper Configuration
Refer to the following table for the jumper setting information that is
applicable to this module. Bold indicates the default position of the jumper.
Channel 1
Jumper Slidewire Rotary sensor
W11 A B
W12 C A,B
W13 A B
W14 Installed Not Installed
W15 A Not Installed
W16 Installed Not Installed
W17 Not Installed Installed
Channel 2
Jumper Slidewire Rotary sensor
W21 A B
W22 C A,B
W23 A B
W24 Installed Not Installed
W25 Installed Not Installed
W26 Not Installed Installed
W29 A Not Installed
Channel 3
Jumper Slidewire Rotary sensor
W31 A B
W32 C A,B
W33 A B
W34 Installed Not Installed
W35 A Not Installed
W36 Installed Not Installed
W37 Not Installed Installed
Channel 4
Jumper Slidewire Rotary sensor
W41 A B
W42 C A,B
W43 A B
W44 Installed Not Installed
W45 Installed Not Installed
W46 Not Installed Installed
W49 Installed Not Installed
Bus Address
This module requires four bus addresses and provides four channels. Each
module address must be a multiple of 4 (i.e. 32, 36, 40, 44, 56, etc.) in the
range of 32 to 248. Addresses 0 to 31 are reserved for digital input modules.
The two address rotary switches can be found at the upper right hand corner
of the module above the edge connector as follows:
Most Significant
Less Significant
DPU Compatibility
This module is only compatible with DPU4E and DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It
includes eight analog inputs, four analog outputs, 8 digital inputs and eight
digital outputs. Successive approximation 14-bit A/D converters digitize the
input signals in microseconds. Sixteen-bit digital to analog output
conversion also provides fast analog outputs. Both the analog inputs and
analog outputs self-calibrate on power up. Optical isolation is provided
between the field circuits and the logic. DC/DC converters provide isolated
power to the A/D converters and analog output circuits. The microprocessor
communicates serially with the field circuits via optical isolators.
The analog outputs provide the reference for the slidewires. The analog
inputs measure each slidewire feedback and reference. The digital outputs
provide increase and decrease signals to the triac circuits, while the digital
inputs monitor the state of the limit switches.
5V
DC/DC
24V
+/-15V DC/DC
4-20ma or
+/-10V D/A RAM
2 channels FLASH 64K
4-20 ma Optical Parity
2Mbit
Isolation
0-2.5V
4-20 ma A/D
0-2.5V 4 channels
4-20 ma
68332G CLOCK
Processor
5V
DC/DC 25MHz
DI1 DI8
FPGA
I/O Bus
Open I/O Bus
DO1 DOI8 Collector Interface
Drivers
Output
Virtual
Power
QuadPAT Termination
The IOP346 QuadPAT Termination interfaces with the QuadPAT module via
cable CTO301. It is a DIN rail mounted assembly with two 16-point Euro-
style plugs providing the interface for the field connections. The
QUADPAT module provides 24-volt power for the Termination circuits.
The termination assembly provides the following functions:
Each channel also includes digital input circuits to monitor the two limit
switches associated with each channel. The state of the limit switches is
provided to the DPU buffer.
Feedback Options
Rotary Sensor: Power to the sensor is supplied from the field 24V. The
sensor 4-20ma signal results in a 0.4 to 2V signal across the internal 100 ohm
sensing resistor. Overvoltage protection is provided for the 100 shunt. If a
shorted sensor or an open circuit is detected by the DPU, outputs to the
module are suspended.
Output Options
Single-Phase and Three-Phase Drive Units
TRIAC outputs require the use of the termination assembly.
DC Power Switch
Open collector outputs are wired directly from the module, and the
termination assembly is not required. A commoning strip is required for the
ground connections to the individual power switches. No IEEE surge
suppression is available for the open collector outputs.
The module detects the state of the drive unit limit switches via the
termination assembly. For Normally Closed switches, the module inhibits
drive unit motion when it detects an open limit switch in the direction of
travel. The module will ignore the limit switches if jumper SW4 is
installed. If Normally Open contacts are used, jumper SW4 must be installed
and any interlock while the limit is exceeded must be done in the control
logic or external hardware.
