MaxDna_ Field Wiring

Model IOPI/O Subsystem

Field Wiring277562 Rev. B

Metso Automation MAX Controls •••• 277562 ••••

Refer to this publication for complete and accurate information that helps you better operate and service MetsoAutomation MAX Controls equipment. Your comments and suggestions are welcome.

Metso Automation MAX Controls, Inc.1180 Church RoadLansdale, PA 19446Attention: Manager, Technical Publications

Copyright 1999-2001 by Metso Automation MAX ControlsPrinted in the United States of America

All rights reserved

Metso Automation MAX Controls •••• 277562••••

Contents

PREFACE ........................................................................................................................... IIIAudience ............................................................................................................................................................. iii

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

Mounting and Removing I/O Modules...................................................................................................................... 1-1Removing Plug-in Modules....................................................................................................................................... 1-1

Module Mounting.................................................................................................................................................. 1-1

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

Process Connections and Terminal Assignment ....................................................................................................... 2-1Wiring and Terminations .......................................................................................................................................... 2-1

Field Wiring Practice ............................................................................................................................................ 2-1Termination of Cable Shields................................................................................................................................ 2-2Optional Terminal Lug Wiring.............................................................................................................................. 2-3Module Configuration ........................................................................................................................................... 2-3

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

High Level Analog Inputs Module 081815/081824................................................................................................... 3-1Introduction............................................................................................................................................................... 3-1

Individually Fused Current Inputs with External Drop Resistors.......................................................................... 3-1Individually Fused Current Inputs with Internal Drop Resistors .......................................................................... 3-3Inputs with External Loop Supply and External Drop Resistors .......................................................................... 3-5Inputs with External Loop Supply and Internal Drop Resistors ............................................................................ 3-8Isolated High Level Analog Input Module 081815 Terminal Connections........................................................ 3-10Field Wiring ........................................................................................................................................................ 3-10Voltage Inputs ..................................................................................................................................................... 3-10

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

Thermocouple/Millivolt Inputs Module 081803 ....................................................................................................... 4-1Requirements............................................................................................................................................................. 4-1

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

Resistance Input Modules 081804 and 081814 ......................................................................................................... 5-1Types......................................................................................................................................................................... 5-1

Three-Wire RTDs ................................................................................................................................................. 5-1

Model IOP I/O Subsystem Field Wiring

Metso Automation MAX Controls •••• 277562 ••••

Four-Wire RTDs ................................................................................................................................................... 5-4

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

Output Driver Modules CAT 064594, PAT 064314 ................................................................................................. 6-1Terminal Connections ............................................................................................................................................... 6-1

Current Adjusting Type (CAT) ............................................................................................................................. 6-1Position Adjusting Type (PAT)............................................................................................................................. 6-4

AC Drive Units.................................................................................................................................................. 6-4DC Drive Units.................................................................................................................................................. 6-4PAT Feedback................................................................................................................................................... 6-4Two-Wire Rotary Sensor................................................................................................................................... 6-5Four-Wire Rotary Sensor .................................................................................................................................. 6-5

Duration Adjusting Type (DAT) ......................................................................................................................... 6-10Connecting Model MAS Auto/Manual Station ................................................................................................... 6-12

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

Analog Output Module Terminal Connections ........................................................................................................ 7-1Description ............................................................................................................................................................ 7-1

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

Quad PAT Output Module Terminal Connections .................................................................................................. 8-1

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

Digital Input/Output Module Terminal Connections............................................................................................... 9-1Introduction ........................................................................................................................................................... 9-1

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

Counter/Timer Input Connections and Terminal Assignment............................................................................. 10-1


Preface

AudienceThis publication provides the information required to complete field wiringfor the following MAXDNA Model IOP Series modules:

• Digital Input Modules 081809, 081808, 081807, 081806, 056663,056511, 056662, 056521, 056661,

• Digital Output Modules 056513, 056693, 056512, 056692, 064319

• Counter/Timer Module 056516

• Analog Output Modules 056515, 080403, 080424, 064594, 080401

• High Level Analog Input Modules 081815 and 081824

• Thermocouple/Millivolt Input Module 081803

• Resistance Input Modules, 081804 and 081814

• Output Driver Modules CAT 064594, PAT 064314

• Relay Digital Outputs 081820 and 081823

Individual terminal assignments are included for all channels on eachmodule. Information is provided on support frame mounting for the ModelIOP Input/Output System.

Chapter 2 also addresses the termination of cable shields and optionalterminal lug wiring.

For more information on the preparation and adjustment of individual mod-ules, refer to the following Metso Automation MAX Controls publications.

Book No. Title277566 Analog Output Modules Preparation and Adjustment

277565 Counter/Timer Module Preparation and Adjustment

277564 Digital Input/Output Module

277563 Input/Output System Installation, Preparation, andAdjustment


Metso Automation MAX Controls •••• 277562••••iv

277569 Output Driver Field Wiring, Preparation andAdjustment

277567 Analog Input Modules Preparation and Adjustment

277570 Heavy Duty Relay Panel

277571 Binary Control Module Preparation and Adjustment


Chapter 1

Mounting and RemovingI/O Modules

Removing Plug-in ModulesBefore you wire I/O modules/chassis assemblies, you must remove themfrom their support frames. Refer to Figure 1-1. I/O design allows you toinstall and remove modules with the +24 V dc power supply applied.

Caution: While pulling and terminating field wiring, you may need toremove printed circuit modules. Before mounting plug-in modules, read thecaution statement inside the front cover of this publication concerningelectrostatic discharge (ESD).

