max

maxPAC Hardware Reference Guide

278596 Rev. A7

Metso Automation • 278596 •

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

Copyright © 2005 by Metso Automation MAX Controls, Inc.

Printed in the United States of America All Rights Reserved


Contents

PREFACE ............................................................................................................................III

CHAPTER 1...................................................................................................................... 1-1

maxPAC Input/Output Subsystem ............................................................................................................................1-1 Overview ...................................................................................................................................................................1-1

Model IOP I/O Subsystem.....................................................................................................................................1-1 Cabinet...............................................................................................................................................................1-1 Chassis Assembly ..............................................................................................................................................1-2 DPU Mounting ..................................................................................................................................................1-4 I/O Modules.......................................................................................................................................................1-4 I/O Module Types..............................................................................................................................................1-5

Power Supply.........................................................................................................................................................1-6 Field Termination Options.....................................................................................................................................1-7

Local Terminations (standard)...........................................................................................................................1-7 Remote Terminations (option)...........................................................................................................................1-7 Termination Assemblies ....................................................................................................................................1-7

Installing Model IOP I/O Equipment ....................................................................................................................1-8 Sequence of Mounting Operations ........................................................................................................................1-8 Mounting I/O Chassis Assemblies.........................................................................................................................1-9 Cabling, Power, and Ground Wiring .....................................................................................................................1-9

Supplying 24V Power to the I/O Modules ......................................................................................................1-10 Interconnecting I/O Racks ...............................................................................................................................1-10 Summary of Cabling Rules for maxPAC I/O ..................................................................................................1-14 maxPAC I/O Bus Cables .................................................................................................................................1-14

Module Mounting Considerations .......................................................................................................................1-16 I/O Modules ...................................................................................................................................................1-16 DPU Modules ..................................................................................................................................................1-16

Module Addressing .............................................................................................................................................1-17 Backup Configuration Options............................................................................................................................1-17

Shared Configuration.......................................................................................................................................1-17 Redundant Configuration ................................................................................................................................1-18 Mixed Configuration .......................................................................................................................................1-19

Remote I/O ..........................................................................................................................................................1-20 Specifications.......................................................................................................................................................1-22

Environment ....................................................................................................................................................1-22 I/O Bus.............................................................................................................................................................1-22 Inputs/Outputs .................................................................................................................................................1-22

CHAPTER 2...................................................................................................................... 2-1

Analog Input Modules Isolated Input Module IOP301............................................................................................2-1



Overview .................................................................................................................................................................. 2-1 LED Indication ..................................................................................................................................................... 2-1 Bus Address .......................................................................................................................................................... 2-2 Jumper Configuration ........................................................................................................................................... 2-2 Program Resistors ................................................................................................................................................. 2-2 Module Operation................................................................................................................................................. 2-3 Diagnostics ........................................................................................................................................................... 2-5 Module specifications ........................................................................................................................................... 2-6 Field Wiring.......................................................................................................................................................... 2-7 Field Wiring for Redundant Modules with Common Transmitter........................................................................ 2-8

CHAPTER 3 ...................................................................................................................... 3-1

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

CHAPTER 4 ...................................................................................................................... 4-1

Analog Input Modules 3 Wire RTD Module IOP303.............................................................................................. 4-1 Overview .................................................................................................................................................................. 4-1

LED Indication ..................................................................................................................................................... 4-1 Bus Address .......................................................................................................................................................... 4-2 Jumper Configuration ........................................................................................................................................... 4-2 Module Operation................................................................................................................................................. 4-2 Diagnostics ........................................................................................................................................................... 4-4 Module Specifications .......................................................................................................................................... 4-4 Field Wiring.......................................................................................................................................................... 4-5 Field Wiring For Redundant Modules with Common RTD ................................................................................. 4-6

CHAPTER 5 ...................................................................................................................... 5-1

Analog Input Modules TC Module IOP304 ............................................................................................................. 5-1 Overview .................................................................................................................................................................. 5-1

LED Indication ..................................................................................................................................................... 5-1 Bus Address .......................................................................................................................................................... 5-2 Jumper Configuration ........................................................................................................................................... 5-2 Cold Junction Compensation ................................................................................................................................ 5-2 Module Operation................................................................................................................................................. 5-2 Diagnostics ........................................................................................................................................................... 5-3 Module Specifications .......................................................................................................................................... 5-4 Field Wiring.......................................................................................................................................................... 5-5 Field Wiring For Redundant Modules with Common TC .................................................................................... 5-6

Contents

v

CHAPTER 6...................................................................................................................... 6-1

Analog Output Modules 4-20 mA Output Module IOP320.....................................................................................6-1 LED Indication ......................................................................................................................................................6-1 Bus Address...........................................................................................................................................................6-2 Jumper Configuration ............................................................................................................................................6-2 Module Operation..................................................................................................................................................6-3 Diagnostics ............................................................................................................................................................6-4 Module Specifications ...........................................................................................................................................6-5 Field Wiring...........................................................................................................................................................6-6 Field wiring for redundant modules with common end element ...........................................................................6-7

CHAPTER 7...................................................................................................................... 7-1

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

CHAPTER 8...................................................................................................................... 8-1

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

CHAPTER 9...................................................................................................................... 9-1

Digital Input Modules Counter Timer Module IOP335 ..........................................................................................9-1 LED Indication ......................................................................................................................................................9-1 Bus Address...........................................................................................................................................................9-2 Jumper Configuration ............................................................................................................................................9-2 Module Operation..................................................................................................................................................9-3 Diagnostics ............................................................................................................................................................9-4 Module specifications............................................................................................................................................9-4 Field Wiring...........................................................................................................................................................9-5

CHAPTER 10.................................................................................................................. 10-1

Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350 ..............................10-1 Overview .................................................................................................................................................................10-1

LED Indication ....................................................................................................................................................10-1



Bus Address ........................................................................................................................................................ 10-2 Jumper Configuration ......................................................................................................................................... 10-2 Module Operation............................................................................................................................................... 10-2 Module Specifications ........................................................................................................................................ 10-3 Field Wiring – IOP 351 ...................................................................................................................................... 10-5 Wiring – IOP350 ................................................................................................................................................ 10-6 Field Wiring For Redundant Modules with Common End Element................................................................... 10-7

CHAPTER 11 ................................................................................................................. 11-1

Bus Extender Unit Module IOP371 ....................................................................................................................... 11-1 Overview ................................................................................................................................................................ 11-1

BEM Front Panel ............................................................................................................................................ 11-2 LED Indication ................................................................................................................................................... 11-2 Link Test............................................................................................................................................................. 11-2 Bus Address ........................................................................................................................................................ 11-2 Jumper Configuration ......................................................................................................................................... 11-2

DPU Compatibility ......................................................................................................................................... 11-4 I/O Bus Loading ............................................................................................................................................. 11-4

BEM Operation................................................................................................................................................... 11-5 Optical Cabling............................................................................................................................................... 11-7 Model 564 and maxPAC I/O Compatibility ................................................................................................... 11-7 Termination Requirements.............................................................................................................................. 11-7

Redundant Configuration Approaches................................................................................................................ 11-8 Four Configuration Approaches ..................................................................................................................... 11-8 Configuring Remote I/O only ......................................................................................................................... 11-8 Configuring Local Common I/O..................................................................................................................... 11-8 Configuring Mixed Common and Redundant I/O .......................................................................................... 11-9 Single DPU Configurations .......................................................................................................................... 11-10

BEM Configuration Considerations ................................................................................................................. 11-12 Calculating Link Capacities.......................................................................................................................... 11-12

Ensuring Link Availability ............................................................................................................................... 11-13 Detecting Failover Conditions ...................................................................................................................... 11-13 Cabling Recommendations ........................................................................................................................... 11-13

Specifications.................................................................................................................................................... 11-14

CHAPTER 12 ................................................................................................................. 12-1

QuadPAT Module IOP336..................................................................................................................................... 12-1

QuadPAT Termination Module IOP337 ............................................................................................................... 12-1 Overview ................................................................................................................................................................ 12-1

Front Panel...................................................................................................................................................... 12-2 LED Indication ................................................................................................................................................... 12-2 Jumper Configuration ......................................................................................................................................... 12-2 Bus Address ........................................................................................................................................................ 12-4 DPU Compatibility ............................................................................................................................................. 12-4 Module Operation............................................................................................................................................... 12-4

QuadPAT Termination ................................................................................................................................... 12-5 Feedback Options ............................................................................................................................................... 12-6 Output Options ................................................................................................................................................... 12-6 Limit Switch Detection....................................................................................................................................... 12-6 Redundant Configuration.................................................................................................................................... 12-7

Contents

vii

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

CHAPTER 13................................................................................................................. 13-1

Turbine Valve Positioner Module IOP341 .............................................................................................................13-1

Turbine Valve Termination Module IOP342.........................................................................................................13-1 Overview .................................................................................................................................................................13-1

Positioner Front Panel .........................................................................................................................................13-2 LED Indication ....................................................................................................................................................13-3 Jumper Configuration ..........................................................................................................................................13-4 Bus Address.........................................................................................................................................................13-5 DPU Compatibility ..............................................................................................................................................13-5 Module Operation................................................................................................................................................13-5

Turbine Valve Termination .............................................................................................................................13-7 Configuration.......................................................................................................................................................13-7 Calibration ...........................................................................................................................................................13-7 Diagnostics ..........................................................................................................................................................13-8 Module Field Connections.................................................................................................................................13-10 Termination Field Connections .........................................................................................................................13-11 Group1 Analog I/O Configuration ....................................................................................................................13-12 Group2 Analog I/O Configuration ....................................................................................................................13-13 Digital I/O Configuration ..................................................................................................................................13-14 Specifications.....................................................................................................................................................13-15

CHAPTER 14................................................................................................................. 14-1

Overspeed Trip Module IOP345 .............................................................................................................................14-1

Overspeed Termination Module IOP346 ...............................................................................................................14-1 Overview .................................................................................................................................................................14-1

Overspeed Front Panel.....................................................................................................................................14-2 LED Indication ....................................................................................................................................................14-2 Jumper Configuration ..........................................................................................................................................14-3 Bus Address.........................................................................................................................................................14-4 DPU Compatibility ..............................................................................................................................................14-4 Module Operation................................................................................................................................................14-4