Redundant Configuration
Standby Mode
Standby mode is activated when a QUAD PAT module is one of a redundant
pair in a backup configuration and its DPU is inactive. All outputs from the
module will be suspended while in the standby mode. The slidewire
reference is also disabled in the standby mode.
Jumper Positions
Jumpers must be re-positioned to remove the 100-ohm slidewire end resistor
and the open slidewire detection resistor from the circuit. See jumper table.
These resistors must be mounted externally.
Jumper W2 is set to designate one module as primary and the other as
backup.
Jumper W5 is removed from both modules to defeat force INT.
Terminal Connections
When using the Quad PAT modules in a redundant configuration all
terminals must be wired in parallel.
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
1 1
DEC1 (DO01) Reference Out 1
2 2
INC1 (DO02) Feedback1/Field 24V
3 3
HI LIM1 (DI01) Return/AI In
4 4
LO LIM1 (DI02) Field Ground
5 5
DEC2 (DO03) Reference Out 2
6 6
INC2 (DO04) Feedback2/Field 24V
7 7
HI LIM2 (DI03) Return/4-20ma In
8 8
LO LIM2 (DI04) Field Ground
9 9
DEC3 (DO05) Reference Out 3
10 10
INC3 (DO06) Feedback3/Field 24V
11 11
HI LIM3 (DI05) Return/4-20ma In
12 12
LO LIM3 (DI06) Field Ground
13 13
DEC4 (DO07) Reference Out 4
14 14
INC4 (DO08) Feedback/Field 24V
15 15
HI LIM4 (DI07) Return/4-20ma In
16
16
LO LIM4 (DI08) Field Ground
17
24V
11
18
GND
Field P2 P1 module
1 1
CH1 120V ac CH1 Decrease
2 2
CH1 ac neutral CH1 Increase
3 3
CH1 ac neutral CH1 HI Limit
4 4
CH1 Decrease CH1 LO LIMIT
5 5
CH1 Increase CH2 Decrease
6 6
Hi Limit1 CH2 Increase
7 7
Limit Com CH2 Hi Limit
8 8
Lo Limit1 CH2 Lo Limit
9 9
CH2 120V ac
10 10
CH2 ac neutral
11 11
CH2 ac neutral
12 12
CH2 Decrease
13 13
CH2 Increase
14 14
Hi Limit2
15 15
Limit Com
16 16
Lo Limit2
17
24V
18
Logic Ground
Field P3 P1 module
1 1
CH3 120V ac
2 2
CH3 ac neutral
3 3
CH3 ac neutral
4 4
CH3 Decrease
5 5
CH3 Increase
6 6
Hi Limit3
7 7
Limit Com
8 8
Lo Limit3
9 9
CH4 120V ac CH3 Decrease
10 10
CH4 ac neutral CH3 Increase
11 11
CH4 ac neutral CH3 Hi Limit
12 12
CH4 Decrease CH3 Lo Limit
13 13
CH4 Increase CH4 Decrease
14 14
Hi Limit4 CH4 Increase
15 15
Limit Com CH4 Hi Limit
16 16
Lo Limit4 CH4 Lo Limit
17
24V
18
Logic Ground
AO01(4-20ma) AO01(4-20ma)
1 W15 A 1 W15 A
B B
AO01(+/-10V) AO01(+/-10V)
A A
W11 AuxAI01 W11 AuxAI01
B B
W16 W17
F1
W16 W17
F1
24VF1 24VF1
2 W12 2 W12
A A
AI01 AI01
C B C B
100K 100K
3 A W13 A W13
3
W14 W14
B therm B therm
F1 F1
4 shunt 4 shunt
F1 F1
AO02(4-20ma) AO02(4-20ma)
5 W29 W29
5
A A
AuxAI02 AuxAI02
W21 B W21 B
24VF1 24VF1
F1 F1
6 A 6 A
AI02 AI02
C
W22 B
W22 C B
F1 F1
shunt shunt
8 8
F1 F1
AO03(4-20ma) AO03(4-20ma)
9 W15 A 9 W35 A
B B
AO03(+/-10V) AO03(+/-10V)
A A
W11 AuxAI03 W31 AuxAI03
B B
W36 W37
F2
W36 W37
F2
24VF2 24VF2
10 W12 10 W32
A A
AI03 AI01
C B C B
100K 100K
11 A W13 A W33