To remove module/chassis assemblies:

1. Loosen the top and bottom lock-down screws that attach module tochassis assembly; the lock-down screws are not removable from themodule assembly. Use the ejector to release module from the supportframe bus connector and the chassis assembly connector.

2 Place forefinger behind the upper tab of the ejector. Place thumb onlower ejector tab.

3 Simultaneously pull with your forefinger and push with your thumb.

4 Lever action of the ejector simultaneously releases the module from theI/O bus connector and the chassis assembly.

5. Slide module forward and out of the top and bottom card guides ofchassis assembly. Temporarily store the module observing the handlingprecautions described inside the front cover of this publication.

Module MountingBefore installing any modules, refer to Publication 277563, Model IOPInput/Output System Installation, Preparation, and Adjustment, and to the


Metso Automation MAX Controls •••• 277562••••1-2

appropriate preparation and adjustment publication to check for correctmodule addressing and jumper selection.

To mount I/O modules:

1. With chassis assembly in place and all wiring completed, positionmodule into top and bottom card guides of the chassis. Gently slidemodule forward, verifying that the connector pins on the solder side ofthe module engage the corresponding contact guides on the chassisassembly.

2. When the contacts are engaged and resistance is felt, firmly press onthe front panel of the module front plate to make the simultaneousconnections on the front and rear. Apply pressure to the left of theLEDs to place the force directly in line with the printed circuit card ofthe module.

3. Secure module to chassis assembly with the top and bottom lock-downscrews on the front of the module.

Figure 1-1. Model IOP I/O Chassis Module Installation


Chapter 2

Process Connections andTerminal Assignment

Wiring and TerminationsThis section describes process input and output connections to the ModelIOP I/O. For easy access, wire termination is at the front of the cabinet. Awire duct (4 in. x 6 in.), provided for wire routing, is located directly behindthe terminal strips on the chassis assembly.

Warning - shock hazard: Field wiring from end-element devices may be ashigh as 240 V ac or 120 V ac/dc. Remove the voltage from the field wiresbefore making connections.

Field wiring should be done after chassis assembly mounting and before themodules are installed. If modules are installed, remove them as described inChapter 1.

Because of the compact design of the Model IOP I/O, and the closeness ofadjacent modules, you should keep the field wiring from the wire duct to theterminals short to avoid interference with adjacent modules (See Figure 2-1).One or two 14 AWG wires may be used per terminal. Wire sizes rangingfrom 10 to 18 AWG can be accommodated. The screw terminals also includewire clamps, making lugs unnecessary.

The jumper strips provided, (part number 064362), should be used forcommoning instead of additional wiring, but it is not recommended that thejumper strips be used for high current output loads. For example, if you wereusing all 16 outputs of a 2 A per output module, the current could be as highas 32 A (16 x 2 A).

Field Wiring PracticeBefore connecting end element devices (process inputs and outputs) to theModel IOP I/O chassis assembly, follow these general rules to maintain theintegrity of the signals. These rules apply to most field wiring applications,not solely MAXDNA distributed control equipment.



•••• All low-level signal wiring should always be physically separate fromall high-level power wiring.

•••• Analog signal wiring should be made with shielded twisted-pairs andshould not be in the same vertical wire bundle with high level ac or dcwiring.

•••• Digital ac wiring should be in its own vertical wire path(s), separatedfrom digital dc vertical wiring path(s).

•••• Try to keep high and low level ac and dc signals separate.

These specific rules are summarized as follows: Wherever possible, grouptogether wiring of the same type (ac or dc) and same level (voltage orcurrent), and separate each wire group from the other wire groups.

Termination of Cable ShieldsMost low-level signals connected to the MAXDNA system are run inshielded cables to keep the common mode voltage between the signal andthe ground reference for that signal as small as possible.

Shields are grounded at the point of usage. For example, analog input shieldsshould be grounded at the Remote Processing Unit (RPU) cabinet (seebelow), and analog output shields should be grounded at the field device.

Note: a grounded thermocouple is an exception. In this case, the shieldshould be grounded at the thermocouple junction, and not at the RPUcabinet.

In many cases, terminals are provided for shield connection. In those caseswhere no shield terminals exist, or if all available shield terminals are used,an isolated bus bar can be installed in the bottom of the cabinet and can beused for terminating the shields. This bus bar is often supplied with thesystem, and should be connected (using an insulated conductor) directly tothe systems' central ground point.

Note: if a shield is connected to ground at the RPU cabinet, it must not begrounded at any other point.

Also, from the point that the shield exits the cable to the point where it isterminated, the shield should be insulated using some insulating tape orsheath to prevent any electrical shorts.

Process Connections and Terminal Assignments

Metso Automation MAX Controls •••• 277562•••• 2-3

Optional Terminal Lug WiringThe Output Driver Auto/Manual cable is terminated using terminal lugs onthe end of the leads. This technique can be used in other applications, suchas where small wires (under size 18 AWG) must be terminated. In theseapplications, the following hardware can be used:

•••• Terminal Lug - Amp #640903-1, 250 series, 22-18 AWG (No partnumber)

•••• 45 Degree Tab - Augat/RDI Part QC8-45-4. Part Number 198947.•••• 90 Degree Tab - Augat/RDI Part QC8-90-4. Part Number 198946.•••• 3/8 x 8-32 Bindhd Screw - Part Number 304718

Note: the screw and plate provided with the terminal strip should bediscarded and replaced with the 3/8 x 8-32 screw listed above.