Overspeed Trip Termination...........................................................................................................................14-5 Diagnostics ..........................................................................................................................................................14-6 Module Field Connections...................................................................................................................................14-7 Termination Field Connections ...........................................................................................................................14-8 Group1 Analog I/O Configuration ......................................................................................................................14-9 Group2 Analog I/O Configuration ....................................................................................................................14-10 Digital I/O Configuration ..................................................................................................................................14-11



Specifications.................................................................................................................................................... 14-12

CHAPTER 15 ................................................................................................................. 15-1

HART Input Module IOP307 .................................................................................................................................. 15-1

HART Output Module IOP322 ............................................................................................................................... 15-1

HART Transceiver Module IOP364 ....................................................................................................................... 15-1 Overview ................................................................................................................................................................ 15-1

LED Indication ................................................................................................................................................... 15-2 Jumper Configuration ......................................................................................................................................... 15-2 Bus Address ........................................................................................................................................................ 15-2 DPU Compatibility ............................................................................................................................................. 15-3 Module Operation............................................................................................................................................... 15-3 Diagnostics ......................................................................................................................................................... 15-4 HART Analog Input Field Connections ............................................................................................................. 15-6 HART Analog Output Field Connections .......................................................................................................... 15-7 HART Transceiver Field Connections ............................................................................................................... 15-8 Transceiver to Analog Input Wiring................................................................................................................... 15-9 Transceiver to Analog Input Wiring................................................................................................................. 15-10 Transceiver to Analog Input Wiring................................................................................................................. 15-11 Transceiver to Analog Input Wiring................................................................................................................. 15-12 Transceiver to Output Driver Wiring................................................................................................................ 15-13 Transceiver to Analog Output Wiring .............................................................................................................. 15-13 HART Analog Input Wiring............................................................................................................................. 15-14 HART Analog Input Wiring............................................................................................................................. 15-15 HART Analog Input Wiring............................................................................................................................. 15-16 HART Analog Output Wiring .......................................................................................................................... 15-17 Specifications.................................................................................................................................................... 15-18


Preface

This publication, which describes the installation and operation of maxPAC, assumes familiarity with the DPU and its configuration. For additional information on related topics, refer to the following publications:

Book No. Book Title

278590 Model PDP Series 200 maxDPU4E Hardware Guide

278705 Model PDP Series 400 maxDPU4F Hardware Guide

278561 System Power and Grounding


Chapter 1

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.

Model IOP I/O Subsystem

Cabinet Two standard cabinet types are available for the mounting of I/O system hardware. The cabinet is available as either a NEMA (National Electrical Manufacturers Association) type 1 or 12 and consists of the following:

Welded steel construction Front and Rear access I/O mounted in front and rear of cabinet (standard) I/O mounted in front and terminations in rear of cabinet (option) Other mounting arrangement options are also available

Removable doors 19” rack mount rails with standard E.I.A. hole spacing Top or bottom Cable access Size 85 7/8” h x 24 ¾”w x 38 7/8”d

Optional Cabinet styles and sizes are also available.


Metso Automation • 278596 • 1-2

The following figure shows a typical cabinet arrangement with I/O in both the front and rear of the cabinet.

Figure 1-1. Typical Cabinet Arrangement, Front and Rear Views

Chassis Assembly

Three chassis assembly types are available for the installation of the I/O module as follows:

IOP382 Eight-pack assembly to accommodate up to eight maxPAC I/O modules. The DPU4F can also reside in this chassis.

IOP383 Six-pack assembly to accommodate a DPU4E or a Model 564 I/O module in the right most position along with six maxPAC I/O modules; the DPU4E takes up the equivalent of two maxPAC I/O module positions.

IOP381 Four-pack assembly to accommodate four maxPAC or Model 564 I/O modules.



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.

The backplane also contains ribbon cable connectors to interconnect chassis assemblies and extend the I/O bus to the maximum number of modules supported by the DPU.

I/O BusConnector

Field 24V

Field 48V

System 24V

I/O BusConnectors

Figure 1-2. Eight-Pack Rack

Figure 1-3. Six Wide Rack with DPU4E



Model Number Description

IOP381 4-wide frame assembly

IOP382 8-wide rack assembly

IOP383 6-wide rack assembly

IOP015 maxPAC Chassis used with IOP381

IOP011,012 Model 564 Chassis used with IOP381

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;

Rotary address switch;

Light Emitting Diodes (LED) for module status indication;

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 TC module includes front-end connectors with thermistors to measure the junction temperature for cold junction compensation.

The I/O modules may be inserted and withdrawn safely with 24 Vdc and field power applied.



Figure 1-4. Typical I/O Module Front Panel

I/O Module Types Because of the variety of input and output ranges needed in distributed control applications, the Model IOP I/O offers many types of easily configurable discrete and analog I/O modules. For a list of modules, along with their ranges and number of points per module, refer to the following tables.

Digital Input (AC/DC)*

Part Number Description

IOP330 24 Vdc common input; 16 channels

IOP334 24 Vdc isolated input; 16 channels

IOP331 48 Vdc common input; 16 channels

IOP332 120 Vac/dc isolated input; 16 channels

IOP333 240 Vac/Vdc isolated input; 16 channels

IOP350 Form C relay; 10 channels

IOP351 Form A/B relay; 16 channels

IOP335 Pulse I/O , 8 channels *ac Voltages/currents are RMS



Analog Input


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


IOP320 4-20 mA common output, 8 channels Other


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.

Power supply features consists of the following:

Redundant AC power inputs 250 Watt power supply modules Hot replaceable Current Sharing Power factor correction Front panel indicators on each module AC input Output voltage status Output current level External status signals



Field Termination Options A maxPAC system uses three field cable termination approaches:

Local Terminations Field cables terminate directly on the I/O module.

Remote Terminations Field cables terminate on terminal blocks remotely to the I/O module with an interconnecting cable back to the I/O module.

Termination Assemblies The QuadPAT, Turbine Valve and Overspeed modules require a DIN rail mounted termination assembly. Field cables terminate on this assembly with an interconnecting cable back to the I/O module.

Local Terminations (standard) Each I/O module is supplied with two 16 point, “Euro-Style” screw clamp plugs that mate to the Printed Circuit Board Header on the module. Field cables would be routed directly to these Euro-Style plugs, which can accept up to a #12awg conductor.

Remote Terminations (option) Many remote field cable termination options are possible. Listed below are a few examples:

I/O in front of cabinet, terminations in the rear of cabinet. Termination cabinet mounted adjacent to I/O cabinet. Termination cabinet located remotely from I/O cabinet.

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


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



Installing Model IOP I/O Equipment This section covers the physical mounting and installation of the Model IOP I/O equipment. See "Module Mounting Considerations," before mounting any equipment.

The following tools and hardware are required:

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."

Sequence of Mounting Operations Mounting the parts of the Model IOP I/O in proper order can save time and duplication of effort.

Follow this sequence as closely as possible for best results:

1. Refer to field wiring instructions that can influence mounting locations for chassis assemblies and chassis assembly/module replacement.

2. Mount the chassis assemblies; see "Mounting I/O Chassis Assemblies."

3. Perform all steps as outlined in "Cabling, Power, and Ground Wiring."

5. Complete field wiring.

6. Refer to "Module Addressing" for switch settings and jumper selections.

7. Install I/O modules.

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.



Mounting I/O Chassis Assemblies The Model IOP I/O chassis assembly attaches to the rear mounting rails in standard 19-inch maxDNA I/O cabinets. Three chassis styles are available. See “Chassis Assembly.” Up to seven chassis assemblies may be installed in a standard cabinets.

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.

To attach the chassis assembly:

1. At the desired chassis assembly mounting location in the cabinet, place eight 10-32 nut retainers (Metso Part No. 003530) in the rear mounting rail holes that correspond to the eight screw slots on the Model IOP chassis assembly.

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.

Cabling, power wiring, and chassis assembly to cabinet frame grounding should be completed before mounting the I/O modules. See next section.

Cabling, Power, and Ground Wiring This section describes power wiring, Model IOP I/O connection, and connection to other Model IOP I/O units. The connections covered in this section should be done after the chassis assemblies are in place and before the I/O modules are mounted. Some cabling can be done when the I/O modules are mounted, but the job is easier when they are removed. (See also Interconnecting I/O Racks).

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.

Refer to Publication 278561, System Power and Grounding, for a discussion of cabinet grounding.



Supplying 24V Power to the I/O Modules The I/O system requires a 24 Vdc ±4.0 Vdc power supply. Normally, this is a maxDNA power supply mounted in the cabinet holding the DPU; to ensure reliability, Metso Automation recommends using a maxDNA power supply exclusively. If another 24 Vdc power supply is used, it must meet the same specification requirements as the maxDNA supply. All modules are individually fused. The CMOS technology in the Model IOP I/O design results in low module power consumption.

Whether the power source is the standard maxDNA supply or another supply, the +24 Volts connector plugs into the 24V connector on the right side of the I/O backplane.

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.

Interconnecting I/O Racks Use a ribbon cable to interconnect, in a daisy chain manner, two or more adjacent I/O chassis assemblies in the same maxDNA I/O cabinet group. The cables should be installed in a manner that minimizes the total I/O bus length. This is done by utilizing the I/O bus connectors on both ends of the racks so that the bus “flows through” the racks.

For example, consider the two-cabinet system shown in Figure 1-5a. A maxDPU4F pair is installed in the leftmost slots of the top two racks in cabinet 1. The bus begins at the DPU and flows through the rack to the connectors on the right side of the rack (P9 & P10). A ribbon cable connects the right side of rack 1 to the right side of rack 2. The bus flows through rack 2 to connector P11. Another ribbon cable connects the left side of rack 2 to the left side of rack 3. The bus flows through rack 3 to connectors P9 and P10. This same pattern is repeated until the last rack has been reached.

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.

Figure 1-5a. Interconnecting maxPAC I/O Racks (Shared I/O)

P9

P10 P11

P9

P10 P11

P9

P10 P11

P9

P10

P9

P10 P11

P9

P10 P11

P9

P10 P11

P9

P10 P11

DPU

P11

DPU

Cabinet #2 Cabinet #1

Terminator



Terminating systems with Redundant or Mixed (Shared + Redundant) I/O is a little more complicated than a system with only Shared I/O. Refer to the following figures for examples. Additional information on Shared, Redundant and Mixed I/O is contained in the Backup Configuration Options section of this manual.

