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MACO Series Controller Installation
Table of Contents
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
General
............................................................................................... 4
1.1
CE EMC Compliance .................................................................... 5
1.2
Notes on EMC Shielding ............................................................... 5
Installing & Wiring the T/C-Analog Board ................................................ 23
Installing & Wiring the Communications Board ....................................... 30
Installing & Wiring the Data Handler Board ............................................ 33
Installing & Wiring the Analog I/O Board ................................................ 36
Installing & Wiring the High Speed Ana Sig Processor (Parison) Board . 41
6.1
Introduction ................................................................................. 41
6.2
Wiring of All Analog Inputs & Outputs ......................................... 41
6.2.1
Input/Output Specifications .................................................. 41
6.2.2
Analog Input/Output Wiring Guidelines ................................ 42
6.2.3
Analog I/O Applications Wiring ............................................ 42
6.3
Wiring of DC Inputs & Outputs .................................................... 42
Installing & Wiring the Seq/Hydraulics Board ......................................... 54
Installing & Wiring the Power Supply Board ........................................... 56
Installing & Wiring AC Output Boards ..................................................... 61
Installing & Wiring DC Output Boards ..................................................... 66
Installing & Wiring Analog Output Boards ............................................... 72
Installing & Wiring AC Input Boards ........................................................ 77
Installing & Wiring DC Input Boards ........................................................ 81
Installing & Wiring AC/DC Input Boards .................................................. 86
Wiring the 32 In/32 Out or 24 In/24 Out Digital I/O Boards ..................... 90
15.1 Introduction ................................................................................. 90
15.2 Specifications .............................................................................. 90
MACO Series Specifications ................................................................... 97
Application Guide for Sensors and Analog Signals ............................... 102
17.1 General ..................................................................................... 102
17.2 Hydraulic Pressure Transducers ............................................... 102
17.3 Position Transducers ................................................................ 102
17.4 Tachometer ............................................................................... 102
17.5 Analog Outputs ......................................................................... 102
17.6 Extrusion/Parison Pressure Transducers .................................. 102
Figures
Figure 1.0 12 Slot Enclosed Controller Dimensions ....................................... 6
Figure 1.1 16 Slot Enclosed Controller Dimensions ....................................... 7
Figure 1.2 12 Slot Open Frame Controller Dimensions ................................. 8
Figure 1.3 9 Slot Open Frame Controller Dimensions ................................... 9
Figure 1.4 7 Slot Open Frame Controller Dimensions ................................. 10
Figure 1.5 12 Slot Controller Board Locations (5 Slots of I/O) ..................... 11
Figure 1.6A 16 Slot Controller Board Locations (8 Slots of I/O) ..................... 12
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 1 of 104
MACO Series Controller Installation
Figures (continued)
Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O) ..................... 13
Figure 1.6C 16 Slot Controller Board Locations (6 Slots of I/O) ..................... 14
Figure 1.6D 9 Slot Controller Board Locations (3 Slots of I/O) ....................... 15
Figure 1.7 7Slot Controller Board Locations .................................................. 16
Figure 1.8 Multi-Chassis Installation ............................................................ 17
Figure 1.9 12 Slot Motherboard Bus Layout ................................................ 18
Figure 1.10 16 Slot Motherboard Bus Layout ................................................ 19
Figure 1.11 9 Slot Motherboard Bus Layout .................................................. 20
Figure 1.12 AC Power Connections for 9 Slot Controllers ............................. 21
Figure 1.13 AC Power Connections for 12 Slot Controllers ........................... 21
Figure 1.15 DC Power Connection for 7 Slot Controllers ............................... 22
Figure 1.14 AC Power Connections for 16 Slot Controllers ........................... 22
Figure 2.0 Installing Resistors for Current Inputs ......................................... 24
Figure 2.1 A-60063-0XX or A-60133-0XX 12 Zone Temperature Board ..... 25
Figure 2.2 A-60063-1XX or A-60133-1XX 12 Zone Analog Input Board ...... 26
Figure 2.3 A-60063-2XX or A-60133-2XX 6 Zone Analog Input / 6 Zone T/C
Input Board.................................................................................. 27
Figure 2.4 A-60063-3XX or A-60133-3XX 6 Zone T/C Input Board ............. 28
Figure 2.5 Wiring T/C Inputs using the T/C-Analog Card ............................. 29
Figure 2.6 Wiring Analog Inputs using the T/C-Analog Card ....................... 29
Figure 3. A-60050 Communications Motherboard ..................................... 31
Figure 3.1 Wiring Communications Daughterboards ................................... 32
Figure 4.0 A-60010 Data Handler Board ...................................................... 34