Module ConfigurationEach Model IOP I/O chassis assembly contains 40 #8 screw terminals.Depending on module type and the type of connections, you will not alwaysneed to use all 40 terminals. For example, on the digital modules, 32terminals are active and 8 are spares used for busing of loads and contacts,or the spares may not be used at all. The screw terminals include wireclamps, allowing for bare wires.

Jumper strips are provided for commoning. The screws are arranged instaggered rows of 20 terminals each, protected by a cover plate removablefor wiring access. Cover plates are labeled to show module number and wireidentification. Label information is completed on site when wiring iscompleted. Terminal assignments are the same regardless of which type ofdigital I/O module is plugged into the chassis.

Caution: The Model APS1xx +24 V dc power supply used to power anyMAXDNA hardware should never be used for external relay contact wetting.Use an isolated, separate supply for contact wetting to provide noise andinterference protection for the MAXDNA hardware.

Each type of digital Model IOP I/O Module, which plugs into the chassisassembly containing the field connections, handles 16 inputs or outputs.Inputs, outputs, input levels, and output levels are not mixed on the samemodule. In other words, all points on the same module are identical.However, the Relay Output Module 064319 can have any mix of normallyopen or normally closed contacts, up to 16. On the chassis assembly, threescrew terminals are associated with each of the 16 inputs/outputs (commonsare shared by 2 points). The terminal arrangement is standard, with input andoutput ranges determined by the module used.



The Model IOP I/O Module design provides isolation of each input andoutput from the I/O bus and from the other inputs and outputs. When manyinputs or outputs on the same module are using the same field power source,you can reduce wiring by using the jumper strips provided for each module.Be careful when using the jumper strips on output modules because thecombined current load of several outputs can become excessive.

Figure 2-1 shows a top view of two adjacent Model IOP Modules. Take careto position the field wiring so that there is no interference with adjacentmodules. This point can be easily overlooked since the modules will not beinstalled during field wiring. Be careful not to make big loops in the wiringbetween the duct and the terminal board that will obstruct moduleinstallation.

Caution: You must remove plug-in modules before performing field wiring.If modules are replaced in the wrong location, equipment damage can occurdue to possible field wiring voltage/current level differences between chassisassemblies. Return plug-in modules to their original positions when fieldwiring is completed. Use the labels provided on the screw terminal covers ofthe chassis assemblies to record module number and wiring information.

To help prevent incorrect module replacement, a good practice is to groupthe same voltage/current range modules together vertically as much aspossible. Keep the corresponding field wiring in the same vertical paththrough the wire ducts on the chassis assemblies.

Figure 2-1. Model IOP I/O field wiring. Top view of adjacent modules


Chapter 3

High Level Analog InputsModule 081815/081824

IntroductionInput connections vary by input type and application. Refer to this chapterfor information about various connection options. Current inputs requiremounting of drop resistors. Module 081824 information is presented first.Module 081815 information appears later in this chapter.

Individually Fused Current Inputs with External Drop ResistorsThe 081824 module is manufactured with jumpers in position forindividually fused current inputs. Jumper positions do not have to bechanged. Figure 3-1 illustrates input connections for channels 1 and 2. Table3-1 provides connections for additional channels.

The 081824 module is manufactured with a 0.4 Volt to 2.0 Volt span forcurrent input through a 100 Ohm resistor. These resistors can be mounted onthe terminal board (see Figure 3-1), or in a location external to the module.A 24 Volt dc power supply is to be connected to terminals 38 and 39 asshown in Figure 3-1. The power supply should be rated to provide 20 mA foreach transmitter loop.

Note: do not use the Model APS1xx +24 V system power supply for thiscurrent source.



Figure 3-1. Current inputs, individually fused common loop supply,external resistors, 081824

High Level Analog Inputs Module 081815/081824


Table 3-1. Current Input Connections; Individually Fused/Protected;Common External Loop Supply External Resistor, 081824

Terminal No. Channel Designation

12345678910111213141516171819202122232425262728293031323334353637383940

1 and 211223344

3 and 45 and 6

5 5667788

7 and 89 and 10

99101011111212

11 and 1213 and 14

131314141515——15

Resistors 1 and 2Transmitter 1 —, resistor 1Transmitter 1 +Transmitter 2 —, resistor 2Transmitter 2 +Transmitter 3 —, resistor 3Transmitter 3 +Transmitter 4 —, resistor 4Transmitter 4 +

Resistors 3 and 4Resistors 5 and 6

Transmitter 5 —, resistor 5Transmitter 5 +Transmitter 6 —, resistor 6Transmitter 6 +Transmitter 7 —, resistor 7Transmitter 7 +Transmitter 8 —, resistor 8Transmitter 8 +


Transmitter 9 —, resistor 5Transmitter 9 +Transmitter 10 —, resistor 10Transmitter 10 +Transmitter 11 —, resistor 11Transmitter 11 +Transmitter 12 —, resistor 12Transmitter 12 +


Transmitter 13 —, resistor 13Transmitter 13 +Transmitter 14 —, resistor 14Transmitter 14 +Transmitter 15 —, resistor 15Transmitter 15 +Power Supply +Power Supply —No Connection

Individually Fused Current Inputs withInternal Drop Resistors

The module 081824 is manufactured with jumpers in position forindividually fused current inputs. Jumper positions do not have to be



changed. Figure 3-2 illustrates input connections for channels 1 and 2. Table3-2 provides connections for additional channels. The 081824 module ismanufactured with a 0.4 Volt to 2.0 Volt span for current input through a100 Ohm resistor. These resistors are to be mounted on the printed circuitassembly in position shown in Figure 3-2. The 081824 module ismanufactured with component jacks for mounting these resistors.