DPUP11 P9

P10

DPUP11 P9

P10

P11 P9

P10

Terminator

P11 P9

P10

Terminator

I/O Backup Cable(047472)

I/O Bus Cable

Redundant I/OPrimary

Redundant I/OPrimary

Redundant I/OSecondary

Redundant I/OSecondary

Figure 1-5b. Terminating & Cabling Redundant I/O



DPUP11 P9

P10

DPUP11 P9

P10

P11 P9

P10

Terminator

P11 P9

P10

Terminator

I/O Bus Cable

P11 P9

P10

Terminator

Pri

Sec

Com

RedundantI/O - Primary

RedundantI/O - Secondary

RedundantI/O - Primary

RedundantI/O - Secondary

SharedI/O

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.

Y-Cable

Figure 1-5c. Terminating & Cabling Mixed I/O



Summary of Cabling Rules for maxPAC I/O • Keep the total I/O bus length (cables + backpanels) as short as possible.

The following techniques will do this.

• Use “flow through” cabling.

• When connecting columns of racks together, connect the bottom rack of column 1 to the bottom rack in column 2 or the top rack of column 1 to the top rack of column 2. In other words, do not cable a top rack to a bottom rack.

• 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).

• In a system with Common (shared) I/O, the terminator should be placed at the far end of the common I/O bus. In a system with Redundant I/O, install a terminator at the far end of both redundant I/O bus segments. In a system with mixed (common + redundant) I/O, terminate all segments.

• The maximum number of maxPAC modules supported by the maxDPU4E or maxDPU4F within a cabinet or adjacent cabinet pair is 60. This number of modules is reduced when the electrical I/O bus is extended to other cabinets.

• 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.

maxPAC I/O Bus Cables A variety of different maxPAC I/O bus cables are available. Use the cables that are appropriate for your application based upon the positions of your I/O racks. Due to the orientation and location of the connectors, different cables are used for connections to P9/P10 vs. P11 when the racks are spaced relatively close together. For longer runs, the same types of cables may be used for all connectors.

Cables for maxPAC Connections to P9 & P10


CPO301 10 inches - 0 rack units between racks

CPO303 12 inches - 1 rack unit between racks





Cables for maxPAC Connections to P11


CPO323 12 inches – 0 or 1 rack units between racks

CPO324 14 inches – 2 rack units between racks

CPO325 28 inches – 10 rack units between racks

Long Cables for maxPAC Connections to P9, P10 or P11

For I/O bus connections to a cabinet outside the cabinet group, use the following cables:


CPO307 7-foot cable

CPO315 15-foot cable

CPO400-LL Custom length cable (about 20 feet maximum)

Cables for Connections between maxPAC and 564 Racks

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.


CPO504 13 inches - 2 rack units between racks (use P9 or P10)

CPO507 7-foot cable

CPO515 15-foot cable

CPO500-LL Custom length cable (about 20 feet maximum)



Module Mounting Considerations

I/O Modules As you determine how modules are positioned in a cabinet, give some thought to the signal levels that are to be wired to the modules. High and low signal levels and AC and DC wiring should be kept separate. In general, wherever possible, modules receiving the same type and level of signals should be grouped together, with similar signal types arranged in vertical columns.

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.

Before installing an I/O module in the right-most position of a chassis assembly, make sure the +24Vdc is connected to the chassis assembly as well as the I/O bus cable. Additionally, connect the cabinet frame ground to the Model IOP I/O chassis assembly before installing an I/O module in the extreme left position of a chassis assembly. Refer to "Cabling, Power, and Ground Wiring."

Before installing any modules, complete all field wiring.

Model IOP I/O is designed to allow module installation and removal with the +24Vdc power supply ON.

To mount modules:

1. With chassis assembly in place and all wiring completed, position module into top and bottom card guides of the chassis. Gently slide module forward, verifying that the connector pins on the side of the module board engage the corresponding contact guides on the chassis assembly.

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.

To convert the hexadecimal address to the equivalent logical (decimal) 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.

2. Multiply the high order switch setting by 16 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.

For example, a 2 setting of S2 (2 x 16 = 32) and an A setting of S1 (10) gives a module a logical (decimal) address of 42, the decimal equivalent of the hexadecimal word 2A formed by the switch setting.

Module addressing is completely independent of module physical locations. Each module address must be different from all other module addresses in the system. Digital input modules must have an address less than 32 decimal. Addresses are determined by the system designer during system planning.

Backup Configuration Options Three input/output configuration options are available: shared, redundant, and mixed.

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

I/O Bus

DPU

DPU

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

Figure 1-6. Shared Configuration

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.



Redundant netw ork

I/O B us

DPU

DPU

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

CPO 309

Figure 1-7. Redundant Configuration

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.

The output-enable signal to the modules is handled internally by the mixed backup adapter; Part No. CPO401.

In redundant or mixed configurations, the inactive DPU polls its redundant modules for hardware failures when it is not performing control actions. No transfer of control will occur if a failure is detected by the inactive DPU. The inactive DPU also continuously updates its analog output modules with current values so that bumpless transfer occurs when the inactive DPU becomes active.



Redundant network

I/O Bus

DPU

DPU

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

BackupAdapter

IO

IO

IO

IO

IO

I/O Bus

Common I/O Bus

Figure 1-8. Mixed Configuration

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.

Remotelocation

ControlRoom

DPU

DPU

BEM

IO

IO

IO

IO

BEM

IO

IO

IO

IO

BEM

BEM

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

OpticalCable

YADAPTER

backplanebackplane

redundant network

Figure 1-9. Typical Bus Expander Module Configuration



Specifications

Environment The Model IOP I/O operates in the temperature range of 0°C to 60°C 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.

To further enhance reliability, I/O incorporates module address verification and multiple module detection checks. Bus fault detection is also performed by automatic confirmation of input data on every module.

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.

In addition to logic state indication, digital output modules contain fused outputs and a front-panel blown fuse indicator. Each output also has a deadman timer (approximately 1 second) that can be optionally used to freeze or drop out all outputs if the module is not updated by the DPU.


Chapter 2

Analog Input Modules Isolated Input Module IOP301

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.

Jumper Installed Not Installed

W1 50 Hz 60Hz W6 Model 564 maxPAC

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 Automation

IN IN IN IN OUT

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.

1D

1C

1E

200

1D

1C1E

1D

1C1E

200

200

100

100

100

-

+

Rp

24V(-)

24V(+)

Xmitter

Rs

4-20 ma powered by system

Voltage input

4-20 ma powered externally,internal shunt

2

1

1A

1A

A/D

A/D

RpVoltage

Rs

2

1

RpXmitter

Rs

2

1

A/D

+

-

+

-

+

-

From backplane1B

1B

1A 1B

24V

+

-

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



representing the voltage input, which is read by the microcontroller. 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. Prior to starting each conversion, the microcontroller selects one of the two input channels by means of two solid-state, optically coupled relays. The two inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open input and over range conditions are checked.

A separate DC/DC converter provides isolated power to each A/D converter measuring circuit. Communication between the microcontroller and each A/D is serial at 100kHz. A separate group of optical isolators provide the isolation between each 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.

Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.



FLASH

FPGAI/O Bus

Regulator 24V 5V - logic

uC

OPTO

optical isolation field to logic

DC/DC

A/D 1

REF

A/D 8

REF

Channel 1

Channel 2

Channel 15

Channel 16

DC/DC

OPTO

Optical isolationbetween each pairof channels

Multiplexer

Multiplexer

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:

Error Condition Code A/D send fault 0x12 A/D receive fault 0x13 A/D self calibration failure 0x14 Bad A/D communication 0x15 A/D does not complete conversion 0x16 RAM Test Failure (power-on) 0x22



CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32

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 - voltage input

300 Ohms 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 (from 24V system supply)

400 mA



Field Wiring

P2

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 8

1

2

15

16

3

4

9

10

7

5

6

13

14

11

12

In(+)

24V,In(-)

P3

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

8

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 16

1

2

15

16

3

4

9

10

7

5

6

13

14

11

12

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

In(+)

24V,In(-)

8



Field Wiring for Redundant Modules with Common Transmitter The following figure shows the recommended wiring for two redundant IOP301 analog input modules that share a common two-wire or four-wire transmitter.

Redundant inputs must be configured as voltage inputs with an external 100-Ohm shunt resistor. The recommended maximum distance between the shunt and the I/O module is 10 meters. The +24V connection should be independently fused to each transmitter.

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.

thermistor

(-)

(+)

Primary IOP301 AI Module

4 wireTransmitter

(-)

(+)

Secondary IOP301 AI Module

100

Twisted pair

Four Wire Transmitter



(+)

(-)

thermistor

(-)

(+)


Twisted pair

2 wireTransmitter

(-)

(+)

Secondary IOP301 AI Module

100 24V Supply

Two Wire Transmitter


Chapter 3

Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305

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.



Jumper Configuration The module contains two jumpers. Refer to the following table for jumper setting information.

Jumper Installed Not Installed W1 50 Hz 60Hz W6 Model 564 maxPAC

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 digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. Immediately following each measurement, open input and over range conditions are checked. A DC/DC converter provides isolated power to the A/D 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. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.

Analog Input Modules 4-20 mA Input Module IOP 302 Voltage Input Module IOP 305


Channel 1

Channel 16

FLASH

FPGAI/O Bus


uC OPTO


DC/DC

A/D

REF

A/D

REF

SignalConditioning

SignalConditioning

5V - field

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

Fuse

A/D

200

100

From backplane24V(-)

24V(+)

The following sketch shows the input circuit for the voltage-input module.