Figure 4.1 Wiring the DH Board (Overbraid in Conduit to Op Station) ......... 35
Figure 4.2 Wiring the Data Handler Board (Overbraid to Op Station) .......... 35
Figure 5.0 A-60051 Analog I/O Motherboard ............................................... 37
Figure 5.1 Analog I/O Wiring (Connector P2) ............................................... 38
Figure 5.2 Analog I/O Wiring (Connector P3) ............................................... 39
Figure 5.3 Wiring the Analog I/O Board ....................................................... 40
Figure 6.0 A-13815 High Speed Ana Sig Processor (Parison) Board .......... 43
Figure 6.1 High Speed Analog (Parison) Sensor Wiring .............................. 44
Figure 6.2 High Spd Ana (Parison) Card Pressure Transducer Wiring ........ 45
Figure 6.3 High Spd Ana (Parison) Card DC Input and Output Wiring ........ 45
Figure 6.4 One-Head Time-Based Machine with B-C Servo Amp ............... 46
Figure 6.5 Two-Head Time-Based Machine with B-C Servo Amp ............... 47
Figure 6.6 Two-Head Position-Based Machine with B-C Servo Amp .......... 48
Figure 6.7 Two-Hd Position-Based Mach w/Pushout and B-C Servo Amp .. 49
Figure 6.8 Accumulator Machine (Velocity Control) with B-C Servo Amp .... 50
Figure 6.9 Two-Head Position-Based Machine with Moog Servo Amp ....... 51
Figure 6.10 Wiring the High Spd Ana (Parison) Board DC Inputs ................. 52
Figure 6.11 Wiring the High Spd Ana (Parison) Board DC Outputs ............... 52
Figure 6.12 Wiring the High Spd Ana (Parison) Board Analog Inputs ........... 53
Figure 6.13 Wiring the High Spd Ana (Parison) Board Analog Outputs ......... 53
Figure 7. A-60012 or A-60083 Seq/Hydr Board ......................................... 55
Figure 8.0 A-13395 Power Supply Board ..................................................... 57
Figure 8.1 A-60045 Power Supply Board ..................................................... 58
Figure 8.2 Wiring the Power Supply Board in 9 Slot Systems ..................... 59
Figure 8.3 Wiring the Power Supply Board in 12 Slot Systems ................... 59
Figure 8.4 Wiring the Power Supply Board in 16 Slot Systems ................... 60
Figure 9.0 A-13402 Standard Density AC Output Board ............................. 63
Figure 9.1 A-13904 High Density AC Output Board ..................................... 64
Figure 9.2 AC Output Wiring ........................................................................ 65
Figure 10.0 A-60068 24 Output DC Out Board .............................................. 68
Figure 10.1 A-60107 16 Output DC Out Board .............................................. 69
Figure 10.2 DC Output Wiring ........................................................................ 70
Figure 10.3 Wiring the DC Output Board ....................................................... 71
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 2 of 104
MACO Series Controller Installation
Figures (continued)
Figure 11.0
Figure 11.1
Figure 11.2
Figure 11.3
Figure 12.0
Figure 12.1
Figure 12.2
Figure 13.0
Figure 13.1
Figure 13.2
Figure 13.3
Figure 14.
Figure 14.1
Figure 15.1
Figure 15.2
Figure 15.3
Figure 16.
Figure 17.
Figure 18.
1640-IN-031-C-08
Locating the Analog Output Boards ............................................ 73
A-60033 Analog Output Board .................................................... 74
Analog Output Wiring .................................................................. 75
Wiring the Analog Output Board ................................................. 76
A-13900 or A-60089 Standard Density AC Input Board ............. 78
High Density AC Input Board Assembly ...................................... 79
AC Input Wiring ........................................................................... 80
A-60070 Standard Density DC Input Board ................................ 82
High Density DC Input Board Assembly ..................................... 83
DC Input Wiring ........................................................................... 84
Wiring the DC Input Board .......................................................... 85
High Density AC/DC Input Board Assembly ............................... 88
A-13991-100 High Density DC/AC Input Board Assembly ......... 89
32 In/32 Out or 24 In/24 Out A-60150-x ...................................... 91
32 In/32 Out or 24 In/24 Out Digital I/O Wiring ........................... 92
32 In/32 Out or 24 In/24 Out Sample Wiring ............................... 93
Communications Cable Pinouts .................................................. 94
Communications Cable Part Numbers ........................................ 95
Firmware Model Numbers ........................................................... 96
Eurotherm/Barber-Colman
Page 3 of 104
MACO Series Controller Installation
1. General
The wiring guidelines outlined in this manual are to be used in addition to all
applicable electrical and safety codes. Be sure to follow all requirements of
such codes as well as other recognized safety practices.
This controller must be installed in a suitable enclosure which will minimize or
prevent the accumulation of dust, dirt, or other particles which could build up and
clog ventilation slots. Periodic inspections must be scheduled to insure that slots
do not become clogged.
Cleaning of the control cabinet and the controller should be done using a vacuum
cleaner. Do not use compressed air as this could force particles into the controller
and actually worsen conditions.
Air temperature within the enclosure must not exceed 60°C (140°F). The temperature will tend to be higher at the top of the enclosure so if possible, locate the
controller toward the middle or the lower portion. Allow adequate space for air to
flow around the controller. It is strongly recommended that a full four inches or more
be maintained on all sides wherever possible. This space allows for wiring
installation and free flow of air to the bottom of the controller.