A 24 Volt dc power supply is to be connected to terminals 38 and 39 asshown in Figure 3-2. The power supply should be rated to provide 20 mA foreach transmitter loop.


Figure 3-2. Current inputs, individually fused common loop supply,internal resistors, 081824.

Table 3-2. Current Input Connections, Individually Fused/Protected,Common Loop Supply Internal Resistors

Terminal No. Channel Designation12

1

No connectionTransmitter 1



345678910

11121314151617181920

21222324252627282930

313233343536373839

40

1223344

5 5667788

99101011111212

131314141515

Transmitter 1 +Transmitter 2 Transmitter 2 +Transmitter 3 Transmitter 3 +Transmitter 4 Transmitter 4 +

No connection

no connectionTransmitter 5 Transmitter 5 +Transmitter 6 Transmitter 6 +Transmitter 7 Transmitter 7 +Transmitter 8 Transmitter 8 +

No connection

No connectionTransmitter 9 Transmitter 9 +Transmitter 10 Transmitter 10 +Transmitter 11 Transmitter 11 +Transmitter 12 Transmitter 12 +

No connection

No connectionTransmitter 13 Transmitter 13 +Transmitter 14 Transmitter 14 +Transmitter 15 Transmitter 15 +Power Supply +Power Supply

No connection

Inputs with External Loop Supply andExternal Drop Resistors

The modules are manufactured with jumpers in position for individuallyfused current inputs. Jumper positions must be changed for external loopsupplies. Figure 3-3 illustrates the input connections for channels 1 and 2.Table 3-3 provides input connections for additional channels. The 081824module is manufactured with a 0.4 Volt to 2.0 Volt span for current inputthrough a 100 Ohm resistor. These resistors can be mounted on the terminal



board (see Figure 3-3), or in a location external to the module. A 24 Volt dcpower supply is to be connected in the loop as shown in Figure 3-3. Thepower supply should be rated to provide 20 mA for each transmitter loop.


Figure 3-3. Current inputs, external loop supply, external resistors,081824

Table 3-3. Current Input Connections, External Loop Supply ExternalResistors, 081824


1122334

No connectionTransmitter 1 , resistor 1Power Supply , resistor 1Transmitter 2 , resistor 2Power Supply , resistor 2Transmitter 3 , resistor 3Power Supply , resistor 3



910

11121314151617181920

21222324252627282930

31323334353637383940

4

5 5667788

99101011111212

131314141515

Transmitter 4 , resistor 4Power Supply , resistor 4

No connection

No connectionTransmitter 5 , resistor 5Power Supply , resistor 5Transmitter 6 , resistor 6Power Supply , resistor 6Transmitter 7 , resistor 7Power Supply , resistor 7Transmitter 8 , resistor 8Power Supply , resistor 8

No connection

No connectionTransmitter 9 , resistor 9Power Supply , resistor 9Transmitter 10 , resistor 10Power Supply , resistor 10Transmitter 11 , resistor 11Power Supply , resistor 11Transmitter 12 , resistor 12Power Supply , resistor 12

No connection

No connectionTransmitter 13 , resistor 13Power Supply , resistor 13Transmitter 14 , resistor 14Power Supply , resistor 14Transmitter 15 , resistor 15Power Supply , resistor 15

No connectionNo connectionNo connection



Inputs with External Loop Supply and Internal Drop ResistorsThe module 081824 is manufactured with jumpers in position forindividually fused current inputs. Jumper positions must be changed forexternal loop supplies. Figure 3-4 illustrates the input connections forchannels 1 and 2. Table 3-4 provides input connections for additionalchannels. The 081824 module is manufactured with a 0.4 Volt to 2.0 Voltspan for current input through a 100 Ohm resistor. These resistors are to bemounted on the printed circuit assembly in position shown in Figure 3-4.The 081824 module is manufactured with component jacks for installationof these resistors. A 24 Volt dc power supply is to be connected in the loopas shown in Figure 3-4. The power supply should be rated to provide 20 mAfor each transmitter loop.


T2

T1+ -

+ -

1

3

5

39

38

4

2

40

R2100 ohm *

R6100 ohm *

R-CNETWORK

R-CNETWORK

W1

W2W3

W4W5

W6

Solid StateSelf-Reset Fuse*

Ch 1 - R2Ch 2 - R6Ch 3 - R10Ch 4 - R14

Ch 5 - R18 Ch 9 - R67 Ch 13 - R75Ch 14 - R79Ch 15 - R83

Ch 10 - R38Ch 11 - R42Ch 12 - R46

Ch 6 - R22Ch 7 - R55Ch 8 - R71

CHASSISTERMINAL BOARD

return

(+)

ch #1

(-)

(+)

ch #2

(-)

+24V

-24V

HIGH LEVEL ANALOG INPUT MODULE

PS+ -

Figure 3-4. Current inputs, external loop supply internal resistors



Table 3-4 - Current Input Connections - External Loop Supply InternalResistors


11121314151617181920

21222324252627282930

31323334353637383940

11223344

5 5667788

99101011111212

131314141515

No connectionTransmitter 1 Power Supply Transmitter 2 Power Supply Transmitter 3 Power Supply Transmitter 4 Power Supply

No connection


No connection


No connection

No connectionTransmitter 13 Power Supply Transmitter 14 Power Supply Transmitter 15 Power Supply

No connectionNo connectionNo connection



Isolated High Level Analog InputModule 081815 Terminal Connections

The 081815 isolated high level analog input module provides 15 isolatedvoltage input channels. Each channel has a 0 to 2.4V span. For currentinputs, a 100 Ohm shunt resistor must be installed externally. For voltageinput spans other than 2.4V, voltage divider resistors must be installedexternally.