A/D

Voltage Input Module


Error Condition Code A/D send fault 0x12 A/D receive fault 0x13 A/D self calibration failure 0x14 Bad A/D communication 0x15 A/D does not complete conversion 0x16 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power –on) 0x32

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 (from 24V system supply)

125 mA



Field Wiring for IOP302 P2

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 8

124V

2TransmitterIin

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

1524V

16Iin

324V

4Iin

924V

Iin

724V

8

Iin

524V

6

Iin

1324V

14Iin

1124V

12Iin

P3

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 16

124V

2Transmitter

Iin

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

1524V

16Iin

324V

4

Iin

924V

Iin

724V

8Iin

524V

6Iin

1324V

14Iin

1124V

12Iin

1010



Field Wiring – IOP 305 Analog Input Module

P3P2

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 8

1

2

15

16

3

4

9

10

7

8

5

6

13

14

11

12

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 16

1

2

15

16

3

4

9

10

7

8

5

6

13

14

11

12

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

(+)

(-)

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V

0-2.4V



Field Wiring For Redundant Modules with Common Transmitter The following figure shows the recommended wiring for two redundant IOP305 analog input channels that share a common transmitter.

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.

thermistor

(+) DCS 24V Loop Supply(-)

(-)

(+)


Twisted pair

Transmitter 2-wire

(-)

(+)

Secondary IOP 305 AI Module

100


Chapter 4

Analog Input Modules 3 Wire RTD Module IOP303

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.





Jumper Configuration The module contains three jumpers. Refer to the following table for jumper setting information.

Jumper Installed Not Installed W2 Common I/O Redundant I/O W3 50 Hz 60 Hz W4 Not used W6 Model 564** maxPAC

** For version B or earlier, W7 must be installed for model 564 operation

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.

Analog Input Modules 3 Wire RTD Module IOP 303


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.


Channel 1

Channel 8

FLASH

FieldInterfaceCircuits I/O Bus


uC

DC/DC 5V - field

OPTO


A/D

REF

ExcitationCurrent

FieldInterface Circuits




Error Condition Code A/D send fault 0x12 A/D receive fault 0x13 A/D self calibration failure 0x14 Bad A/D communication 0x15 A/D does not complete conversion 0x16 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power –on) 0x32

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 Compensation

5 Ohms each lead

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 (from 24V system supply)

125 mA

Analog Input Modules 3 Wire RTD Module IOP 303


Field Wiring P2

Channel 1

Channel 2

Channel 3

Channel 4

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

P3

Channel5

Channel 6

Channel 7

Channel 8

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Note: Field wires must be of equal length



Field Wiring For Redundant Modules with Common RTD

(+)

(-) Primary IOP303 RTD Module Ret W2 – not installed

Twisted pair, same length

(+)

(-) Secondary IOP 303 RTD Module Ret

W2 - not installed


Chapter 5

Analog Input Modules TC Module IOP304

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.




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.

Jumper Installed Not Installed W3 50 Hz 60Hz W2 Common I/O Redundant I/O W6 Model 564 maxPAC

Cold Junction Compensation If this module is configured by the DPU to perform cold junction compensation, a thermistor (Metso Part No. 074566) must be installed in connectors P4 and P5 at the front of the module, above and below the input connectors.

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 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 for each configured input measurement, and selects the input channel by means of two solid state, optically coupled relays.



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.


When thermocouples are measured, the module monitors the TC cold junction temperature and the input value read is compensated for the cold junction temperature. Thermistors, installed at the terminal blocks provided above and below the field connectors, are used to measure the TC cold junction temperature. When remote terminations are used, these thermistors must be removed from the module and moved to the wiring connections at the remote terminations. The microcontroller schedules periodic measurements of the thermistors and uses these measurements to calculate a cold junction temperature for each channel.

Channel 1

Channel 16

FLASH

FPGAI/O Bus


uC

DC/DC 5V - field

OPTO


A/D

REF

OPEN TC

Field Interface Circuits

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:

Error Condition Code A/D send fault 0x12 A/D receive fault 0x13 A/D self calibration failure 0x14 Bad A/D communication 0x15 A/D does not complete conversion 0x16 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32


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 (from 24V system supply)

125 mA



Field Wiring P2

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 8

7

8

5

3

4

1

2

9

10

+

-

+

-

+

-6

+

-

+

-

+

-12

11

+

-

+

-11

13

14

15

16

P3

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 16

7

8

5

3

4

1

2

9

10

+

-

+

-

+

-6

+

-

+

-

+

-12

11

+

-

+

-11

13

14

15

16



Field Wiring For Redundant Modules with Common TC

(+)

(-)

Primary IOP304 TC Module

W2 – not installed

(+)

(-) Secondary IOP 304 TC Module

W2- not installed

TC extension wire

Note: Thermistors must be installed in both modules.


Chapter 6

Analog Output Modules 4-20 mA Output Module IOP320

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.

Jumper Installed Not Installed W1 Run Mode Calibrate Mode W2 Hold Output Reset Output W3 Secondary Primary W4 Common I/O Redundant I/O W6 8 addresses N/A

Analog Output Modules 4-20mA Output Module IOP320


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.

A watchdog timer function is included to monitor communications on the I/O bus. The watchdog timers will timeout if there is no communications on the I/O bus for longer than 0.7 seconds. When this occurs, the outputs will either reset or remain in their last state depending on the position of the onboard program jumper.

Module calibration is done automatically at power up following startup diagnostics.

The 24-Volt loop supply is available to the module from the backplane. All the outputs are connected to the loop supply.



FLASH

FPGAI/O Bus


uC

AO Module

OPTO


D/A 1

D/A 8

Channel 1

Channel 8 OPTO

4-20 ma out

4-20 ma out

Powered from field24V supply




Error Condition Code RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32 Calibration Error (channel 1 to 8) 0x41 – 0x48


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 (from 24V system supply)

175 mA



Field Wiring P2

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8

1

Return2Load

Iout

15

Return16

Iout

3

Return4

Iout

9

Return 10

Iout

7

Return8

Iout

5

Return6

Iout

13

Return14

Iout

11

Return12

Iout

Load

Load

Load

Load

Load

Load

Load



Field wiring for redundant modules with common end element

(+)

(-) Primary IOP320 AO Module

W2 – not installedW3 – not installedW4 - not installed

(+)

(-) Secondary IOP 320 AO Module

W2 – not installedW3 – installedW4 – not installed

CurrentLoopControlledDevice


Chapter 7

Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331

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.

To other channels

24V/48V(-) 24V/48V(+)

SignalConditioningCircuit

I/O BUSInterfaceCircuit

Fuse disconnect



Module specifications

IOP 330 – 24V IOP331 – 48V Rated Input Voltage 24Vdc nominal, 40 Vdc

maximum 48Vdc nominal, 60V dc maximum

Input current per point 5 mA @ 24 Volts 5 mA @ 48 Volts On-State Voltage 8.5 Volts 22 Volts Isolation User input to logic

250 VAC continuous, 1,500 VAC for 1 minute

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 (from 24V system supply)

50 mA



Field Wiring P2

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 811

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

P3

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 1611

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16



Field Wiring For Redundant Modules with Common DI

(+)

(-)

Primary IOP30,331 DI Module

(+)

(-)

Secondary IOP 330,331 DI Module


Chapter 8

Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333

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 (W1—W16) must be installed for AC inputs.

Note: IOP334 does not include jumpers.

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.

SignalConditioningCircuit

I/O BUSInterfaceCircuit

Input Voltage

Digital Input Modules 24V DC Isolated Input Module IOP334

120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333



IOP 332 – 120V IOP333 – 240V IOP334 – 24V

Rated Input Voltage

120 Volts ac/dc nom. 180 Volts max

240 Volts ac/dc nom. 280 Volts max

24V dc nominal, 40V dc max

Input current per point

5 mA @ 120 Volts 5 mA @ 240 Volts

5 mA @ 24Volts

On-State Voltage 48 Volts dc 70 Volts dc 100 Volts ac

8.5 Volts dc

Isolation User input to

logic

60 VAC; 250 VAC continuous, 125 VAC; 1500 VAC for 1 minute

Isolation Channel to

channel

350 VAC continuous

Indicators 1 LED per point provides status indication LED provides power and communication indication

I/O Bus Address One address

Input Power (from 24V

system supply)

50 mA



Field Wiring P2

Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

P3

Channel 9 Channel 10 Channel 11 Channel 12 Channel 13 Channel 14 Channel 15 Channel 16 11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

AC/DC

Digital Input Modules 24V DC Isolated Input Module IOP334

120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333


Field Wiring For Redundant Modules with Isolated DI

(+)

(-)

Primary DI Module

(+)

(-)

Secondary DI Module

AC/DC


Chapter 9

Digital Input Modules Counter Timer Module IOP335

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

Software stored in FLASH

Low Power Dissipatioin

Configuration per channel

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:

Jumper Installed Not Installed W1A - 16A 24 V 48V

This microprocessor-based module supports up to eight pulse input channels. Each channel can be independently configured for both function type and debounce time. The functions supported are:

Mode 1 – Frequency Input

Frequency in counts per second in input1. Input 2 is not used. The Pulse I/O Buffer in DPU4E supports the following timebase mode selections for frequency measurement: 20 msecs, 50 msecs, 100 msecs, 250 msecs, 500 msecs, and 1 second. For the selected timebase, the Pulse I/O module measures frequency for the specified duration and normalizes each measurement to cycles per second. The measurement is updated at the end of each interval and the counts read by the DPU when the module is scanned represent the average of the last four measurements in cycles/second. The scan rate of the DPU is asynchronous from the scan rate by the module. The accuracy of the frequency measurement is +/-1 count for the one-second timebase. The accuracy for the other timebases is approximately the normalizing multiplier divided by 4. Thus for the shortest timebase (20 msecs), the accuracy is reduced to approximately +/-12 counts.

In applications requiring fast frequecy measurements, a period measurement (mode 7) can also be used to measure frequency. Since each count in the period measurement corresponds to 0.5 microseconds, the inverse of the period will yield a fast frequency measurement with an accuracy of 0.1% for a 2000Hz input and 0.25% for a 5000Hz.

Mode 2– Simple Event Counter (default configuration)



32 bit accumulation of OFF-to-ON transitions in input1. Input2 provides an external accumulator reset.

Mode 3 – Up/Down Event Counter

Net counts of OFF to ON transitions in input1 and input2. Input1 counts up and input2 counts down.

Mode 4 – On-Time Timer

The timebase frequency (0.5 usec/count) is counted while input1 = ON. Input 2 provides an external reset.

Mode 5 – Up/Down Pulse Timer

Counts corresponding to the on-time difference in input1 and input2. The timebase frequency (0.5 usec/count) is counted up while input1 = ON and counted down while input2 is ON.

