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metso automation maxPAC, Reference Manual

The metso automation maxPAC Reference Manual is a comprehensive user guide for maximizing the potential of this advanced automation system. With easy-to-understand instructions and troubleshooting tips, this manual is available for free download from our website, ensuring seamless integration of the product into your operations.

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Metso Automation MAX Controls Inc. 

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 277596 

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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

Installing Model IOP I/O Equipment .....................................................................................................................1-7
Sequence of Mounting Operations.........................................................................................................................1-8
Mounting I/O Chassis Assemblies .........................................................................................................................1-8
Cabling, Power, and Ground Wiring......................................................................................................................1-9

Supplying 24V Power to the I/O Modules .........................................................................................................1-9
Interconnecting Adjacent I/O Chassis ..............................................................................................................1-11

Module Mounting Considerations........................................................................................................................1-12

I/O Modules......................................................................................................................................................1-12
DPU Modules ..................................................................................................................................................1-12

Module Addressing ..............................................................................................................................................1-13
Backup Configuration Options ............................................................................................................................1-14

Shared Configuration .......................................................................................................................................1-14
Redundant Configuration .................................................................................................................................1-15
Mixed Configuration........................................................................................................................................1-15

Remote I/O...........................................................................................................................................................1-16
Specifications.......................................................................................................................................................1-18

Environment.....................................................................................................................................................1-18
I/O Bus.............................................................................................................................................................1-18
Inputs/Outputs..................................................................................................................................................1-18

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

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

Overview....................................................................................................................................................................2-1

LED Indication ......................................................................................................................................................2-1
Bus Address ...........................................................................................................................................................2-2

Summary of Contents for maxPAC

Page 1: ...maxPAC Hardware Reference Guide 277596 Rev C1 ...

Page 2: ...operate and service Metso Automation MAX Controls equipment Your comments and suggestions are welcome Metso Automation MAX Controls Inc 1180 Church Road Lansdale PA 19446 Attention Manager Technical Publications Copyright 2000 2002 by Metso Automation MAX Controls Inc Printed in the United States of America All rights reserved ...

Page 3: ...ce of Mounting Operations 1 8 Mounting I O Chassis Assemblies 1 8 Cabling Power and Ground Wiring 1 9 Supplying 24V Power to the I O Modules 1 9 Interconnecting Adjacent I O Chassis 1 11 Module Mounting Considerations 1 12 I O Modules 1 12 DPU Modules 1 12 Module Addressing 1 13 Backup Configuration Options 1 14 Shared Configuration 1 14 Redundant Configuration 1 15 Mixed Configuration 1 15 Remote...

Page 4: ...ing 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 Mo...

Page 5: ...s 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 Pulse I O Module IOP335 9 1 LED Indication 9 1 Bu...

Page 6: ... 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 7 Four Configuration Approaches 11 7 Configuring Remote I O only 11 8 Configuring Local Common I O 11 8 Configuring Mixed Common and Redundant I O 11 8 Single DPU Configurations 11 9 BEM Configuration ...

Page 7: ...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 277522 Model PDP DPU Preparation and Adjustment 277590 Model 200 Series maxDPU4E Hardware Guide 277561 System Power and Grounding ...

Page 8: ...U 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 ...

Page 9: ...sembly Three chassis assembly types are available for the installation of the I O module as follows q IOP382 Eight pack assembly to accommodate up to eight maxPAC I O modules q IOP383 Six pack assembly to accommodate a DPU or a Model 564 I O module in the right most position along with six maxPAC I O modules the DPU takes up the equivalent of two maxPAC I O module positions q IOP381 Four pack asse...

Page 10: ...er 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 Bus Connector Field 24V Field 48V System 24V I O Bus Connectors Figure 1 2 Eight Pack Rack Figure 1...

Page 11: ...m 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 q A color bar on the module faceplate identifies the module type Each module type has a unique color q Euro style terminal connector blocks for field wiring each block contains 16 connectors q Rotary address switch q Light Emitting Diodes LE...

Page 12: ...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...

Page 13: ...he Model APS Power Supply Assembly which provides 24V dc power for Distributing 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 MAX Controls typically installs the power supply modules in an N 1 redundancy configuration Because each module is individually iso...

Page 14: ...e 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 16 point Euro Style plugs suppl...

Page 15: ...ottom 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 chas...

Page 16: ...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 277561 System Power and Grounding for a discussion of cabinet grounding Supplying 24V Power to the I O Modules The I O system requires a...

Page 17: ...he ribbon cable should match the pin 1 marking in the connector Depending on the spacing between maxPAC chassis the following ribbon cable lengths are available Part Number Description CPO301 10 inches 0 rack units between racks CPO303 12 inches 1 rack unit between racks CPO304 14 inches 2 rack units between racks CPO305 26 inches 10 rack units between racks For I O bus connections to a cabinet ou...