Field WiringInput connections vary by type of input and application. Refer to thefollowing sections for information pertaining to three different kinds ofconnections.

Voltage InputsThe 081815 module is manufactured with an input span of 0 to 2.4 Volts.Voltage above this will require a voltage divider. See Figure 3.5 and Table3.5.

Note: do not use the Model APS +24 V system power supply for this currentsource.



+

V1

-

+

V2

-

40

39

38

5

4

3

2

1 return

(+)

ch #1

(-)

(+)

ch #2

(-)

+24V

-24V

R5400K

R2400K

CHASSISTERMINAL BOARD

HIGH LEVEL ANALOGINPUT TERMINATION MODULE

R3100K

R6100K

W2C

W2A

W1C

W1A

W1B

R-CNETWORK

R-CNETWORK

W2B R4100 ohm

R1100 ohm

W1D

W2D

-24V

Note: R1 and R4 are not installed.

Figure 3-5. Voltage Inputs, 081815



Table 3-5. Voltage Input Connections, 081815Terminal No. Channel Designation

12345678910111213141516171819202122232425262728293031323334353637383940

—11223344——5 5667788——99101011111212——131314141515———

No connection*Input 1 +Input 1 —Input 2 +Input 2 —Input 3 +Input 3 —Input 4 +Input 4 —

**

Input 5 +Input 5 —Input 6 +Input 6 —Input 7 +Input 7 —Input 8 +Input 8 —

**

Input 9 +Input 9 —Input 10 +Input 10 —Input 11 +Input 11 —Input 12 +Input 12 —

**

Input 13 +Input 13 —Input 14 +Input 14 —Input 15 +Input 15 —

No connection***

*These terminals are connected together and may be used for grounding inputs.** Screw/pin 40 is connected internally and is not to be wired as a tie point.


Chapter 4

Thermocouple/Millivolt InputsModule 081803

RequirementsThermocouple inputs require the use of extension leadwire; refer to Table 4-1. Thermocouples can be grounded or ungrounded. Type B thermocouplesand millivolt inputs use copper wire. Shields can be connected to terminals 5and 7.

Four thermal sensors are mounted on the input terminal boards on theterminals shown in Figure 4-1. These sensors are required for thermocoupleinputs. Figure 4-1 illustrates input connections for channels 1, 2, 3, 14 and15. Table 4-2 provides connections for all other channels.

Table 4-1. Thermocouple/Millivolt Module Extension Leadwire Table

THERMOCOUPLECOMBINATION

EXTERNAL TO INSTRUMENT

DUPLEX SINGLE CONDUCTOR Overall

Copper ConstType T

Copper B Const. R B Copper B Const. R-B

Iron ConstType J

Iron W Const R K Iron W Const R-W

*Nickel-ChromiumConstType E

Ni-CrV

Const. R N Ni-CrY

Const R-B

Nickel-ChromiumNickel-AluminumType K

Ni-CrY

Ni-AlR

Y Ni-CrY

Ni-AlR-Y

Plat-Rhod PlatType S or R

Copper K Alloy R G Copper K Alloy R-K

Nicrosil NisilType N

NicrosilO

NisilR

O Nicrosil O Nisil R-O

K - BlackW - White

G - GreenR - Red

B - BlueN - Brown

O - OrangeY - Yellow

T - Tan

* Thermocouple wire used as extension wire



Figure 4-1 - Thermocouple/Millivolt Module input connections

Thermocouple/Millivolt Inputs Module 081803


Table 4-2. Thermocouple/Millivolt Module - Input Connections

Designation Terminal Board DesignationThermal Sensor 2 2 1 Thermal Sensor 1

Thermal Sensor 2 4 3 Thermal Sensor 1

Input 1 + 6 5 Thermocouple Shields

Input 1 - 8 7 Thermocouple Shields

Input 3 + 10 9 Input 2 +

Input 3 - 12 11 Input 2 -






Input 9 24 23 Input 8 -

Input 11 + 26 25 Input 10 +

Input 11 - 28 27 Input 10 -

Input 13 + 30 29 Input 12 +

Input 13 - 32 31 Input 12 -

Input 15 + 34 33 Input 14 +

Input 15 - 36 35 Input 14 -




Chapter 5

Resistance InputModules 081804 and 081814

TypesInputs can be three-wire RTDs as shown in Figure 5-1, four-wire RTDs asshown in Figure 5-2, or any combination of the two. The A, B and C leaddesignations shown on the diagrams are for Thermohm® ResistanceThermometers and are presented for reference. The A and B leads are thepotential leads and the C leads are the current leads. RTDs manufactured byother vendors may have different designations. Refer to manufacturer-supplied specifications and make connections accordingly.

Three-Wire RTDsFigure 5-1 provides an example of input connections for three-wire RTDsfor channels 1 and 7. Refer to Table 5-1 for input connections for channels 2through 6. For three-wire RTDs, the resistance of the A and B leads must beequal. Add jumpers to the terminal board as shown.