11
W14 W34
B therm B therm
F2 F2
12 shunt 12 shunt
F2 F2
AO02(4-20ma) AO04(4-20ma)
13 W49 W49
13
A A
AuxAI04 AuxAI04
W41 B W41 B
24VF1 24VF2
F2 F2
14 A 14 A
AI04 AI04
C
W42 B
W22 C B
F2 F2
shunt shunt
16 16
F2 F2
P2 Termination P1 P2 Module
1
H
120 AC 2
N
3
DEC1 4
M
1 1
5 DO01
INC1
2 2
DO02
3 3
HI LIM 1 DI01
6
7 4 4
DI02
8
LO LIM 1 9
H
120 AC
N 10
11
DEC212
M
5 5
INC2 13 DO03
6 6
DO04
7 7
DI03
HI LIM 2 14
15 8 8
DI04
16
17 17
LO LIM 2 24V
18 18
GND
P3 Termination P1 P2 Module
1
H
120 AC 2
N
3
DEC3 4
M
9 9
5 DO05
INC3
10 10
DO06
11 11
DI05
6
HI LIM 3 12
7 12
COM DI06
8
LO LIM 3
9
H
120 AC
N 10
11
DEC4 12
M
13 13
INC4 13 DO07
14 14
DO08
15 15
DI07
HI LIM 4 14
15 16 16
COM DI08
16
LO LIM 4 17
17
24V
18 18
GND
P2 Module
Dec 1
Power DIO1
Switch Inc 2 DIO2
3
Dec 5
Power DIO3
Commoning Strip
Switch Inc
6 DIO4
7
9
Power DIO5
Switch 10
DIO6
11
12
13
Power DIO3
Switch 14
DIO4
15
16
17
24V
18
GND
Specifications
Power
24Vdc system supply 400 ma
Overview
The Turbine Valve Positioner module implements the logic for real-time
closed loop control of a single turbine valve. The module provides two
independent and electrically isolated channels. Each channel includes a coil
drive output and a position feedback input normally receiving inputs from
position transducers. Each channel also includes auxiliary inputs for
loopback measurement of the output signal.
In addition, a turbine speed input is provided as a service with the intent of
bringing back three speed signals, one on each of three Turbine Valve
Positioner modules for triple redundancy of speed input.
Pos
Valve
Pos > 4-20 ma
Pos
Mode
Governor or
Servo
Throttle Valve
Amp
Position Demand
+/- 10 volt or
K+ +/- 40 ma
Pos Servo
Amp
Err
Coil(s)
Status
Turbine
Speed Freq
Speed
Features
Self-calibration on power-up
Software stored in FLASH
Field to logic isolation
Channel-to-channel isolation
Fast Scan Time
Fast slew rate
Full complement of I/O
Frequency inputs
On-line diagnostics
Downloadable personality
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip
output and frequency input. Two bicolor LEDS, Stat 1 and Stat 2 provide
diagnostic indication
In addition, the lower green LED, labeled Active at the bottom of the front
panel, is on when power is on and the DPU is communicating with the
module. The upper green LED at the bottom of the front panel indicates that
loop power is turned on.
Jumper Configuration
The Turbine Valve Positioner module uses a multi-purpose-positioning
module with multiple jumper options as its base. The base module has four
AI/AO and eight DI/DO. Not all the jumpers are used for this application.
Jumpers W1-W4 at the rear of the module are for factory test only and
must not be installed. Refer to the following table for the jumper setting
information that is applicable to this module. Bold indicates the default
position.