Mode 6 – Pulse Width

ON time of last detected pulse in input1, based on the timebase frequency (0.5 usec/count). Input2 is not used. The measurement is updated at the end of each detected pulse (ON to OFF transition). Counts read by DPU represent the average of the last four measurements.

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.

During normal operation this LED stays on or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:

Error Condition Code RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power –on) 0x32

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 (from 24V system supply)

150 mA



Field Wiring

+

-

+

P2

Input 1

Input 2

Input 3

Input 4

Input 5

Input 6

Input 7

Input811

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

P3

Input 9

Input 10

Input 11

Input 12

Input 13

Input 14

Input 15

Input 1611

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Channel 1

Channel 2

Channel 3

Channel 4 Channel 8

Channel 7

Channel 6

Channel 5-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-


Chapter 10

Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350

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:

Jumper Position 2-3 Position 1-2 W1 Reset Output Hold Output

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.

Channel Number Form A Form B 1 R100 R101 2 R103 R104 3 R106 R107 4 R108 R109 5 R111 R112 6 R114 R115 7 R116 R117 8 R119 R120 9 R122 R123 10 R124 R125 11 R127 R128 12 R130 R131 13 R132 R133 14 R135 R136 15 R138 R139 16 R140 R141

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.

Digital Output Modules Form A/B of Relay Module IOP351

Form C Relay Module IOP350



Channel 1

Channel 16

PROM

I/O BusInterfaceCircuit

I/O Bus

Reg 24V 5V

BUFFER


IOP 350 – Form C IOP351 – Form A/B Maximum Switching Capacity

5 amps @ 250 VAC 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 (from 24V system supply)

400 mA




Channel 1

Channel 16

PROM

I/O BusInterfaceCircuit

I/O Bus

Reg 24V 5V

BUFFER




Field Wiring – IOP 351 P2

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

Channel 6

Channel 7

Channel 8

P3

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Channel 9

Channel 10

Channel 11

Channel 12

Channel 13

Channel 14

Channel 15

Channel 16



Wiring – IOP350

P2

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Channel 1

Channel 2

Channel 3

Channel 4

Channel 5

P3

11

7

8

5

6

3

4

1

2

9

10

11

12

13

14

15

16

Channel 6

Channel 7

Channel 8

Channel 9

Channel 10




Field Wiring For Redundant Modules with Common End Element

(+)

(-) Primary Relay Module

W1 – installed

(+)

(-) Secondary Relay Module

W1 – installed

Power Source

Switched Device


Chapter 11

Bus Extender Unit Module IOP371

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.



BEM Front Panel The BEM front panel contains a pair of optical connectors (optical transceivers), LEDs to report the status of the two optical links, a push button for link testing, and an output contact, used to detect and report the failure of either optical cable when redundant cables are provided (optional).

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.

Jumper Installed Not Installed W1 Remote Local W3 Redundant Common

Bus Extender Modules, configured in pairs, support both locally and remotely mounted I/O cards. The local BEM installed with the DPU plugs into the I/O backplane to access the DPU's parallel I/O bus. Locally mounted I/O can share the I/O bus with the BEM. The remote BEM receives the bus data over the optical link and establishes the I/O bus at the remote location.

A single DPU, or redundant pair of DPUs, can communicate with I/O modules that are locally and/or remotely mounted. 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 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.

Local I/O Bus

DPU

BEM

I/O

BEM

BEM

I/O

Remote I/O Bus

Optical Links

DPU

“Y“ Cable

I/O

I/O

Optical Links

BEM

I/O

I/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."



Local Model IOP I/O Bus - Up to 60 BEMs and/or I/O Modules

DPU

BEM

I/O

BEM

BEM

I/O

Remote I/O Bus – Area 3Up to 45 Modules



Redundant Optical Links

Figure 11-2. The DPU Supports up to 60 Modules Locally and Up to 45 per Remote Location.

In addition to the configuration described in Figure 11-1, BEMs may be non-redundant, and configured with redundant or non-redundant DPUs. All options are possible. See " Redundant Configuration Approaches."

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.

I/O Bus Loading BEMs may also be used to expand the number of I/O modules that may be configured locally. The local BEM represents the same bus loading as one I/O module, regardless of the number of I/O modules attached to the remote I/O bus. Without the use of BEMs, a single DPU supports up to 60 modules. When BEMs are used, a DPU could support up to 60 modules locally and up to 45 modules (including a remote BEM) at each remote location. The DPU supports a maximum of 255 I/O addresses (local + remote modules).

Important: Remember other factors limit the number of modules you may configure, such as I/O mix, DPU loading, application requirements, etc. Such



sizing factors need to be considered when planning I/O configurations. See also "BEM Configuration Considerations."

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.

Transmitter (Serializer) – Converts a snapshot of the parallel bus data into 160Mb TTL level serial stream.

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.



Buffers B

uffers

Buffers

Transmitter

Receiver

Receiver

Transmitter

Fiber

Fiber

OUT/IN

DATA

ADDR

LO/HI

LATCH

ACK

DATA[8..0]

ALT_IN

XACK

Remote564 Bus

INT

PrimaryDPU

ALT_IN

SecondaryDPU

OUT/IN

DATA

ADDR

LO/HI

LATCH

ACK

DATA[8..0]

ALT_IN

XACK

INT

Buffers

OUT/IN

DATA

ADDR

LO/HI

LATCH

ACK

DATA[8..0]

XACK

INT

Transmitter

Receiver

RedundantFiber OpticTransceiver

Receiver

Transmitter

Fiber

Fiber

Local Area Remote area




MACK

MACK

MACK

MACK

Local BusExpanders

Remote BusExpanders

CPLD

CPLD CPLD

CPLD

Status

Status

Figure 11-3. BEM Functional Block Diagram

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.

On power-up transceiver 1 is selected. If a failure is detected, the circuit will switch the link to transceiver 2, a digital output will be set and an LED will



identify which link is operational. If the link cannot be established using transceiver 2 the circuit will go back to transceiver 1 and the sequence will repeat indefinitely until the link is established.

Power on reset – The power on reset circuit includes a watchdog timer to monitor the operation of the CPLD.

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.

Multimode 62.5-micron cable is used to connect the local and remote Extender modules. Cable is run between the redundant optical transceivers to support redundant optical cable pairs. If redundant cables are provided, one cable pair is always active while the second pair serves as a hot standby link. See "Ensuring Link Availability.

Model 564 and maxPAC I/O Compatibility Because the Extender module has the same form factor as the Model IOP I/O modules, it can be used in either Model 564 or maxPAC applications. The module installs in an IOP015 4-pack I/O Chassis or any of the maxPAC chassis described in chapter 1.

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 DPU itself acts as a terminator so one Terminator card (CPO402) is required on the other end of the DPU local bus segment. The Local BEM does not require any more termination than this.

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 BEM’s electrical bus. See the figure titled “Termination of Local and Remote BEM Busses”.



Redundant Configuration Approaches In a redundant configuration, I/O may be configured only at the remote end or both locally and remotely. A redundant configuration consists of a primary and secondary DPU; each with its own associated BEM.

Four Configuration Approaches Redundant DPUs and redundant BEMs may be employed in any of the following configuration schemes:

1. Remote I/O only (redundant, common or mixed). 2. Remote I/O and local redundant I/O. 3. Remote I/O and local common I/O. 4. Remote I/O and mixed local I/O consisting of common and redundant

configurations.

Configuring Remote I/O only In a redundant configuration using only remote I/O (configuration scheme No. 1), the local DPUs and associated BEMs are placed in one rack. The IOP381 4-wide rack is used for this application. The DPU4E chassis are mounted at either end of the rack. The BEMs are installed next to each DPU using the IOP015 Chassis. Resistor R1 located in the center of the backplane must be removed to isolate the “active” DPU control line.

Configuring Local Common I/O In a redundant DPU configuration using local common I/O (configuration scheme No. 3), the I/O bus “active” control signal from each DPU must be

Figure 11–4. Termination of Local and Remote BEM Busses

P9

P10 P11

P9

P10 P11

P9

P10

P9

P10 P11

DPU

P11

DPU

Terminator

P9

P10 P11

P9

P10 P11

Terminator

BEM Fiber Optic Cables

BEM



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:

Analog Output – W4 installed Thermocouple – W2 installed RTD – W2 installed

Configuring Mixed Common and Redundant I/O Configurations with mixed redundant and common I/O can be used at either the local or remote end. The I/O bus from each DPU at the local end or each BEM at the remote end is connected separately to the redundant modules. A mixed backup adapter, (Part No. 080441) is used to combine the redundant I/O buses into a common I/O bus. See Figure 11-4.

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.



Remotelocation

ControlRoom

DPU

DPU

BEM

IO

IO

IO

IO

BEM

IO

IO

IO

IO

BEM

BEM

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

IO

OpticalCable

YCABLE

backplanebackplane

Figure 11-5. Redundant DPUs with local common and remote common I/O configuration using Y cable.

Single DPU Configurations For configurations using a single DPU, setup schemes as described in "Four Configuration Approaches" still apply. However, the special cabling used in redundant configurations is of course not needed. This applies to Part No. 04374 and the mix cable adapter. Additionally, special jumper considerations as listed in "Configuring Local Common I/O" do not apply. See Figure 11-5.



Remotelocation

ControlRoom

DPU

IO

IO

BEM

IO

IO

IO

IO

BEM

IO

IO

IO

IO

IO

IO

IO

OpticalCable

backplane

Optical Redundant Cable

BEM

To otherLocations

Figure 11-6. Single DPU with common and remote I/O configuration. The redundant optical cables shown in this illustration are optional but recommended.



BEM Configuration Considerations Communication between the DPU and the remote I/O occurs in real time using the existing Model IOP protocol. The remote I/O modules communicate with the DPU, as if they were local I/O. Extenders are transparent to the bus.

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."

Calculating Link Capacities While as noted, a DPU supports up to 45 modules per remote location, a link delay that is proportional to distance is introduced by the speed of light. The Extender circuits themselves introduce very little delay. The distance factor primarily limits the number of Digital Input modules set for SOE operation since they must be scanned every 1 msec.