Several different chassis types are available; 12 slot and 16 slot enclosed versions;
as well as 9 slot and 12 slot open versions. As of June 2001, the 12 slot enclosed
version is no longer available, but a (new) 7 slot open version (24 Vdc only) is
introduced.
The left side of the controller is for analog voltages from thermocouples and other
sensors and the right side is for discrete Input and Output card signals (switching
voltages). The power supply card is the divider between the two types of signals.
A typical base control system requires approximately 1 kVA.
Note that this manual refers to wiring classifications in terms of "Class 1" and
"Class 2" which are classifications of the U.S. National Electrical Code (NEC).
Class 1 wiring is analogous to "Mains" and Class 2 is analogous to "SELV"
(separated extra low voltage).
Note also that this manual refers to AC power wiring in terms of "L1" and "L2." "L1"
is analogous with "Live" and "L2" is analogous with "Neutral."
A.1
CAUTION:
Do Not Operate Without Cover in Place. Cover must be in place both for operator
safety and to insure proper cooling of internal components.
This Controller is intended for Panel Mounting
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 4 of 104
MACO Series Controller Installation
1.1 CE EMC Compliance
This MACO control system is in full compliance with CE EMC requirements as long
as AC input boards, AC output boards and analog output boards are excluded. Use
of these boards will require additional EMC testing by the machine manufacturer.
Wiring guidelines to ensure the machine is CE EMC compliant are included with
each board described in this document. For additional wiring information, refer to
the following publications:
Recommended Guideline for Wiring & Grounding Machine Controls
Society of the Plastics Industry, Inc.
1275 K Street, N.W. – Suite 400
Washington, D.C. 20005
(202) 371-5200
IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise
Inputs to Controllers from External Sources
(IEEE Std 518-1982)
1.2 Notes on EMC Shielding
No special EMC measures are required for signal control or DC power wiring less
than 3 meters in length. For signal wiring in excess of 3 meters, routing in metallic
conduit or an overbraid is required up to within 10 cm of the end point.
For this document, the term "shield" applies to a BRAIDED shield that is grounded
only at one end. FOIL shields should NOT be used (they offer poor protection that
is degraded further by using a drain wire to terminate the shield). Proper shield
termination must provide a peripheral clamping arrangement so that no internal
conductors are visible. The term "overbraid" applies to a special type of shield that
is grounded at BOTH ends. Cable can be purchased for this purpose or overbraid
can be added to existing cable. This type of shield affords protection to very high
frequencies, especially when significant magnetic fields (caused by high currents)
are present. As with braided shields, proper overbraid termination must provide a
peripheral clamping arrangement so that no internal conductors are visible.
Specific requirements for shields and overbraids are identified on the individual
figures within this document.
Where external power supplies are required, a CE recognized supply must be
used. Test results on CE power supplies have shown that they may emit noise
above 30 MHz. Install a ferrite bead suitable for power cord use at the output
terminals of the supply.
External supplies (and their ground distribution block) must be located within 30
cm of the bottom of the controller chassis.
If bond straps other than those supplied with this controller are used, they must
maintain a 5:1 length to width ratio.
For information on obtaining ferrite beads, bond straps, shielded cable or overbraid,
contact the factory or your local sales representative.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 5 of 104
MACO Series Controller Installation
Figure 1.0 12 Slot Enclosed Controller Dimensions
Front View
1.37" (35mm) Approx.
1" (25.4mm)
Approx.
(4) .531"
(13.48mm)
Latch (2)
13.562" (345mm)
Ref.
10.500" (266.70mm)
6-32 EMC
Bond Stud
18.312" (465.12mm)
(4) .281"
(7.14mm)
2" (50mm)
Approx.
19.0" (483mm) Ref.
Dimensions are in inches
and (millimeters)
Side View
Allow Approx. 2"
(51mm) Clearance
each Side
for Latches
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow (Fans)
8" (203mm)
Approx.
(with Cover)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 6 of 104
MACO Series Controller Installation
Figure 1.1 16 Slot Enclosed Controller Dimensions
Front View
1.37" (35mm) Approx.
1" (25.4mm)
Approx.
(4) .531"
(13.48mm)
Latch (2)
13.562" (345mm)
Ref.
10.500" (266.70mm)
6-32 EMC
Bond Stud
2" (50mm)
Approx.
26.625" (676.28mm)
(4) .281"
7.14mm)
27.5" (697mm) Ref.
Power Connection
Dimensions are in inches
and (millimeters)
Side View
Allow Approx. 2"
(51mm) Clearance
each Side
for Latches
Power Connection
6-32 EMC
Bond Stud
Allow Approx. 3-4" (75 - 100mm)
Clearance at Top and Bottom
for Air Flow (Fans)
8" (203mm)
Approx.