Page 18: ...s own special six wide I O chassis in the right most position since the DPU is wider than the I O cards and requires good air flow Likewise when using a second DPU for backup it must be inserted in the same six wide chassis style mounted 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 app...

Page 19: ...ck 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 256 logical addresses The lower switch is the low order address and the upper switch is the high order address maxPAC modules use ...

Page 20: ...ule addresses in the system 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 DP...

Page 21: ... U D P U I O I O I O I O I O I O I O I O I O I O CP0309 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 ...

Page 22: ...figuration 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...

Page 23: ...nicate with I O that are locally and or remotely mounted See Figure 1 9 Remote location Control Room D P U D P U B E M I O I O I O I O B E M I O I O I O I O B E M B E M I O I O I O I O I O I O I O I O I O I O I O I O I O I O Optical Cable Y ADAPTER backplane backplane redundant network Figure 1 9 Typical Bus Expander Module Configuration ...

Page 24: ...t 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 or transformer isolated from the maxDNA I O bus Channel to channel is...

Page 25: ...ltage 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 ...

Page 26: ...mation Jumper Installed Not Installed W1 50 Hz 60Hz W6 DPU4A B DPU4E 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 MAX Controls 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 installat...

Page 27: ... 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 1C 1E 1D 1C 1E 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 ...

Page 28: ...r 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 microcontro...

Page 29: ...nostics 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 s...

Page 30: ... 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 Vol...

Page 31: ... 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 ...

Page 32: ... 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 vo...

Page 33: ... Modules Isolated Input Module IOP301 Metso Automation MAX Controls Inc 277596 2 9 thermistor Primary IOP301 AI Module Twisted pair 2 wire Transmitter Secondary IOP301 AI Module 100 24V Supply Two Wire Transmitter ...

Page 34: ...mmon 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 ...

Page 35: ...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 converte...

Page 36: ...ning 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 backplan...

Page 37: ...nication 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 o C 1 5uv o C RTI Accuracy 0 1 of reading at 25o C Source Im...

Page 38: ...tter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter 15 24V 16 Iin 3 24V 4 Iin 9 24V Iin 7 24V 8 Iin 5 24V 6 Iin 13 24V 14 Iin 11 24V 12 Iin P3 Channel 9 Channel 10 Channel 11 Channel 12 Channel 13 Channel 14 Channel 15 Channel 16 1 24V 2 Transmitter Iin Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter Transmitter 15 24V 16 Iin 3 24V 4 Iin 9 24V Iin 7...

Page 39: ...el 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 ...

Page 40: ...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...

Page 41: ... 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 ...

Page 42: ...ting 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 amp...

Page 43: ...rom 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 Channel 1 Channel 8 FLASH Field Interface Circuits I O Bus Regulator 24V 5V logic uC DC DC 5V field OPTO optical isolation field to logic A D REF Excitation Current Field Interface Circuits ...

Page 44: ...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 Temperature Sensitivity 0 004 of reading o C 1 5uv o C RTI Accuracy 0 15 of reading 0 5o C Input Multiplexer Solid state FET optical isolation Conversion method Sigma Delta oversam...

Page 45: ...omation MAX Controls Inc 277596 4 5 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 ...

Page 46: ...e Guide Metso Automation MAX Controls Inc 277596 4 6 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 ...

Page 47: ...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 ...

Page 48: ...ve 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 microcontr...

Page 49: ...e 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 per...

Page 50: ...tion 15 bits plus sign Scan Rate 16 points converted in 1 seconds Temperature Sensitivity 0 004 of reading o C 1 5uv o C RTI Accuracy 0 15 of reading 0 05o C 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 tempe...

Page 51: ...596 5 5 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 ...

Page 52: ...tomation MAX Controls Inc 277596 5 6 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 ...

Page 53: ...nector 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 lo...

Page 54: ...ins four jumpers Refer to the following table for jumper setting information 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 2 addresses future use Note the W6 switch setting shown in the above table applies to modules with two rotary switches installed For modules with only one rotary switch use ...

Page 55: ...en 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 Th...

Page 56: ...PGA I O Bus Regulator 24V 5V logic uC AO Module OPTO optical isolation field to logic D A 1 D A 8 Channel 1 Channel 8 OPTO 4 20 ma out 4 20 ma out Powered from field 24V supply 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 ...

Page 57: ... 0x25 Interrupt Error power on 0x26 FPGA Download Error power on 0x32 Calibration Error channel 1 to 8 0x41 0x48 Module Specifications Resolution 12 bits Scan Rate 8 msec Temperature Sensitivity 0 004 of reading o C 1 5uv oC RTI Accuracy 0 1 of reading 05 of span at 25o C Span 4 to 20 mA Calibration Self calibration on power up with calibration jumper set Load Impedance 0 800 Ohms Input Power from...