Channel 1 Channel 2
Jumper Position Jumper Position
4-20ma +/-10V 4-20ma +/-10V
W11 B W21 A
W12 A, B W22 C
W13 B W23 B
W14 Not Installed W24 Not Installed
W15 A B W29 Not Installed
W16 OUT IN W25 OUT IN
W17 OUT IN W26 OUT IN
Channel 3 Channel 4
Jumper Position Jumper Position
4-20ma +/-10V 4-20ma +/-10V
W31 B W41 A
W32 A, B W42 C
W33 B W43 B
W34 Not Installed W44 Not Installed
W35 A B W49 Not Installed
W36 OUT IN W45 OUT IN
W37 OUT IN W46 OUT IN
Refer to the following table for the Turbine Valve Termination jumpers.
W11 and W12 select the resistance in series with the +/-10V or 4-20 ma
output from the Positioner module. W13 and W14 select the +/-40 ma
output or the output selected in the Positioner module (4-20 ma or +/-10V).
When the +/-40 ma output is selected, the +/-10V output must be selected in
the Positioner module. Bold indicates the default position:
Bus Address
This module consumes two bus addresses. The two address rotary switches
can be found at the upper right hand corner of the module above the edge
connector as follows:
Most Significant
Less Significant
DPU Compatibility
This module is only compatible with maxDPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes
four analog inputs, four analog inputs, 8 digital inputs and eight digital outputs. Four
auxiliary analog inputs are also included for diagnostic use. Successive
approximation 14-bit A/D converters digitize the input signals in microseconds.
Sixteen-bit digital to analog output conversion also provides fast analog output
current or voltage. Both the analog inputs and analog outputs self-calibrate on
power up.
+/-15V
24V DC/DC 24V
4-20ma or
+/-10V D/A
4-20 ma 2 channels
Optical
0-2.5V Isolation
4-20 ma A/D
0-2.5V 4 channels
4-20 ma
5V
DC/DC
24V
+/-15V DC/DC
4-20ma or
+/-10V D/A RAM
2 channels FLASH 64K
4-20 ma Optical Parity
2Mbit
Isolation
0-2.5V
4-20 ma A/D
0-2.5V 4 channels
4-20 ma
68332G CLOCK
Processor
5V
DC/DC 25MHz
DI1 DI8
FPGA RS232
I/O Bus
Open I/O Bus
DO1 DOI8 Collector Interface
Drivers
Output
Virtual
Power
The analog I/O is separated into two electrically isolated groups as shown in the
functional sketch. There is also optical isolation between the field circuits and the
logic. DC/DC converters provide isolated power to the A/D converters and analog
output circuits. The microprocessor communicates serially with the field circuits
via optical isolators.
Each of the four analog output circuits provides 4-20 ma. Two of the circuits
provide 10 to +10 volt outputs. The A/D in each group has four inputs. Two of
the inputs are used as auxiliary inputs for diagnostic monitoring of the analog
outputs.
It coverts the +/-10V signals to 0-2 volts plus sign to be fed to the
module for diagnostic loopback.
A current sense circuit measures the output current and provides a 0-2v
signal proportional to the current to the I/O module.
It conditions and isolates the frequency input and provides a 5-volt TTL
compatible signal to the module.
Configuration
The Turbine Valve Module provides a serial port for downloading the
configuration programs that are generated and compiled with the maxPAC
Positioning Module Compiler Tool. Up to nine programs (personalities) can
reside in the module FLASH. The interpreter code running in the module
executes any one of the nine personalities selected via the DPU. A module
personality typically defines an exchange of variable data between the DPU
POS Buffer and the module I/O and other parameters defined in the module
shell; it also includes the logic sequence that implements the required
application. See the maxPAC Positioning Module Programming Guide.
Calibration
The Turbine Valve Module can be configured via on-board jumper selection
to provide either a current or voltage output. The module is factory
calibrated for 4-20 ma current outputs and the calibration constants are stored
in FLASH. Calibration is only required when the FLASH program is
upgraded.
The Module Compiler provides functions that allow the user to either
override or restore the factory calibration values. When voltage outputs are
used, the factory calibration values for channels 1 and 3 must be changed to 0
and 65535. This can be accomplished by setting AOLo and AOHi for the
two channels in the first pass of the application program, or by downloading
a calibration program that overrides the values stored in FLASH.