(with Cover)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 7 of 104
MACO Series Controller Installation
Figure 1.2 12 Slot Open Frame Controller Dimensions
Front View
1.705
(43mm)
.531 (13.49mm) (4)
8.750
(222.3mm)
12.160
(106.4mm)
6-32 EMC
Bond Stud
.281 (7.14mm) (4)
19.250 (489mm)
.400
(10mm)
1.705
(43mm)
20.050 (509mm)
Reference
Side View
Dimensions are in inches
and (millimeters)
Allow Approx. 2" (50mm)
Clearance each Side
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow
8.400
(213mm)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 8 of 104
MACO Series Controller Installation
Figure 1.3 9 Slot Open Frame Controller Dimensions
Front View
1.705
(43mm)
.531 (13.49mm) (4)
8.750
(222.3mm)
12.160
(106.4mm)
6-32 EMC
Bond Stud
.281 (7.14mm) (4)
15.665 (398mm)
.400
(10mm)
1.705
(43mm)
16.415 (417mm)
Reference
Side View
Dimensions are in inches
and (millimeters)
Allow Approx. 2" (50mm)
Clearance each Side
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow
8.400
(213mm)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 9 of 104
MACO Series Controller Installation
Figure 1.4 7 Slot Open Frame Controller Dimensions
8.300
(210.8mm)
0.640
(16.2mm)
0.500
(12.7mm)
Ø 0.281
(7.14mm)
Ø 0.531
13.49mm)
11.300
(287mm)
8.750
(222.3mm)
1.275
(32.38mm)
14.000 (355.6mm)
14.800 (376mm)
Reference
0.400
(10mm)
Dimensions are in inches
and (millimeters)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 10 of 104
MACO Series Controller Installation
Figure 1.5 12 Slot Controller Board Locations (5 Slots of I/O)
Mother Board
IMPORTANT:
EMC Critical Item
Slot #12
Slot #11
Slot #10
Slot # 9
Slot # 8
Power Supply
Temperature #1
Slot #2
Slot #3
Data Handler
Slot #5
Sequence/Hydraulics
Optional:
Standard:
Slot #1:
Slot #4:
Slot #5:
Slot #6:
Slot #7:
Temp (T/C-Ana) Bd #1 (or Parison)
Data Handler Bd
Analog I/O
Sequence/Hydraulics Bd
Power Supply Bd (See Note)
Note: In 11 or 12-slot controllers, primary power is
connected directly to the power supply board.
Note: When counting boards in multi-rack systems (for
switch settings, RLD/screen programming) count each
control rack separately.
B.1
1640-IN-031-C-08
Slot #2: Temp (T/C-Ana) Bd #2 (or Parison)
Slot #3: Communications Bd
Slot #8:
Slot #9:
Slot #10:
Slot #11:
Slot #12:
Output Bd #1
Output Bd #2 or Input Bd #4
Output Bd #3 or Input Bd #3
Output Bd #4 or Input Bd #2
Input Bd #1
Note: Analog output boards (if used) follow the last
digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
Eurotherm/Barber-Colman
Page 11 of 104
MACO Series Controller Installation
Mother Board
Figure 1.6A 16 Slot Controller Board Locations (8 Slots of I/O)
Energize CR 605
and
Energize CR 607
(if Hi Density I/O)
IMPORTANT:
EMC Critical Item
See Wiring
Detail Below
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Data Handler
Power Supply
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Slot #10
Slot #9
Standard:
Optional:
Slot #1: Temperature (T/C-Analog) Bd #1
Slot #5: Sequence/Hydraulics Bd
Slot #7: Data Handler Bd
Slot #8: Power Supply Bd
Slot # 2,
3,4 & 6:
Analog I/O Bd #1 in Slot #3.
2nd Seq Bd in Slot #6.
Start in Slot #2 with remaining Temperature
Bds (5 max.), followed by Comm Bd.,
followed by all Parison Bds (2 max.).
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Slot # 9:
Slot #10:
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Output Bd #5
Output Bd #6 or Input Bd #3
Input Bd #2
Input Bd #1
Top
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
E24-1261
Viewed from side
of Controller
B.1
1640-IN-031-C-08
E24-1134-005
Note: Analog output boards (if used) follow the
last digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
Eurotherm/Barber-Colman
Page 12 of 104
MACO Series Controller Installation
Mother Board
Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O)
Energize CR 604
and
Energize CR 607
(if Hi Density I/O)
IMPORTANT:
EMC Critical Item
See Wiring
Detail Below
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Slot #7
Data Handler
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Slot #10
Power Supply
Standard:
Optional:
Slot # 2, 3, Analog I/O Bd #1 in Slot #3. Analog I/O Bd #2
4, 6 & 7: in Slot #7 (requires 2nd Seq Bd in Slot #6).
Start in Slot #2 with remaining Temperature
Bds (6 max.), followed by Comm Bd., followed by all Parison Bds (2 max.).