An IO Bus Configuration Limits utility is provided to calculate the effect of link distance on the number of modules and scan rate supported by the DPU. Refer to Publication 278609 (System Resources Guide) for a description of this program.

Links can be connected in series or in parallel, the preferred configuration approach. In a parallel link, a star approach, each remote location's BEM is connected to a BEM located on the electrical bus with the DPU.

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.



Ensuring Link Availability To ensure link availability, installations may include multiple levels of redundancy. In configurations using only a single DPU, redundant cables ensure availability. The loss of either cable pair will automatically route the signal to the alternate cable pair. Only a momentary loss of the remote I/O, (milliseconds), will occur while the Extender switches over to the inactive cable.

To ensure optimal availability, each cable pair should be routed separately to minimize the probability of damage to both cables. With separate cables, in the event a cable should break or fail, a second cable is still available.

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.

Detecting Failover Conditions A Form C relay is provided to indicate a link failure. When a BEM experiences a failover between the redundant links, a momentary relay closure occurs. Attach the DI Contact on module front panel to a Digital Input Module to monitor this logic output. The module produces a logic output to indicate and report the occurrence of an optical link failover or link failure.

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

Link bus loading: One module

Number of I/O Modules Per Location: On the DPU Local Bus: 60 maximum including local BEM(s) On Each Remote BEM Bus: 45 maximum including remote BEM Approval Bodies and Standards The product meets SAMA PMC33.1 EMI/RFI specs at three different frequencies, and is designed to meet IEC 801-2 static specification (8,000 Volts).

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 μm multimode fiber optic cable CON062-LLLL Two- fiber optical cable CON064-LLLL Four-fiber optical cable

Operating wavelength λ 1300 nm.


Chapter 12

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


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:

LED Color Description Output Green Decrease Output Red Increase Limit Green Decrease Limit Limit Red Increase Limit Limit Amber No limit Limit OFF No Power

For normally open limit switches the LED indication is as follows:

LED Color Description Output Green Decrease Output Red Increase Limit Green Increase Limit Limit Red Decrease Limit Limit OFF No limit Limit OFF No Power

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.

QuadPAT Module IOP336 QuadPAT Termination IOP337


Jumper Installed Not Installed W1 Not Used W2 Backup Primary W3 Not Used W4 Ignore Limit Stop on Limit W5 Common I/O Redundant W6 QuadPAT Other

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. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. A FPGA includes the I/O bus control logic and provides support logic for the other circuits.



5V

0-2.5V4-20 ma 0-2.5V4-20 ma

4-20 ma

DO1 – DOI8

4-20ma or+/-10V

4-20 ma

4-20ma or+/-10V

0-2.5V4-20 ma 0-2.5V4-20 ma

24V

5V

+/-15V

24V

DI1 – DI8

OutputVirtual Power

OpenCollector Drivers

FPGAI/O Bus

68332G Processor 25MHz

FLASH 2Mbit

I/O Bus Interface

RAM 64K Parity

CLOCK

OpticalIsolation

A/D 4 channels

D/A2 channels

OpticalIsolation

DC/DC

A/D4 channels

DC/DC

+/-15V

24V

D/A2 channels

DC/DC

DC/DC

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:

• It provides four optically isolated TRIAC circuits. Each circuit includes a pair of TRIACs for the increase and decrease signals as well as the output suppression circuits



• 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

Slidewire: The bottom of the slidewire is connected to ground through a 100-ohm resistor to allow detection of an open slidewire. A reference current of 2 ma produces an approximate voltage range of 0.5 to 2 volts for the slidewire. Open wipers are detected through a pulldown resistor on the slidewire input. If a high or low signal reading is detected when the module is scanned by the DPU, outputs to the module from the DPU will be suspended.

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.

Limit Switch Detection 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. Note: The QPAT buffer includes status attributes (Out0xLimitHi or Out0xLimitLo) that represent the state of the High and Low Limit inputs. These inputs are normally wired to the limit contacts of the drive unit. The contacts are most often Normally Closed contacts and open when the limit is reached. In this case, when the contact is open (the limit exceeded) the status will be equal to one. If Normally Open contacts are used, the status attributes will be one and go to zero when the limit is reached (contact closed). The jumper on the card to ignore the limit does not affect these status attributes

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. Backup transfer Bump The specified backup transfer bump is 0.2%. On insertion or withdrawal of an inactive module, up to a 1% temporary bump can occur and the drive unit will return to its original position within a few seconds depending on the stroke time of the drive. This bump can be avoided by disabling the ac power to the inactive module termination, while inserting or withdrawing the inactive module.


Error Condition Code ADC Serial Transmit Fault 0x12 ADC Serial Transmit Fault 0x13 ADC Sanity Test Failed 0x15 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Error 0x32 FPGA Download Error (power-on) 0x33 FLASH Erase Error 0x35 FLASH Programming Error 0x36 FPGA Error 0x37 Serial I/O Failure 0x38 Parity Error 0x39



Module Field Connections

LO LIM4 (DI08)

HI LIM4 (DI07)

DEC4 (DO07)

INC4 (DO08)

LO LIM3 (DI06)

HI LIM3 (DI05)

HI LIM2 (DI03)

LO LIM2 (DI04)

DEC3 (DO05)

INC3 (DO06)

LO LIM1 (DI02)

DEC2 (DO03)

INC2 (DO04)

HI LIM1 (DI01)

INC1 (DO02)

Reference Out 1

Return/4-20ma In

Field Ground

Reference Out 4

Feedback/Field 24V

Return/4-20ma In

Field Ground

Reference Out 3

Feedback3/Field 24V

P2

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

P3

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

Return/AI In

Field Ground

Reference Out 2

Feedback2/Field 24V

Return/4-20ma In

Field Ground

Feedback1/Field 24V

DEC1 (DO01)

1118

1724V

GND



Termination Field Connections Channels 1-2

Lo Limit2

Limit Com

Hi Limit2

CH2 Decrease

CH2 Increase

CH2 ac neutral

CH2 ac neutral

CH2 120V ac

18

17

CH2 Lo Limit

CH2 Hi Limit

Lo Limit1

Limit Com

Hi Limit1

CH1 Decrease

CH1 Increase

CH1 ac neutral

CH1 ac neutral

P2

7

8

5

3

4

1

2

9

10

6

12

11

13

14

15

7

8

9

10

12

11

16

13

14

15

24V

Logic Ground

CH1 LO LIMIT

CH1 120V ac

16

Field moduleP1

CH1 Increase

CH1 HI Limit

CH2 Decrease

CH2 Increase

CH1 Decrease1

2

3

4

5

6



Termination Field Connections Channels 3-4

Lo Limit4

Limit Com

Hi Limit4

CH4 Decrease

CH4 Increase

CH4 ac neutral

CH4 ac neutral

CH4 120V ac

CH3 Increase

CH3 Decrease

CH3 Lo Limit

CH3 Hi Limit

18

17

CH4 Increase

CH4 Decrease

Lo Limit3

Limit Com

Hi Limit3

CH3 Decrease

CH3 Increase

CH3 ac neutral

CH3 ac neutral

CH4 Lo Limit

CH4 Hi Limit

P3

7

8

5

3

4

1

2

9

10

6

12

11

13

14

15

7

8

9

10

12

11

16

13

14

15

24V

Logic Ground

CH3 120V ac

16

Field moduleP1

1

2

3

4

5

6



Group1 Analog I/O Configuration

3

P3

C

8

7

AI01C

24VF1

5

4

2

1

W11

W21

W14W13

W12

B

B

A

A

B

A

B

W15 A

therm

100K

shunt

AuxAI01

AO01(4-20ma)

AO01(+/-10V)

F1

F1

F1

AI02

W24

W23

W22

B

B

A

A

B

A

W29

therm

100K

shunt

6

AuxAI02

AO02(4-20ma)

F1

F1

F1

24VF1

Slidewire

3

P3

C

8

7

AI01C

24VF1

5

4

2

1

W11

W21

W14W13

W12

B

B

A

A

B

A

B

W15 A

therm

100K

shunt

AuxAI01

AO01(4-20ma)

AO01(+/-10V)

F1

F1

F1

AI02

W24

W23

W22

B

B

A

A

B

A

W29

therm

100K

shunt

6

AuxAI02

AO02(4-20ma)

F1

F1

F1

24VF1

Rotary Sensor

W16 W17 W16 W17

W25 W26W25 W26




11

P3

C

16

15

AI03C

24VF2

13

12

10

9

W11

W41

W14W13

W12

B

B

A

A

B

A

B

W15 A

therm

100K

shunt

AuxAI03

AO03(4-20ma)

AO03(+/-10V)

F2

F2

F2

AI04

W44

W43

W42

B

B

A

A

B

A

W49

therm

100K

shunt

14

AuxAI04

AO02(4-20ma)

F2

F2

F2

24VF1

Slidewire

11

P3

C

16

15

AI01C

24VF2

13

12

10

9

W31

W41

W34W33

W32

B

B

A

A

B

A

B

W35 A

therm

100K

shunt

AuxAI03

AO03(4-20ma)

AO03(+/-10V)

F2

F2

F2

AI04

W44

W43

W22

B

B

A

A

B

A

W49

therm

100K

shunt

14

AuxAI04

AO04(4-20ma)

F2

F2

F2

24VF2

Rotary Sensor

W36 W37 W36 W37

W45 W46W45 W46



Digital I/O Configuration Channels 1-2 Single-Phase and Three-Phase Motors

4

9

12

11

10

24V

GND 18

17

7

6

8

DO04

DI03

DI04

DI01

2

3 3

2

1

6

3

1 Module Termination

13

7 4 4

P2

1

DI02

5 5

8 8

7

P2

DO03

DO02

DO01

P1

5

6

18

17

H

N 2 120 AC

DEC1

INC1

M

DEC2

INC2

M

H

N 120 AC

14

16

15

HI LIM 2

LO LIM 2

HI LIM 1

LO LIM 1



Digital I/O Configuration Channels 3-4 Single-Phase and Three-Phase Motors

1414

15

8

DO08

DI07

DI08

DI05

10

1111

10

9

6

2

3

1 Module Termination

13

7 1212

P2

9

DI06

13 13

16 16

15

P3

DO07

DO06

DO05

P1

5

4

11

12

9

10

LO LIM 3

COM

HI LIM 3

16

15 14

LO LIM 4

COM

HI LIM 4

17

18

17

18

24V

GND

DEC3

INC3

M

DEC4

INC4

M

H

N 2 120 AC

H

N 120 AC



Digital I/O Configuration - DC Power Switches

16

15

14

13

12

11

7

8

Dec

Inc

Inc

Dec

24V

GND18

17

ModuleP2

Power Switch

2

1

DIO2

DIO1

Power Switch 10

9

DIO6

DIO5

Power Switch

DIO4

DIO3

4

3

Power Switch

6

5

DIO4

DIO3Commoning Strip



Specifications

TRIAC Outputs – 120VAC: Maximum Voltage: 200 VAC Continuous on-state current: 2A On-state voltage: 1.6 VAC Off-state current: 3.5 mA Hold Current: 50 mA Open Collector Outputs Maximum Current: 100mA Maximum Voltage: 28VDC Maximum on-resistance: 0.2 ohms Power 24Vdc system supply 400 ma Temperature 0-60 degrees C Humidity 0-90% no-condensing Surge (TRIAC Outputs only) IEEE-472-1974


Chapter 13

Turbine Valve Positioner Module IOP341

Turbine Valve Termination Module IOP342

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. The product consists of a maxPAC Positioning Module and a Turbine Valve Termination card. The Termination card provides both current and voltage outputs for characterizing the output for different coil types. It also provides signal conditioning for the frequency input.