Page 58: ...6 6 Field Wiring P2 Channel 1 Channel 2 Channel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 1 Return 2 Load Iout 15 Return 16 Iout 3 Return 4 Iout 9 Return 10 Iout 7 Return 8 Iout 5 Return 6 Iout 13 Return 14 Iout 11 Return 12 Iout Load Load Load Load Load Load Load ...

Page 59: ...MAX Controls Inc 277596 6 7 Field wiring for redundant modules with common end element Primary IOP320 AO Module W2 not installed W3 not installed W4 not installed Secondary IOP 320 AO Module W2 not installed W3 installed W4 not installed Current Loop Controlled Device ...

Page 60: ...ese 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 ...

Page 61: ...ptical 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...

Page 62: ...lts maximum 48 Volts nominal 60 Volts 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 s...

Page 63: ... 7 4 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 ...

Page 64: ...les 24V Common Input Module IOP330 48V Common Input Module IOP331 Metso Automation MAX Controls Inc 277596 7 5 Field Wiring For Redundant Modules with Common DI Primary IOP30 331 DI Module Secondary IOP 330 331 DI Module ...

Page 65: ...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 ...

Page 66: ...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 ...

Page 67: ... 24 Volts ac dc nom 40 Volts 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 indicati...

Page 68: ...nel 3 Channel 4 Channel 5 Channel 6 Channel 7 Channel 8 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 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 ...

Page 69: ...Input Module IOP334 120V AC DC Isolated Input Module IOP332 240V AC DC Isolated Input Module IOP333 Metso Automation MAX Controls Inc 277596 8 5 Field Wiring For Redundant Modules with Isolated DI Primary DI Module Secondary DI Module AC DC ...

Page 70: ...rent configuration for each channel Picture 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 addresses It is compatible with DPU4E only Jump...

Page 71: ... 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 measu...

Page 72: ...verage 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...

Page 73: ...25 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 su...

Page 74: ...g P2 Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input8 11 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 16 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 8 Channel 7 Channel 6 Channel 5 ...

Page 75: ...elays 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 ...

Page 76: ...he 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 rela...

Page 77: ... 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 c...

Page 78: ...maxPAC Hardware Reference Guide Metso Automation MAX Controls Inc 277596 10 4 optical isolation field to logic Channel 1 Channel 16 PROM I O Bus Interface Circuit I O Bus Reg 24V 5V BUFFER ...

Page 79: ...MAX Controls Inc 277596 10 5 Field Wiring IOP 351 P2 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 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 ...

Page 80: ...tomation MAX Controls Inc 277596 10 6 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 ...

Page 81: ...odule IOP351 Form C Relay Module IOP350 Metso Automation MAX Controls Inc 277596 10 7 Field Wiring For Redundant Modules with Common End Element Primary Relay Module W1 installed Secondary Relay Module W1 installed Power Source Switched Device ...

Page 82: ...tribute 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 ...

Page 83: ...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 ...

Page 84: ...ablished between the local and remote Extender modules as shown in figure 10 1 Local I O Bus D P U B E M I O B E M B E M I O Remote I O Bus Optical Links D P U Y Cable I O I O Optical Links B E M I O I O Figure 10 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 ...

Page 85: ...ith 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 MAX Controls 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 mo...

Page 86: ...CK 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 10 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 transmit...

Page 87: ...Fiber Optic Transceiver Receiver Transmitter Fiber Fiber Local Area Remote area Redundant Fiber Optic Transceiver Redundant Fiber Optic Transceiver Redundant Fiber Optic Transceiver M A C K M A C K M A C K M A C K Local Bus Expanders Remote Bus Expanders CPLD CPLD CPLD CPLD Status Status Figure 10 3 BEM Functional Block Diagram Optical Transceivers Convert the TTL level transmit serial data into a...

Page 88: ...s 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 IOP01...

Page 89: ...active control signal from each DPU must be 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...

Page 90: ...e 10 4 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 consi...

Page 91: ...rol Room D P U I O I O B E M I O I O I O I O B E M I O I O I O I O I O I O I O Optical Cable backplane Optical Redundant Cable B E M To other Locations Figure 10 6 Single DPU with common and remote I O configuration The redundant optical cables shown in this illustration are optional but recommended ...

Page 92: ...ulating Link Capacities While as noted a DPU supports up to 60 I O per location a link delay exists proportional to distance The Extender circuits themselves introduce very little delay The distance factor primarily impacts Digital Input modules set for SOE operation The following table shows the maximum number of DI modules which can be handled at various cable distances This is caused by the nee...

Page 93: ...ity 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 s...

Page 94: ...augment cable reliability Metso Automation MAX Controls 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 ...

Page 95: ...nd 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 0o C to 60o C 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 ...

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