Slot #1: Temperature (T/C-Analog) Bd #1
Slot #5: Sequence/Hydraulics Bd
Slot #8: Data Handler Bd
Slot #9: Power Supply Bd
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Top
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
E24-1261
Viewed from side
of Controller
B.1
1640-IN-031-C-08
Slot #10:
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Output Bd #5 or Input Bd #3
Output Bd #6 or Input Bd #2
Input Bd #1
Note: Analog output boards (if used) follow the
last digital output board.
E24-1134-005
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
Eurotherm/Barber-Colman
Page 13 of 104
MACO Series Controller Installation
Mother Board
Figure 1.6C 16 Slot Controller Board Locations (6 Slots of I/O)
Energize CR 606
and
Energize CR 607
(if Hi Density I/O)
IMPORTANT:
EMC Critical Item
See Wiring
Detail Below
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Slot #7
Data Handler
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Power Supply
Slot #9
Standard:
Optional:
Slot #2, 3, Analog I/O Bd #1 in Slot #3.
4, 6, 7 & 9: 2nd Seq Bd in Slot #6.
Start in Slot #2 with remaining Temperature
Bds (5 max.), followed by Comm Bd.,
followed by all Parison Bds (2 max.).
Slot #1: Temperature (T/C-Analog) Bd #1
Slot #5: Sequence/Hydraulics Bd
Slot #8: Data Handler Bd
Slot #10: Power Supply Bd
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Top
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
E24-1261
Viewed from side
of Controller
B.1
1640-IN-031-C-08
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Input Bd #2
Input Bd #1
Note: Analog output boards (if used) follow the
last digital output board.
E24-1134-005
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
Eurotherm/Barber-Colman
Page 14 of 104
MACO Series Controller Installation
Figure 1.6D 9 Slot Controller Board Locations (3 Slots of I/O)
Mother Board
Energize CR 605
and
Energize CR 607
(if Hi Density I/O)
3 Slots of I/O
IMPORTANT:
EMC Critical Item
See Wiring
Detail Below
Slot #1
Slot #2
Data Handler
Slot #4
Sequence/Hydraulics
Slot 1:
Slot 2:
Slot 3:
Slot 4:
Slot 5:
Slot #9
Slot #8
Slot #7
Power Supply
Temperature (T/C-Analog)
Temperature, Communications or Analog I/O
Communications or Analog I/O
Data Handler (only)
Sequence/Hydraulics (only)
Slot 6:
Slot 7:
Slot 8:
Slot 9:
Power Supply (only)
Input Bd #1
Output Bd #2
Output Bd #1
Note: When counting boards in multi-rack systems (for
switch settings, RLD/screen programming) count each
control rack separately.
Top
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
E24-1261
Viewed from side
of Controller
B.1
1640-IN-031-C-08
E24-1134-005
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
Eurotherm/Barber-Colman
Page 15 of 104
MACO Series Controller Installation
Figure 1.7 7 Slot Controller Board Locations
Sequence/Hydraulics
Slot #2*
Data Handler
Slot #4
Slot #7
Slot #6
Power Supply & Communications
*If process control/line graphs is
specified in sequence options, this
slot must have Analog I/O card.
Slot 1:
Slot 2:
Slot 3:
Slot 4:
Sequence/Hydraulics (only)
Analog I/O*, T/C-Analog or Parison/Motion
Data Handler (only)
T/C-Analog or Parison/Motion
Slot 5: Power Supply & Communications (only)
Slot 6: Combo I/O or Analog Output
Slot 7: Combo I/O or Analog Output
Note: When counting boards in multi-rack systems (for
switch settings, RLD/screen programming) count each
control rack separately.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 16 of 104
MACO Series Controller Installation
Figure 1.8 Multi-Chassis Installation
Controllers in a multi-rack configuration can be any combination of 7 Slot, 9 Slot,
11 Slot, 12 Slot or 16 Slot Chassis. Controller 1 is the "primary" controller.
Controllers 2, 3 and 4 are "secondary" controllers.
Secondary controllers must contain a power supply board, a data handler board
and a sequence/hydraulics board. Additional board requirements will depend on
the application.
Controllers are interconnected by the connections to each data handler board.
Controller addresses are determined by Switch S2 on each data handler board.
The last controller of the installation must have its line terminating resistors
jumpered to the "in" position (J19 and J20). All other controllers must have these
resistors jumpered to the "out" position.
Wire each controller separately, but to the same source distribution and ground
distribution.