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
The turbine valve module can also execute on line diagnostics to verify the
integrity of the loop. This test must be defined in the personality program.
The module shell includes four AOs (AO01-AO04), four AIs (AI01-AI04),
four Auxiliary AIs (AuxAI01- AuxAI04), eight DIs (DI01-DI08) and eight
DOs (DO01 DO08). These shell variables are associated with I/O signals
at the module I/O connector. The bipolar analog outputs generated by the
module are converted at the termination assembly to a 0-2V plus sign signal.
As shown in the Group1 Analog I/O configuration sketches at the end of the
chapter, the analog output from the module is buffered by the termination
and fed back to AuxAI02. The coil current is fed back to AI02, while the
sign is available as status DI02 (1 is negative).
The personality program must define the input types to be 0-2V. Also the
analog value read at those inputs must be sign adjusted. For example, the
configuration program includes the following code to define the input types
and adjust the sign.
If FirstPass
AIType01 = 1 ;4-20ma AI
AIType02 = 3 ;0-2V AI
AuxAIType02 = 3
EnableOutputs = 1
EndIf
If DI02 = 0
Coil1ACurRaw = AuxAI02
Coil1V = AI02
Else
Coil1ACurRaw = AuxAI02 * -1.0
Coil1V = AI02 * -1.0
EndIf
1 1
DO1 4-20 ma or +/-10V out
2 2
DO2 Ch 1-2 Field Power
3 3
DI1 4-20 ma input
4 4
DI2 Ch 1-2 Field Ground
5 5
DO3 Voltage Feedback
6 6
DO4 Voltage Feedback
7 7
DI3
8 8
DI4
9 9
DO5 4-20 ma or +/-10V out
10 10
DO6 Ch 3-4 Field Power
11 11
DI6 4-20 ma input
12 12
DI7 Ch 3-4 field Ground
13 13
DO7 Voltage Feedback
14 14
DO8 Voltage Feedback
15 15
DI7
16
16
DI8
17
24V
11
18
GND
1 1
Coil 1 (+) Field 24V_1
2 2
Coil 2 (-) Field Ret_1
3 3
Chassis Gnd 4-20 ma or +/-10V out
4 4
Field 24V_1 +/-10V_1 loopback
5 5
4-20ma input Coil_1 Current loopback
6 6
Coil 1 (+) Ch 1-2 Field Ground
7 7
Coil 2 (-) Field 24V_2
8 8
Chassis Gnd Field Ret_2
9 9
Field 24V_2 4-20 ma or +/-10V out
10 10
4-20ma input +/-10V_2 loopback
11 11
Coil_2 Current loopback
12 12
24V
13 13
frequency
DI2 (+/-10V_1 sign)
14 14
DI3 (+/-10V_2 sign)
0.2-10V
15 15
frequency
DI1 (frequency)
16 16
NO DO1
17
COM 24V
11
18
NC Logic Ground
Termination Module
P2 P1 P3
+/- 40 ma
W13
AO01(4-20ma)
50 50 62 50 3 1 W15 A
1
B
AO01(+/-10V)
Current W11 A
W11 AuxAI01
Sense B
2
Sign 1 Buffer F1
24VF1
F1
3 1 2 W12
A
24VF1 C AI01
B
4
24VF1 100K
4-20 ma 6 3 A W13
5
W14
B therm
F1
shunt
2 4
F1
F1
W29 AO02(4-20ma)
4 5
Output voltage
A
AuxAI02
W21 B
24VF1
F1
Output current 5 6 A C
AI02
W22 B
W23 100K
7 A
B therm W24
F1
shunt
8
F1
Termination Module
P2 P1 P3
+/- 40 ma
W14
AO03(4-20ma)
50 50 62 50 9 9 W35 A
6
B
AO03(+/-10V)
Current W12 A
W31 AuxAI03
Sense B
7
Sign 2 Buffer F1
24VF3
F2
8 7 10 W32
A
24VF2 C AI03
B
9
24VF2 100K
4-20 ma 12 11 A W33
10
W34
B therm
F2
shunt
8 12
F2
F2
AO04(4-20ma)
10 13 W49
Output voltage
A
AuxAI04
W41 B
24VF2
F2
Output current 11 14 A C
AI04
W42 B
W43 100K
15 A
B therm W44
F2
shunt
16
F2
Termination Module
P2 P1 P2
W1
24VF2
12
15 3
DIO1
13
13 7
W2 Sign 1 DIO3
14
Conditioning 14 8
15 Circuit Sign 2 DIO4
16
17 16 2
DO02
18
17 17
24V
18 18
GND
Specifications
Turbine valve Outputs
Analog
+/- 10 VDC at 40 ma. or
+/- 40 ma at 200 ohms max
4-20 ma (isolated 24V supplied from the system)
Accuracy:
+/-10V, 4-20 ma: 0.25% of full scale
+/- 40 ma: +/-1% of full scale
Resolution: 16 bits
Slew Time: 5 msecs
Digital
Form C Relay
5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC
Isolation
Galvanic isolation between two analog I/O groups.