The logic shown in the following 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 Tuning constants for the PI loop, I/O status, and other signals are accessible via the maxDPU4F.



Positioner Front Panel The Turbine Valve Positioner front panel contains LEDs to report the status of the digital inputs and outputs, and LEDs for module status indication. It also includes the two I/O connectors and a connector for the configuration cable.

K+ƒ

ServoAmp

Governor orThrottle ValvePosition Demand

ServoAmp

+/- 10 volt or+/- 40 ma

Pos

Pos

4-20 ma>

Coil(s)Status

Freq

ValvePos

PosErr

Mode

SpeedTurbine

Speed

Turbine Valve Positioner IOP341 Turbine Valve Termination IOP342


Features

Self-calibration on power-up

Channel-to-channel isolationField to logic isolationSoftware stored in FLASH

Fast Scan TimeFast slew rateFull complement of I/OFrequency inputsOn-line diagnosticsDownloadable 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




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:

Jumper function A B Installed Not Installed

W1 Wetting Voltage

Local Remote

W2 Frequency Voltage

0.2 – 10V 24V

W11 Channel 1 Series R

160 ohms and +/-10V

100 ohms or 4-20ma

210 ohms

W12 Channel 2 Series R

160 ohms and +/-10V

100 ohms or 4-20ma

210 ohms

W13 V/I Out +/- 40 ma +/-10 volts or 4-20ma

W14 V/I Out +/- 40 ma +/-10 volts or 4-20ma

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.

5V

0-2.5V4-20 ma 0-2.5V4-20 ma

4-20 ma

DO1 – DOI8

4-20ma or+/-10V

4-20 ma

4-20ma or+/-10V

0-2.5V4-20 ma 0-2.5V4-20 ma

24V

5V

+/-15V

24V

DI1 – DI8

OutputVirtual Power


FPGAI/O Bus


FLASH 2Mbit

I/O Bus Interface

RAM 64K Parity

CLOCK

OpticalIsolation

A/D 4 channels

D/A2 channels

OpticalIsolation

DC/DC

A/D4 channels

DC/DC

+/-15V

24V

D/A2 channels

DC/DC

DC/DC

RS232

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.



The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. The Time Processor Unit (TPU) included in the 68332 processor is used to process the frequency measurements. A FPGA includes the I/O bus control logic and provides support logic including parity.

Turbine Valve Termination

The IOP342 Turbine Valve Termination interfaces with the Positioner module via cable CTO302. It is a DIN rail mounted assembly with an 18-point Euro-style plug providing the interface for the field connections. The Positioner module provides 24-volt field power for the Termination circuits. The termination assembly provides the following functions:

• It coverts the +/-10V signals to 0-2 volts plus sign to be fed to the module for diagnostic loopback.

• A voltage-to-current converter converts the +/-10V signals to –40 to 40 ma. Either voltage or current output is available via jumper selection.

• 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:

Error Condition Code ADC Serial Transmit Fault 0x12 ADC Serial Transmit Fault 0x13 ADC Sanity Test Failed 0x15 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32 FLASH Erase Error 0x35 FLASH Programming Error 0x36 FPGA Error 0x37 Serial I/O Failure 0x38 Parity Error 0x39

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




DI1

DO2

DO1

DI8

DI7

DO7

DO8

DI7

DI6

DI3

DI4

DO5

DO6

DI2

DO3

DO4

4-20 ma or +/-10V out

Ch 3-4 Field Power

Voltage Feedback

Voltage Feedback

4-20 ma input

4-20 ma or +/-10V out

Ch 3-4 field Ground

P2

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

P3

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

Ch 1-2 Field Power

Voltage Feedback

Voltage Feedback

4-20 ma input

Ch 1-2 Field Ground

1118

1724V

GND



Termination Field Connections

DI3 (+/-10V_2 sign)

Coil_2 Current loopback

DI2 (+/-10V_1 sign)

+/-10V_2 loopback

4-20 ma or +/-10V out

Field Ret_2

Field 24V_2

18

Field 24V_2

4-20ma input

Chassis Gnd

Coil 2 (-)

Coil 1 (+)

NO

0.2-10Vfrequency

24Vfrequency

Field 24V_1

4-20ma input

Chassis Gnd

Coil 2 (-)

DO1

DI1 (frequency)

P2

7

8

5

3

4

1

2

9

10

6

12

11

13

14

15

7

8

9

10

12

11

16

13

14

15

24V

Logic Ground

+/-10V_1 loopback

Coil 1 (+)

11

16

17

Field moduleP1

Field Ret_1

4-20 ma or +/-10V out

Coil_1 Current loopback

Ch 1-2 Field Ground

Field 24V_11

2

3

4

5

6

COM

NC




4-20 ma

P3

C

8

7

5

AI01C

24VF1

4 5

Output voltage

42

6

21

13

Sign 1

50 62 5050

P2

W11

W21

W11

W13

24VF1

1

5

2

3

4 24VF1

W14W13

W12

B

B

A

A

B

A

B

W15 A

therm

100K

shunt

3

AuxAI01

AO01(4-20ma)

AO01(+/-10V)

+/- 40 ma

Buffer

Current

Sense

F1

F1

F1

F1

AI02

W24

W23

W22

B

B

A

A

B

A

W29

therm

100K

shunt

6

AuxAI02

AO02(4-20ma)

F1

F1

F1

F1

Output current

24VF1

P1Termination Module




15

114-20 ma

P3

C

16

11

AI03C

24VF3

10 13

Output voltage

128

12

107

99

Sign 2

50 62 5050

P2

W31

W41

W12

W14

24VF2

6

10

7

8

9 24VF2

W34W33

W32

B

B

A

A

B

A

B

W35 A

therm

100K

shunt

AuxAI03

AO03(4-20ma)

AO03(+/-10V)

+/- 40 ma

Buffer

Current

Sense

F2

F1

F2

F2

AI04

W44

W43

W42

B

B

A

A

B

A

W49

therm

100K

shunt

14

AuxAI04

AO04(4-20ma)

F2

F2

F2

F2

Output current

24VF2




Digital I/O Configuration

18

17

16

216

P2

7

3

DIO4

18 18

17

14 8

13

15

Sign 2

P2

GND

W2

W1

24VF2

12

13

14

15

DO02

DIO3

DIO1

24V17


Conditioning Circuit

Sign 1



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 Turbine valve Inputs

Analog: 4-20 ma (isolated 24V supplied from the system)

Accuracy: 0.15% Resolution: 14 bits Scan Time: 5 msecs

Frequency: Frequency: 0 -10KHz

Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz – 50Kz.

Input voltage: 200 mv. to 10V or 24V.

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 RS232 Port: 9600 baud Power 24Vdc system supply 500 ma Temperature 0-60 degrees C Humidity 0-90% no-condensing Surge IEEE-472-1974


Chapter 14

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.

F

F

TurbineSpeedPulses

F

Median

>

>

Runback %

Trip %

RunbackOutput

TripOutput

Median Speed

Raw Speed2

Raw Speed1

Raw Speed3

FieldDPU

Runback Status

Trip Status

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


Fast frequency measurements

Field to logic isolationFast scan time

On-line diagnosticsDownloadable personality

Overspeed Front Panel The Overspeed module front panel contains LEDs to report the status of the digital inputs and outputs, and LEDs for module status indication. It also includes the two I/O connectors and a connector for the configuration cable.

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

Overspeed Trip Module IOP345 Overspeed Termination IOP 346


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.

Jumper Position Jumper Position W11 B W21 B W12 A W22 Not Installed W13 Not Installed W23 Not Installed W14 Installed W24 Installed W15 Not Installed W25 Installed W16 Installed W26 Installed W17 Installed W29 Not Installed

Jumper Position Jumper Position W31 B W41 B W32 Not Installed W42 Not Installed W33 Not Installed W43 Not Installed W34 Installed W44 Installed W35 Not Installed W45 Not Installed W36 Installed W46 Installed W37 Installed W49 Installed

Refer to the following table for the Turbine Valve Termination jumpers.Bold indicated the default positions:

Jumper function Installed Not Installed

W1 Wetting 1 Voltage

Local Remote

W2 Frequency 1 Voltage

0.2 – 10V 24V


Local Remote


0.2 – 10V 24V


Local Remote


0.2 – 10V 24V



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. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. The Time Processor Unit (TPU) included in the 68332 processor is used to process the frequency measurements. A FPGA provides support logic including parity and the I/O bus control logic.