Note: Resistance of A and B leads must be equal



Table 5-1 - Input Connections for Three-Wire RTDs

Designation Terminal Board Designation

Shield

Shield

1 I1

1 IN +

1 COM

2 IN -

2 I2

3 I1

3 IN +

3 COM

4 IN -

4 I2

5 I1

5 IN +

5 COM

6 IN -

6 I2

7 I1

7 IN +

7 COM

1

2

3

4

5

6 78 910 1112 1314 1516 1718 1920 2122 2324 2526 2728 2930 3132 3334 3536 3738 3940

Shield

Shield

Shield

1 IN -

1 I2

2 I1

2 IN +

2 COM

3 IN -

3 I2

4 I1

4 IN +

4 COM

5 IN -

5 I2

6 I1

6 IN +

6 COM

7 IN -

7 I2

Resistance Input Modules 081804 and 081814


Figure 5-1 - Input Connections for Three-Wire RTDs



Four-Wire RTDsFigure 5-2 provides an example of input connections for four-wire RTDs forchannels 1 and 7. Refer to Table 5-2 for input connections for channels 2through 6.

Figure 5-2 - Input connections for four-wire RTDs

Resistance Input Modules 081804 and 081814


Table 5-2 - Input Connections for Four-Wire RTDs

Designation Terminal Board Designation

Shield

Shield

1 I1

1 IN +

1 COM

2 IN -

3 I1

3 IN +

3 COM

4 IN -

5 I1

5 IN +

5 COM

6 IN -

7 I1

7 IN +

7 COM

1

2

3

4

5

6 78 910 1112 1314 1516 1718 1920 2122 2324 2526 2728 2930 3132 3334 3536 3738 3940

Shield

Shield

Shield

1 IN -

2 I1

2 IN +

2 COM

3 IN -

4 I1

4 IN +

4 COM

5 IN -

6 I1

6 IN +

6 COM

7 IN -


Chapter 6

Output Driver ModulesCAT 064594, PAT 064314

Terminal ConnectionsTerminals 1 through 20 on the chassis assembly terminal board are used forfield wiring. Refer to Figure 6-1 for an illustrated view of individual terminalconnections. Terminals 21 through 40 are reserved for connections

Figure 6-1 - Modules CAT 064594, PAT 064314 terminal connections

Current Adjusting Type (CAT)The CAT Module 064594 is supplied with jumpers already positioned forCAT operation for an output of 4 to 20 mA. Refer to Figures 6-2 and 6-3 forillustrated views of the connections for a CAT controller. Terminals 16 and17 are the source of the current output which can be jumper selected toprovide ranges of 4 to 20 mA, 0 to 16 mA, 0 to 20 mA, or 10 to 50 mA for



full scale. Terminals 11 and 13 are used for 24 V dc field backup. Block andoverride contacts, if applied, can be powered from line voltage (refer toFigure 6-3). Note that the CAT output is not isolated from ground. Block andoverride contacts are wetted by the power connected to terminal 1 (refer toFigure 6-3). Voltages 120 V ac or 125 V dc can be used.

Figure 6-2 - CAT output and 24 V dc field backup

Output Driver Modules CAT 064594 and PAT 064314


Figure 6-3 - CAT output and 24 V dc field backup with blocks andoverrides - 120 V ac wetting voltage



Position Adjusting Type (PAT)The PAT Module 064314 is supplied with jumpers already positioned forPAT operation with a 1,000 Ohm feedback slidewire, 120 V ac drive unitand limit switches, and no-backup 24 V dc power supply. Select otherarrangements, as shown in the following diagrams, by repositioning jumpers.

There are two basic types of output. The first has 120 V ac raise-loweroutputs. This configuration uses 120 V ac interrogating voltage for limitcontacts and drives a single phase drive unit or a three phase power switch.The second, for the dc power switch, uses 24 V dc open collector raise-loweroutputs. This configuration typically uses 24 V dc interrogation voltage forlimit inputs. See "DC Drive Units" below.

Block and override contacts are wetted by the power connected to terminal1. This is normally the drive unit power voltage. Voltages 120 V ac or 125 Vdc can be used.

AC Drive UnitsFigures 6-4, 6-5, and 6-6 illustrate the connections for a single phase driveunit. Figure 6-7 shows a three phase power switch. Loss of drive unit powerwill give simultaneous indication of the raise and lower limits and will beinterpreted as drive unit unavailable. Power to the Blocks and Overrides isfused. Power to the limit switches and Increase/Decrease outputs is fusedand switched. A switch in the OFF position or a blown fuse will beinterpreted as drive unit unavailable. Figures 6-4 and 6-7 also showconnections for 24 V dc field backup.

DC Drive UnitsFigure 6-8 illustrates the connections for the dc power switch. The increaseand decrease outputs are open collector transistor switches. High and lowlimits are available from the dc power switch as open collector outputswhich will interface with 24 V logic on the output module. Fused 24 V dcwill supply logic power to the power switch. Loss of 24 V dc power to thepower switch will result in simultaneous high limit and low limit indicationswhich will be interpreted as drive unit unavailable. A field 125 dc voltagecan be connected to the drive unit power terminals to provide wettingvoltage to the Block and Override contacts.