Common mode between groups: 350V dc or peak ac
Galvanic isolation between field and logic: 500V
Power
24Vdc system supply 500 ma
Overspeed Trip
Module IOP345
Overspeed Termination
Module IOP346
Overview
The Overtrip module measures and processes turbine speed from three separate
tachometers based speed inputs without intervention from the DPU. If the
overspeed logic determines that two out of the three inputs exceed a defined
threshold, Trip contacts are energized to protect the turbine from an overspeed
condition.
Raw Speed3
F
Runback Status
Runback
Runback % > Output
The product consists of a maxPAC Overspeed Positioning Module and an Overspeed Termination
card. The Termination card provides signal conditioning and isolation for the frequency inputs and
also two form C relays.
The logic shown in the sketch is programmed in the maxDPU4F Atom Compiler
language and may be modified by a trained engineer via tools provided. It is one of
up to nine personalities that can be downloaded to the module and stored in flash
memory. A cable is provided for downloading the configuration. Personality
selection, the configuration, I/O status, and other signals are accessible via the
maxDPUF.
Features
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip
outputs and frequency inputs. Two bicolor LEDS, Stat 1 and Stat 2 provide
diagnostic indication
In addition, the lower green LED, labeled Active at the bottom of the front
panel, is on when power is on and the DPU is communicating with the
module. The upper green LED at the bottom of the front panel indicates that
loop power is turned on.
Jumper Configuration
The Overspeed module uses a multi-purpose-positioning module with
multiple jumper options. Not all the jumpers are applicable for this
application because the analog I/O is not used. Refer to the following table
for the jumper setting information that is applicable to this module.
Refer to the following table for the Turbine Valve Termination jumpers.Bold
indicated the default positions:
Bus Address
This module consumes two bus addresses.
Most Significant
Less Significant
DPU Compatibility
This module is only compatible with DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes
four analog inputs, eight analog inputs, 8 digital inputs and eight digital outputs.
The turbine overspeed application utilizes only the digital I/O portion of the module.
The unused analog portion is shown with dashed lines in the functional sketch.