(See Operator
Station Wiring Detail)
Switch S2
(Data Handler Board)
Switch S2
Sw1
Sw2
Sw3
Off
On
Off
On
Off
Off
Off
On
On
Off
Off
Off
Off
Off
On
Single Rack
Ctlr 1
Ctlr 2
Ctlr 3
Ctlr 4
To Operator
Station
EMC Terminal
Block
EMC Terminal
Block
10 ft. (3.3m)
maximium
ISOC0M
Out
3
ISO5V
In
1
Out
3
In
1
ISOC0M
Out
3
ISO5V
In
1
Data -
Out
3
In
1
1
P14
4
5
6
7
8
10 ft. (3.3m)
maximium
ISOC0M
Out
3
ISO5V
In
1
Out
3
In
1
ISOC0M
Out
3
ISO5V
In
1
Out
3
In
1
J19
J19
Data J20
Data +
3
(Overbraid)
J19
Data J20
Data +
2
EMC Terminal
Block
10 ft. (3.3m)
maximium
J19
1
ROCKER DOWN
EMC Terminal
Block
(Overbraid)
(Overbraid)
O
F
F
Data J20
Data +
J20
Data +
1
1
P14
P14
1
P14
Data Handler
Board 1
Data Handler
Board n
Data Handler
Board n
Data Handler
Board (last)
Controller 1
(Primary)
Controller 2
(Secondary)
Controller 3
(Secondary)
Controller 4
(Secondary)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 17 of 104
MACO Series Controller Installation
Figure 1.9 12 Slot Motherboard Bus Layout
A-13394
Slot 1
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 8
Slot 9
Slot 10
Slot 11 Slot 12
DC POWER
ANALOG DATA BUS
CONTROL DATA BUS
COMM. DATA BUS
LOGIC BUS
POWER BUS
FAN1
FAN2
P167
Slot 1
PIN
NUMBER
P1
P2
P3
P4
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
DC POWER BUS
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
ANALOG
DATA BUS
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
1640-IN-031-C-08
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 8
Slot 9
PIN
NUMBER
POWER BUS
P5
P6
P7
P8
P9
P10
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth Ground at P167)
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
CONTROL
DATA BUS
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[0]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Slot 10 Slot 11 Slot 12
PIN
NUMBER
FAN 1
PIN
NUMBER
FAN 2
P157
P158
P159
P160
P161
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
P162
P163
P164
P165
P166
F1/F2 COM
+20V
TACH2
+20V
F1/F2 COM
COMMUNICATIONS
DATA BUS
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[0]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
Eurotherm/Barber-Colman
PIN
NUMBER
LOGIC
DATA BUS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
SLOTS
+20 V
7&8
+20 V
ONLY
F1/F2 COM
F1/F2 COM
Page 18 of 104
MACO Series Controller Installation
Figure 1.10 16 Slot Motherboard Bus Layout
A-13888
A-13887
Slot 1
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 8
Slot 9
Slot 1
Slot 2
DC POWER
ANALOG DATA
BUS 1
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 6
Slot 7
DC POWER
ANALOG DATA
BUS 2
CONTROL DATA BUS
COMM. DATA BUS
Slot 1
PIN
NUMBER
P1
P2
P3
P4
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Slot 2
DC POWER BUS
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
ANALOG
DATA BUS
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
1640-IN-031-C-08
FAN1
FAN2
POWER BUS
P184
Slot 3
Slot 4
LOGIC BUS
LOGIC BUS
Slot 5
Slot 6
FAN1
Slot 7
Slot 8
Slot 9
PIN
NUMBER
POWER BUS
PIN
NUMBER
P5
P6
P7
P8
P9
P10
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth
Ground at P184)
P174
P175
P176
P177
P178
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
CONTROL
DATA BUS
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
CNTL_SLOT[8]
Slot 1
POWER BUS
Slot 2
FAN 1
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
Slot 3
Slot 4
Slot 5
PIN
NUMBER
FAN 2
PIN
NUMBER
P179
P180
P181
P182
P183
F1/F2 COM
+20V
TACH2
+20V
F1/F2 COM
P177
P178
P179
P180
P181
A-13887
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
COMMUNICATIONS
DATA BUS
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
/COMM_SELECT[8]
Eurotherm/Barber-Colman
FAN 1
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
A-13888
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
LOGIC
DATA BUS
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
+20 V
-20 V
F1/F2 COM
F1/F2 COM
Page 19 of 104
MACO Series Controller Installation
Figure 1.11 9 Slot Motherboard Bus Layout
Slot 1
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
Slot 8
Slot 9
DC POWER
ANALOG DATA
BUS 1
ANALOG DATA
BUS 2
CONTROL DATA BUS
COMM. DATA BUS
PIN
NUMBER
P1
P2
P3
P4
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
ANALOG
DATA BUS
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
1640-IN-031-C-08
+5
+5
+5
+5
FAN1
FAN2
POWER BUS
P184
Slot 1
LOGIC BUS
Slot 2
Slot 3
Slot 4
Slot 5
Slot 6
Slot 7
DC POWER BUS
PIN
NUMBER
POWER BUS
Vdc Common
Vdc
Vdc Common
Vdc
P5
P6
P7
P8
P9
P10
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth
Ground at P184)
Slot 8
Slot 9
PIN
NUMBER
CONTROL
DATA BUS
PIN
NUMBER
COMMUNICATIONS
DATA BUS
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
CNTL_SLOT[8]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
/COMM SELECT[8]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Eurotherm/Barber-Colman
LOGIC
DATA BUS
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
+20 V
-20 V
F1/F2 COM
F1/F2 COM
Page 20 of 104
MACO Series Controller Installation
Figure 1.12 AC Power Connections for 9 Slot Controllers
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
Bond to Chassis
within 10 cm of controller
Earth (Safety Earth)
L2
L1
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Local
Ground Rod
Figure 1.13 AC Power Connections for 12 Slot Controllers
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
L1
L2
Earth (Safety Earth)
Bond to Chassis
within 10 cm of controller
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
1640-IN-031-C-08
Local
Ground Rod
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Eurotherm/Barber-Colman
Page 21 of 104
MACO Series Controller Installation
Figure 1.14 AC Power Connections for 16 Slot Controllers
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
Bond to Chassis
within 10 cm of controller
Earth (Safety Earth)
L2
L1
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
Local
Ground Rod
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Figure 1.15 DC Power Connection for 7 Slot Controllers
+24V
N/C
COM
+
-
24 Vdc
Supply
Power Supply outputs MUST have
ferrite beads capable of filtering
30 MHZ to 100 MHZ
A Class 2 Supply is required
24 Vdc, 2.0 Amps (minimum)
24 Vdc, 3.0 Amps (recommended)
DC Power ONLY!