PAT FeedbackSlidewire and rotary sensor feedback can be accommodated. Figure 6-4shows the standard 1,000 Ohm slidewire feedback. The slidewire is poweredwith fused 20 mA current shunted by a 316 Ohm resistor. The bottom of theslidewire is grounded through 250 Ohms. This results in a slidewire voltageof 1 to 5 Volts full scale. A reasonability check of the feedback input allowsdetection of an open slidewire. A pull down resistor on the slidewire input



allows detection of an open wiper. Slidewires with resistance values greaterthan 1,000 Ohms can be shunted to 1,000 Ohms by adding an externalresistor. Slidewires between 500 and 1,000 Ohms will produce anonstandard output with a consequent loss of resolution. The referencesupply is derived from the backed-up 24 V dc.

Two-Wire Rotary SensorFigure 6-5 illustrates the use of a two-wire rotary sensor feedback element.This device is powered from the 24 Vdc system supply and results in aninput of 1 to 5 V dc developed across the internal 250 Ohm resistor. Areasonability check of the input voltage will detect an open circuit.

Four-Wire Rotary SensorFigure 6-6 illustrates the use of the 0 to 16 Volt output rotary sensor. Thisdevice is powered from the 24 V dc system supply. External resistors areadded to provide an input of 0 to 4 Volts. A reasonability check for an opencircuit can only be provided if the sensor has a live zero.



Figure 6-4 - PAT output, 120 V ac Drive Unit with 1,000 Ohm slidewire and 24 V dc fieldbackup



Figure 6-5 - PAT output, 120 V ac Drive Unit with Two-Wire RotarySensor



Figure 6-6 - PAT output, 120 V ac Drive Unit 0-16 V Four-Wire RotarySensor



Figure 6-7 - PAT output, three phase power with 1000 Ohm slidewireand 24 V dc field backup



Figure 6-8 - PAT output, dc power switch with 1000 Ohm slidewire

Duration Adjusting Type (DAT)Figure 6-9 provides connections for DAT output. Switches must be set onthe output driver printed circuit assembly for DAT output. When DAToutput is selected, the increase PAT output is energized with a duty cycleequal to the OUTPUT percent. For example, if the output % is 43, the PATincrease output would be on 43 percent of the time. The PAT decreaseoutput is off when the increase output is on and on when the increase outputis off.



Figure 6-9 - DAT output with 24 V dc field backupDuration Impulse Adjusting Type (DIAT)



Figure 6-10 provides connections for DIAT output. Switches must be set onthe Output Driver printed circuit assembly for DIAT output.

Figure 6-10 - DIAT output with 24 V dc field backup

Connecting Model MAS Auto/Manual StationA Model MAS Auto/Manual Station can be connected to terminals 21through 40 on the Output Driver terminal board. The distance between theOutput Driver and the Auto/Manual Station can be up to 1000 ft. Twenty-conductor interconnecting cable is supplied with the auto/manual station.Refer to Publication 277577, Model MAS Auto/Manual Station Installation,for installation and wiring procedures for the Auto/Manual Station.

The cable end that connects to the Output Driver contains terminal lugs onthe ends of the leads. Terminals 21 through 40 on the Output Driver havemating lugs. Press the lugs on the end of the cable onto the lugs on theOutput Driver terminal board according to Figure 6-11. The shield does nothave a lug. Connect the shield lead under the clamp on terminal 18.



Figure 6-11 - Model MAS Auto/Manual Station connections


Chapter 7

Analog Output ModuleTerminal Connections

Description

The Analog Output Module has 8 output channels each of which uses twowiring modes, two wire and three wire. Two-wire mode is only used for 4 to20 milliamps, and three-wire mode for other ranges (e.g. 0 to 16 milliamps, 0to 20 milliamps or 4 to 20 milliamps). The modules are supplied for three-wire mode operation on all channels. To select two-wire or three-wire modesfor an individual channel, you must change jumpers on the printed circuitassembly.

Three-wire mode is the only way to get a true zero based signal, e.g. 0-16mA. Two-wire mode, which has simpler wire connections, is used tosimulate a two-wire transmitter. Refer to Tables 7-1 and 7-2 for jumperpositions for either two-wire or three-wire output.

Outputs are connected to the terminal board as shown in Figures 7-1 and 7-2,which illustrate connections for one channel each.



Figure 7-1. Two-Wire Output Connections, Analog Output Module080403



Table 7-1. Model IOP I/O Chassis Assembly Analog Output ModuleTwo-Wire Terminal Assignment

Terminal Number Channel Designation12345

678910

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

11

22

33

44

55

66

77

88

No connectionSupplyLoad - ReturnNo connectionNo connection

SupplyLoad ReturnNo connectionNo connectionNo connection

No connectionSupplyLoad - ReturnNo ConnectionNo Connection

SupplyLoad - ReturnNo connectionNo connectionNo connection







Table 7-2. Model IOP I/O Chassis Assembly Analog Output ModuleThree-Wire Terminal Assignment


678910

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

111

22

2

333

44

4

555

66

6

777

88

8

ReturnSupplyLoadNo connectionNo connection

SupplyLoadNo connectionNo connectionReturn

ReturnSupplyLoadNo ConnectionNo Connection








Figure 7-2 Three-Wire Output Connections, Analog Output Module080403


Chapter 8

Quad PAT Output ModuleTerminal Connections

IntroductionThe Quad Position Adjusting Type (PAT) Output Module consists of four channels, eachcapable of producing PAT increase and decrease outputs (120 Vac or open collector) forsingle-phase ac drive units or three-phase power switches. The module, which interfaces withthe Distributed Processing Unit (DPU), accommodates 1000 Ohm slidewire or two-wire rotaryposition sensor feedbacks

Refer to the following table for a listing of the output terminal board connections for the QuadPAT module.