Positioning Module
+/-15V
5V
DC/DC
24V
+/-15V DC/DC
4-20ma or
+/-10V D/A RAM
2 channels FLASH 64K
4-20 ma Optical Parity
2Mbit
Isolation
0-2.5V
4-20 ma A/D
0-2.5V 4 channels
4-20 ma
68332G CLOCK
Processor
5V 25MHz
DC/DC
DI1 DI8
FPGA RS232
I/O Bus
Open I/O Bus
DO1 DOI8 Collector Interface
Drivers
Output
Virtual
Power
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
P2 P3
1 1
DO01
2 2
DO02 24V Field Power
3 3
DI01
4 4
DI02 Field Ground
5 5
DO03
6 6
DO04
7 7
DI03
8 8
DI04
9 9
DO05
10 10
DO06
11 11
DI06
12 12
DI07
13 13
DO07
14 14
DO08
15 15
DI07
16 16
DI08
17
24V
11
18
GND
Field P2 P1 module
1 1
Field 24V
24V
frequency 2 2
Field 24V
3 3
Field Ground
0.2-10V
frequency 4 4
Field Ground
5 5
Frequency 1
24V 6
6
frequency
7 7
Frequency 2
0.2-10V
frequency 8 8
9 9
Frequency 3
24V
10 10
frequency
11 11
0.2-10V 12
frequency 12
13 13
NO DO01
14 14
COM DO02
15 15
NC 24V
16 16
NO 24V
17
COM Logic Ground
11
18
NC Logic Ground
Termination Module
P2 P1 P3
AO01(4-20ma)
1 W15 A
B
AO01(+/-10V)
A
W11 AuxAI01
B
1 F1
24VF1
2 2 W12
A
24VF1 C AI01
B
100K
3 A W13
W14
3 B therm
F1
4 shunt
4
F1
F1
AO02(4-20ma)
5 W29
A
AuxAI02
W21 B
24VF1
F1
6 A C
AI02
W22 B
W23 100K
7 A
B therm W24
F1
shunt
8
F1
AO03(4-20ma)
9 W35 A
B
AO03(+/-10V)
A
W31 AuxAI01
B
F2
24VF2
10 W32
A
C AI03
B
100K
11 A W33
W34
B therm
F2
12 shunt
F2
AO04(4-20ma)
13 W49
A
AuxAI04
W41 B
24VF2
F2
14 A C
AI04
W42 B
W43 100K
15 A
B therm W44
F2
shunt
16
F2
P2 Termination P1 P2 Module
W1
24VF2
12
5 3
DIO1
13
W2
14
Conditioning
15 Circuit
W3
24VF2
12
7 7
DIO3
13
W4
14
Conditioning
15 Circuit
W5
24VF2
12 9 11
DIO5
13
W6
14
Conditioning
15 Circuit 2
13
DO02
13
14
15
14 6
DO04
16
15
17
16 17
24V
18
17
18 18
GND
Specifications
Frequency Input:
Frequency: 0 -10KHz
Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz 10KHz.
Input voltage: 200 mv to 10V or 24V.
Digital Output
Form C Relay
5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC
Power
24Vdc system supply 500 ma
Temperature 0-60 degrees C
Humidity 0-90% no-condensing
Surge IEEE-472-1974
Overview
The set of HART maxPAC I/O modules provide eight isolated HART channels with
an independent HART modem/UART per channel. The analog input and output
modules support standard 4-20 ma signals in addition to the digital HART data. The
HART Transceiver card provides the same HART interface without analog input or
output capability; it is intended for adding HART capability to other analog input or
analog output modules.
H
A Features
R
T Fully isolated channels
Hart modem per channel
16 bit A/D and D/A Performance
Standard variables available in
maxDPUF for use in control
Custom interface for special
purpose control
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip
outputs and frequency inputs. Two bicolor LEDS, Stat 1 and Stat 2 provide
diagnostic indication
In addition, the lower green LED, labeled Active at the bottom of the front
panel, is on when power is on and the DPU is communicating with the
module. The upper green LED at the bottom of the front panel indicates that
loop power is turned on.
Jumper Configuration
The following are the jumper settings for the various HART modules.
Bus Address
These modules normally consume two bus addresses. The HART Output
module consumes eight addresses if set to be compatible with a standard
maxPAC analog output module.
Most Significant
Less Significant
DPU Compatibility
These modules are only compatible with DPU4F.
Module Operation
These microprocessor-based modules provide eight isolated channels of 4-20 ma
inputs or outputs, including the HART interface for each channel.