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 22 of 104
MACO Series Controller Installation
2. Installing & Wiring the T/C-Analog Board
Make certain to use the proper extension wire. Do NOT run extension wire in the
same trough with power wiring.
Note that these boards cannot be calibrated in the field.
For All A-60063 and A-60133 Boards:
There is no address switch on these boards (they are assigned numbers by the
data handler software). Board 1 is the left-most t/c-analog board and numbers
ascend from left to right. Note that for programming purposes a 12 zone board is
treated like two 6 zone boards (e.g., Function A is Board 1; Function B is Board 2
– this allows a system to be switched over from the original 6 zone boards to 12
zone boards). Check to see that there is a wire jumper inserted betweens Pins 1
and 2 of P14 and Pins 15 and 16 of P15.
For A-60063-1XX, A-60063-2XX, A-60133-1XX, A-60133-2XX, A-6013-8XX
(Boards with Analog Inputs)
For A-60063-1XX, A-60133-1XX boards and Function A of A-60063-2XX and A60133-2XX boards, if the inputs are to be used as VOLTAGE inputs, wire each
input plus or minus to the terminals specified in Figures 2.3 and 2.4.
For A-60063-1XX, A-60133-1XX boards and Function A of A-60063-2XX and A60133-2XX boards, if the inputs are to be used as CURRENT inputs, first install
one resistor (505 Ω, 1/2 W, 0.1%, 25 ppm) from kit number 71-975 across the plus
and minus of each input (as shown in Figure 2.0) and then wire to the terminals
specified in Figures 2.2 and 2.3.
The A-60133-8xx board (with 3 analog inputs) is NOT meant to be used for millivolt input on the 3 analog inputs. It is designed for a 0 to 10 Vdc input which is
then INTERNALLY attenuated to 0 to 40 mVdc (note that the analog inputs can
be converted to CURRENT inputs using the resistors described above). When
configuring the board for use, enter a TC - Voltage Card Config setpoint that is
correct for Function B, Zones 1-3. In addition, enter a PID Tuning Selection setpoint
of “4” for Function B, Zones 4-6.
Note that single rack systems using more than one 6-zone card AND using Data
Handler firmware prior to Version 20.x4 MUST use the original (A-13398-X) 6-zone
temperature board or a newer board with firmware from kit 71-1104-00x. All other
systems can use A-60063-3XX boards for replacement 6-zone temperature cards.
If you have an older system that still uses the A-13398-X boards, refer to 1640-IN031-I-05.pdf "archived PDFs" folder of the MACO instruction manual CD (1640CD-001-0-00).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 23 of 104
MACO Series Controller Installation
T/C-Analog Card Specifications
Reference Accuracy:
0.25% of Span, ±1°C
Common Mode Rejection:
135 dB @ 230 Vac 60Hz
Range:
Type J, 0 to 700°C (32 to 1292°F);
Type K, 0 to 950°C (32 to 1742°F)
0 to 10 Vdc
0 to 20 mAdc (scalable)
Series Mode Rejection:
60 dB @ 150 mV 60 Hz
Control Zones:
A-60063-0XX
A-60133-0XX
A-60063-1XX
A-60133-1XX
A-60063-2XX
A-60133-2XX
A-60063-3XX
A-60133-3XX
A-60133-8XX
12 Zones of T/C Input
12 Zones of Analog Input (Vdc or mAdc)
6 Zones of T/C Input (Function B)
6 Zones of Analog Input (Vdc or mAdc)
6 Zones of T/C Input (Function B)
9 Zones T/C Input (Func A 1-6, Func B 1-3)
3 Zones Anlog In (Vdc, Func B 4-6)
Alarms:
2 Process High/ 1 Process Low
Deviation +/Heater Burnout (HBO, T/C inputs only)
Sensor Break
Control Modes:
Auto-Tuned PID (T/C Inputs only)
Manual Tune (T/C Inputs only)
Kit No. 71-975 consists of six 505 Ω, 1/2 W, 0.1%, 25 ppm resistors
T/C-Analog Assembly
A-60063-1XX or A-60133-1XX (12 Zones of Analog Input)
A-60063-2XX or A-60133-2XX (6 Zones of Analog Input)
No. of Kits
2 Kits (12 Resistors)
1 Kit (6 Resistors)
Install these resistors ONLY on the assemblies shown above AND ONLY if the inputs
to the assembly are CURRENT (mAdc) instead of voltage.