+/-15V

5V

0-2.5V4-20 ma 0-2.5V4-20 ma

4-20 ma

DO1 – DOI8

4-20ma or+/-10V

4-20 ma

4-20ma or+/-10V

0-2.5V4-20 ma 0-2.5V4-20 ma

24V

5V

24V

DI1 – DI8

OutputVirtual Power


FPGAI/O Bus


FLASH 2Mbit

I/O Bus Interface

RAM 64K Parity

CLOCK

OpticalIsolation

A/D 4 channels

D/A2 channels

OpticalIsolation

DC/DC

A/D4 channels

DC/DC

+/-15V

24V

D/A2 channels

DC/DC

DC/DC

RS232

Positioning Module

Overspeed Trip Termination

The IOP346 Turbine Overspeed Termination interfaces with the Positioner module via cable CTO303. It is a DIN rail mounted assembly with an 18-point Euro-style plug providing the interface for the field connections. The Positioner module provides 24-volt field power for the Termination circuits. The termination assembly provides the following functions:

• It provides signal conditioning and optical isolation for the three frequency inputs and provides 5-volt square waves to the module.



• Two form C relay outputs are included.


Error Condition Code ADC Serial Transmit Fault 0x12 ADC Serial Transmit Fault 0x13 ADC Sanity Test Failed 0x15 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32 FLASH Erase Error 0x35 FLASH Programming Error 0x36 FPGA Error 0x37 Serial I/O Failure 0x38 Parity Error 0x39




DI07

DI08

DI07

DO07

DO08

DI06

DI03

DI04

DO05

DO06

DI02

DO03

DO04

DI01

DO02

P2

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

P3

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

24V Field Power

Field Ground

DO01

1118

1724V

GND



Termination Field Connections

Frequency 2

Field Ground

Field 24V

COM

NC

DO02

DO01

Frequency 3

18

NO

Logic Ground

24V

P2

7

8

5

3

4

1

2

9

10

6

12

11

13

14

15

7

8

9

10

12

11

16

13

14

15

24V

Logic Ground

0.2-10Vfrequency

11

24Vfrequency

16

17

Field moduleP1

Field Ground

Frequency 1

Field 24V

1

2

3

4

5

6

24Vfrequency

0.2-10Vfrequency

24Vfrequency

0.2-10Vfrequency

NO

COM

NC




3

P3

C

8

7

AI01C

24VF1

5

44

3

22

1

1

P2

W11

W21

24VF1

W14W13

W12

B

B

A

A

B

A

B

W15 A

therm

100K

shunt

AuxAI01

AO01(4-20ma)

AO01(+/-10V)

F1

F1

F1

AI02

W24

W23

W22

B

B

A

A

B

A

W29

therm

100K

shunt

6

AuxAI02

AO02(4-20ma)

F1

F1

F1

F1

24VF1





11

P3

C

16

15

AI03C

24VF2

13

12

10

9

P2

W31

W41

W34W33

W32

B

B

A

A

B

A

B

W35 A

therm

100K

shunt

AuxAI01

AO03(4-20ma)

AO03(+/-10V)

F2

F2

F2

AI04

W44

W43

W42

B

B

A

A

B

A

W49

therm

100K

shunt

14

AuxAI04

AO04(4-20ma)

F2

F2

F2

24VF2




Digital I/O Configuration

ModuleTermination

18

15

13

14

15

16

17

18

17

18

77

P2

6

3

DIO59 11

13 2

14

5

DO04

P2

GND

DO02

DIO3

DIO1

24V

P1

W2

W124VF2

12

13

14

15Conditioning Circuit

W6

W524VF212

13


W4

W324VF2

12

13

14


16

17

15



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 RS232 Port: 9600 baud Power 24Vdc system supply 500 ma Temperature 0-60 degrees C Humidity 0-90% no-condensing Surge IEEE-472-1974


Chapter 15

HART Input Module IOP307

HART Output Module IOP322

HART Transceiver Module IOP364

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.

Har

t Mod

ule

Features

Fully isolated channels

Standard variables available inmaxDPUF for use in control

Hart modem per channel16 bit A/D and D/A Performance

Asset Management throughMetso FieldCare Product line

Custom interface for specialpurpose control

HART



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


Jumper Configuration

The following are the jumper settings for the various HART modules.

Analog Output Module

Jumper Installed Not Installed W1 MaxPAC-8 address * HART – 2 address W2 Hold Output Reset Output W3 Secondary Primary W4 Not used Not used W5 Common I/O Redundant I/O

* This is a compatibility mode jumper that configures the module to operate in 8-address mode like the non-HART maxPAC module.

Analog Input and Transceiver Module

Jumper Installed Not Installed W1 Not used Not used W2 Not used Not used W3 Not used Not used W4 Not used Not used W5 Common I/O Redundant I/O

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

Hart Analog Input IOP307 Hart Analog Output IOP322 Hart Transceiver IOP364


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. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. A FPGA provides support logic including parity and the I/O bus control logic. Optical isolators and a DC/DC converter per channel provide channel to channel and field to logic isolation as well as field power to each of the channels. Eight UARTS provide the interface to the HART modems via the optical isolators. The transceiver module does not include the AI or AO circuits.



4-20ma

4-20 ma

24V

FPGA

I/O Bus


FLASH 2Mbit

I/O Bus Interface

RAM 64K Parity

CLOCK

OpticalIsolation

Hart Modem

***AI or AO

OpticalIsolation

DC/DC

Hart Modem

*** AI or AO

DC/DC

RS232

Hart Module

*** Not included in Tranceiver Module

UART (8)


Error Condition Code ADC Serial Transmit Fault 0x12 ADC Serial Transmit Fault 0x13



ADC Sanity Test Failed 0x15 RAM Test Failure (power-on) 0x22 CPU Stack Error (power-on) 0x23 CPU Error (power-on) 0x24 Checksum Error (power-on) 0x25 Interrupt Error (power-on) 0x26 FPGA Download Error (power-on) 0x32 FLASH Erase Error 0x35 FLASH Programming Error 0x36 FPGA Error 0x37 Serial I/O Failure 0x38 Parity Error 0x39



HART Analog Input Field Connections

P1

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

P2

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

GND

4-20 ma

24V

CH1

GND

4-20 ma

24V

CH2

GND

4-20 ma

24V

CH3

GND

4-20 ma

24V

CH4

GND

4-20 ma

24V

CH1

GND

4-20 ma

24V

CH2

GND

4-20 ma

24V

CH3

GND

4-20 ma

24V

CH4



HART Analog Output Field Connections

P1

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

(+)

(-)4-20 ma inCH1

(+)

(-)4-20 ma inCH2

(+)

(-)4-20 ma inCH3

(+)

(-)4-20 ma inCH4

(+)

(-)4-20 ma inCH5

(+)

(-)4-20 ma inCH6

(+)

(-)4-20 ma inCH7

(+)

(-)4-20 ma inCH8



HART Transceiver Field Connections

P1

7

8

5

3

4

1

2

9

10

6

12

11

16

13

14

15

(+)

(-)

CH1

(+)

(-)

CH2

(+)

(-)

CH3

(+)

(-)

CH4

(+)

(-)

CH5

(+)

(-)

CH6

(+)

(-)

CH7

(+)

(-)

CH8



Transceiver to Analog Input Wiring

Shared IO: Two-wire Transmitter

1D

1C1E

200

100

Transceiver Module - IOP361

AI Module - IOP301 From Backplane

4-20 ma

Rp

24V(-)

24V(+)

Xmitter

Rs2

1

1A

A/D

+ -

1B

HART MODEM2

1




Shared IO: Four-wire Transmitter

1D

1C1E

200

100

4-20 ma

From backplane

Rp

24V(-)

24V(+)

Xmitter

Rs 2

1

1A

A/D

+ -

1B

AI Module - IOP301

HART MODEM2

1





Redundant IO: Two-wire Transmitter

1D

1C

1E

200

100

1D

1C1E

200

100

200

100

Xmitter

From backplane

Rp

24V(-)

24V(+)

Rs2

1

1A

A/D

+ -

1B

AI Module - IOP301

2

1 HART MODEM


From backplane

Rp

24V(-)

24V(+)

Rs2

1

1A

A/D

+ -

1B

AI Module - IOP301

24V Supply (+)

(-)




Redundant IO: Four-wire Transmitter

1D

1C

1E

200

100

1D

1C1E

200

100

200

100

Xmitter

From backplane

Rp

24V(-)

24V(+)

Rs2

1

1A

A/D

+ -

1B

AI Module - IOP301

2

1 HART MODEM


From backplane

Rp

24V(-)

24V(+)

Rs2

1

1A

A/D

+ -

1B

AI Module - IOP301



Transceiver to Output Driver Wiring

4-20 ma

Output Device

16

17

D/A

Output Driver- IOP116

HART MODEM2

1


Transceiver to Analog Output Wiring

4-20 ma

Output Device

1

2

D/A

Analog Output – IOP320

HART MODEM2

1




HART Analog Input Wiring

NOT USED

4-20 ma

200 ohm

100 ohm shunt

1

2

4

2

4

1

TO A/D

To HART modem

To HART modem

100 ohm shunt

24V

TO A/D

TRANSMITTER

Two-WireTransmitter

TRANSMITTER

Four-Wire Transmitter

Disconnect for redundant module input

HART AI Module

24V HART AI Module

200 ohm

Disconnect for redundant module input

Transmitter Power

4-20 ma




Redundant Modules: Two-Wire Transmitter

200 ohm

200 ohm

24V(-)

24V(+)

TRANSMITTER

2

4

1

To HART modem

100ohm shunt

24V

TO A/D

Disconnect for redundant module input. On when DPU active

HART AI Module

2

4

1

To HART modem

24V

TO A/D


HART AI Module

100ohm shunt




Redundant Modules: Four-Wire Transmitter

200 ohm

200 ohm

TRANSMITTER

2

4

1

To HART modem

100ohm shunt

24V

TO A/D


HART AI Module

2

4

1

To HART modem

24V

TO A/D


HART AI Module

100ohm shunt

Transmitter Power



HART Analog Output Wiring

4-20 ma

24V(+)

24V(-)

OUTPUT DEVICE

1

2

HART AO Module

D/A

HART MODEM

Disconnect for redundant module input. Closed when DPU active

Redundant Modules

4-20 ma

24V(+)

24V(-)

OUTPUT DEVICE

1

2

HART AO Module

1

2

D/A

HART MODEM

Disconnect for redundant module input. Closed when DPU active

24V(+)

24V(-)

HART AO Module

D/A

HART MODEM



Specifications

Channels per Module: 8 I/O Bus Address per Module: 2 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

Date post:	11-Nov-2014
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