Hart Module
DC/DC 24V
***
4-20 ma AI or AO
Optical
Isolation
Hart
Modem
DC/DC
68332G CLOCK
Processor
25MHz
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
P1 P2
1 1
24V 24V
2 2
4-20 ma 4-20 ma
CH1 CH1
3 3
4 4
GND GND
5 5
24V 24V
6 6
4-20 ma 4-20 ma
CH2 CH2 7
7
8 8
GND GND
9 9
24V 24V
10 10
4-20 ma 4-20 ma
CH3 CH3
11 11
12 12
GND GND
13 13
24V 24V
14 14
4-20 ma 4-20 ma
CH4 CH4
15 15
16 16
GND GND
P1
1
(+)
CH1 4-20 ma in 2
(-)
3
(+)
CH2 4-20 ma in 4
(-)
5
(+)
CH3 4-20 ma in 6
(-)
7
(+)
CH4 4-20 ma in 8
(-)
9
(+)
CH5 4-20 ma in 10
(-)
11
(+)
CH6 4-20 ma in 12
(-)
13
(+)
CH7 4-20 ma in 14
(-)
15
(+)
CH8 4-20 ma in 16
(-)
P1
1
(+)
CH1 2
(-)
3
(+)
CH2 4
(-)
5
(+)
CH3 6
(-)
7
(+)
CH4 8
(-)
9
(+)
CH5 10
(-)
11
(+)
CH6 12
(-)
13
(+)
CH7 14
(-)
15
(+)
CH8 16
(-)
1A 1B From Backplane
200
24V(-)
4-20 ma 2
Rs
+
100
Xmitter
Rp A/D
1D -
1
1E
1C
HART
2 MODEM
4-20 ma 2
Rs
+
100
Xmitter
Rp A/D
1D -
1
1E
1C
HART
2 MODEM
(-)
24V
(+) Supply
AI Module - IOP301 24V(+)
From
24V(-) backplane
1A 1B
200
200 2
Rs
Xmitter +
100
100 Rp A/D
1D -
1
1E
1C
2
Rs
+
100
Rp A/D
1D -
1
1E
1C
HART
MODEM
2
200 2
Rs
+
100
100 Rp A/D
Xmitter
1D -
1
1E
1C
2
Rs
+
100
Rp A/D
1D -
1
1E
1C
HART
MODEM
2
Output
Device D/A
17
HART
2 MODEM
Output
Device D/A
2
HART
2 MODEM
Two-WireTransmitter
4-20 ma 1
24V HART AI Module
2 200 ohm
To HART modem
Four-Wire Transmitter
1
NOT USED
HART AI Module
24V
To HART modem
1 HART AI Module
24V(+) 24V
2 200 ohm
100ohm TO A/D
shunt
4
24V(-)
To HART modem
1 HART AI Module
24V
200 ohm
2
100ohm TO A/D
shunt
4
To HART modem
1 HART AI Module
24V
2 200 ohm
To HART modem
1 HART AI Module
24V
200 ohm
2
100ohm TO A/D
shunt
4
To HART modem
HART AO Module
Disconnect for redundant module
input. Closed when DPU active 24V(+)
1
4-20 ma HART
D/A
MODEM
OUTPUT
DEVICE
2
24V(-)
Redundant Modules
1
4-20 ma HART
D/A
MODEM
OUTPUT
DEVICE
2
24V(-)
HART AO Module
24V(+)
1
D/A HART
MODEM
2
24V(-)
Specifications
Input Specifications
Type: 4-20 ma
Resolution: 16 bits, A/D per channel
Scan time: 20 msecs.
Accuracy: 0.15% of full scale.
Normal Mode Voltage: 50 volts
Normal Mode Rejection: 60 db @50/60 Hz
Common Mode Voltage: 500 volts
Common Mode Rejection: 120 db @50/60 Hz
Isolation: Channel to channel and field to logic
Output Specifications
Type: 4-20 ma
Accuracy: 0.25% of full scale.
Resolution: 16 bits, D/A per channel
Slew Time: 10 msecs
Load: 250 600 ohms
Common Mode Voltage: 150 volts
Isolation: Channel to channel and field to logic
HART
Meets the HART Foundation physical layer requirements
Power
24Vdc system supply 500 ma
Temperature 0-60 degrees C
Humidity 0-90% non-condensing
Surge IEEE-472-1974