Table 8-1. Quad PAT Output Module Terminal Board ConnectionsTerminal Description Terminal Description1 120 Vac #1 2 Line ac Neutral #13 Drive Unit ac Neutral #1 4 Drive Unit Increase Output

#15 Drive Unit Decrease Output #1 6 120 Vac #27 Line ac Neutral #2 8 Drive Unit ac Neutral #29 Drive Unit Increase Output #2 10 Drive Unit Decrease

Output #211 120 Vac #3 12 Line ac Neutral #313 Drive Unit ac Neutral #3 14 Drive Unit Increase Output

#315 Drive Unit Decrease output #3 16 120 Vac #417 Line ac Neutral #4 18 Drive Unit ac Neutral #419 Drive Unit Increase Output #4 20 Drive Unit Decrease

Output #421 Voltage Reference #1



Table 8-1. Quad PAT Output Module Terminal Board Connections (Continued) 22 Position Feedback #1Terminal Description Terminal Description23 Return #1 24 Signal GRD25 Frame GRD 26 Voltage Reference #227 Position Feedback #3 28 Return #229 Signal GRD 30 Voltage Reference #331 Position Feedback #3 32 Return #333 Signal GRD 34 Frame GRD35 Voltage Reference #4 36 Position Feedback #437 Return #4 38 Signal GRD39 Control Fail Sense 1 40 Control Fail Sense 2


Chapter 9

Digital Input/Output ModuleTerminal Connections

IntroductionFigures 9-1 and 9-2, respectively, illustrate typical Digital Module input andoutput field connections. The connections illustrated in these figures useterminal numbers 1 to 10. The connection pattern formed by these 10terminals is replicated three more times on the chassis assembly.

This is shown in Table 9-1, which provides the complete terminalassignment for one chassis assembly, depicting the staggered mounting ofthe two terminal strips. The jumper strips provided, (part number 064362),are designed to fit into this repeating pattern of four bits (terminals 2 to 9),sandwiched between a top and bottom common terminal (terminals 1 and10). Also notice how all Hot (+) terminals are on the left terminal strip andall Load terminals are on the right terminal strip, allowing for the use of thejumper strips.

Refer to Figure 9-2 for Digital Output Relay Module (081820) terminalconnections. Note that the relay contact circuit is not fused. The relaysprovide dry contacts, either normally open or normally closed. As supplied,the module is set up for normally open contacts. Configure jumpers on themodule printed circuit assembly to select normally open or normally closedcontacts.

Refer to Table 9-2 for Form C Relay Module terminal assignments. Note thatthe Form C module uses a terminal connection pattern that does not resemblethe patterns used on any other input module.

Note: Do not wire Model IOP outputs directly to Model IOP inputs withoutan external load, or the input may not show the true state of the output. Forexample, the snubber current of a triac output may be enough to turn ON aninput, even if the triac is OFF.



Figure 9-1. Model IOP digital input field connections



Figure 9-2. Model IOP digital output field connections



Table 9-1. Model IOP I/O Chassis Assembly DigitalI/O Module TerminalAssignment Form A/B Relay

Terminal Number Designation12345

678910

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

Common (1 & 2)Hot (+) 1Load 1Hot (+) 2Load 2

Hot (+) 3Load 3Hot (+) 4Load 4Common (3 & 4)









Table 9-2. Form C Relay module 081823 field wiring terminalassignmentTerminal Form C1 --------2 # 1 N.O.3 # 1 Common4 # 1 N.C.5 #2 N.C.6 # 2 N.O.7 # 2 Common8 # 3 N.O.9 # 3 Common10 # 3 N.C.11 ------------12 ------------13 # 4 N.C.14 # 4 N.O.15 # 4 Common16 # 5 N.O.17 # 5 Common18 # 5 N.C.19 ------------20 ------------21 # 6 N.C.22 # 6 N.O.23 # 6 Common24 # 7 N.O.25 # 7 Common26 # 7 N.C.27 # 8 N.C.28 # 8 N.O.29 # 8 Common30 ------------31 ------------32 # 9 N.O.33 # 9 Common34 # 9 N.C.35 # 10 N.C.36 # 10 N.O.37 # 10 Common38 -------------39 -------------40 -------------


Chapter 10

Counter/Timer InputConnections and Terminal Assignment

Physical pulse-input connections are generally of a variety of types: 24 V dccontact inputs, 120 V ac contact inputs, 5 V dc differential logic inputs viaRS422 communications port, variable reluctance pickups (magnetic pickup,e.g., turbine speed, flowmeters, rotopulsers), etc. The Counter/Timer modulehas optically isolated, high-speed differential inputs. Other inputs (e.g.,contacts) can be accommodated by slaving an adjacent digital input moduleor by using an input device with 5 Volt signals (common with tachometersand flow signals). The 5 Volts itself must be externally supplied, which isdone with contact wetting supplies in general.

The Counter/Timer Module (056516) consists of eight channels with twoinputs per channel. As supplied, the module is set up for on-card inputs froman external source via the input terminal board. Figure 10-1 illustrates inputconnections for two channels. Table 10-1 provides input connections for alleight channels.



Table 10-1. Model IOP I/O Chassis Assembly Counter/Timer ModuleTerminal Assignment


11121314151617181920

21222324252627282930

31323334353637383940

11112222

33334444

55556666

77778888

No connectionInput 1+Input 1-Input 2+Input 2-Input 1+Input 1-Input 2+Input 2-No connection




Counter/Timer Input Connections and Terminal Assignment


Figure 10-1. Model IOP Counter/Timer Module input connections

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