Cut and form the resistors approximately as shown.
Insert one resistor lead with the plus (+) side of the input
and the other with the minus (-) side. Before applying
power, examine all leads for possible short circuits.
Figure 2.0 Installing Resistors for Current Inputs
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 24 of 104
MACO Series Controller Installation
Figure 2.1 A-60063-0XX or A-60133-0XX 12 Zone Temperature Board
EPROM 1
(U2)
DS1
P1
P2
P3
P4
P14
P15
P5
P6
P7
P8
P9
P10
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P15
Function A
(Zones 1A-6A)
Balco 1 (Jumper Pin 1 & 2)
Balco 1 (Jumper Pin 1 & 2)
Zone 1 T/C (-)
Zone 1 T/C (+)
Zone 2 T/C (-)
Zone 2 T/C (+)
Zone 3 T/C (-)
Zone 3 T/C (+)
Zone 4 T/C (-)
Zone 4 T/C (+)
Zone 5 T/C (-)
Zone 5 T/C (+)
Zone 6 T/C (-)
Zone 6 T/C (+)
Not Used
Not Used
Chassis**
Chassis**
0
1
2
3
4
5
6
7
8
POWER SUPPLY
OUTPUTS TO BUS
J1
See Cable Assemblies for
Wire Description
Function B
(Zones 1B-6B)
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
8
Not Used
Not Used
Zone 1 T/C (-)
Zone 1 T/C (+)
Zone 2 T/C (-)
Zone 2 T/C (+)
Zone 3 T/C (-)
Zone 3 T/C (+)
Zone 4 T/C (-)
Zone 4 T/C (+)
Zone 5 T/C (-)
Zone 5 T/C (+)
Zone 6 T/C (-)
Zone 6 T/C (+)
Balco 2 (Jumper Pin 15 & 16)
Balco 2 (Jumper Pin 15 & 16)
Chassis**
Chassis**
Note that a wire jumper is
used in place of the Balco
on the terminal block (the
Balcos are located on the
PCB). A Balco failure error
will occur if Balcos are used
on the terminal block.
**At the factory, Pin 18 of P14 is connected to Pin 17 of P15 and Pin 18 of P15 is connected to
the EMC bond rail.
CONNECTOR
(ON CARD)
MATING
CONNECTOR
NO FUSES
E24-1135-018
E24-1134-018
LED
DS1
Control Fault
JUMPER
J1
Calibrate (Normal Operation*)
*As shipped (for factory use only)
C.1
1640-IN-031-C-08
WARNING:
Hazardous extraneous voltage capable of causing severe injury or death may exist
between sensor leads and ground. Disconnecting the instrument power may not
remove this voltage. Measure for the presence of voltage between each sensor
lead and ground before servicing. Do NOT place power wiring in the same conduit
or wiring trough with sensor wiring.
Eurotherm/Barber-Colman
Page 25 of 104
MACO Series Controller Installation
Figure 2.2 A-60063-1XX or A-60133-1XX 12 Zone Analog Input Board
EPROM 1
(U2)
DS1
P1
P2
P3
P4
P14
P15
P5
P6
P7
P8
P9
P10
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
8
POWER SUPPLY
OUTPUTS TO BUS
J1
See Cable Assemblies for
Wire Description
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P15
Function A
(Zones 1A-6A)
Function B
(Zones 1B-6B)
PIN
NUMBER
(Jumper Pin 1 & 2)
(Jumper Pin 1 & 2)
Zone 1 (-)
Zone 1 (+)
Zone 2 (-)
Zone 2 (+)
Zone 3 (-)
Zone 3 (+)
Zone 4 (-)
Zone 4 (+)
Zone 5 (-)
Zone 5 (+)
Zone 6 (-)
Zone 6 (+)
Not Used
Not Used
Chassis**
Chassis**
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
8
Not Used
Not Used
Zone 1 (-)
Zone 1 (+)
Zone 2 (-)
Zone 2 (+)
Zone 3 (-)
Zone 3 (+)
Zone 4 (-)
Zone 4 (+)
Zone 5 (-)
Zone 5 (+)
Zone 6 (-)
Zone 6 (+)
(Jumper Pin 15 & 16)
(Jumper Pin 15 & 16)
Chassis**
Chassis**
Note that the wire jumper
remains in place
for analog inputs.
**At the factory, Pin 18 of P14 is connected to Pin 17 of P15 and Pin 18 of P15 is connected to
the EMC bond rail.
CONNECTOR
(ON CARD)
MATING
CONNECTOR
NO FUSES
E24-1135-018
E24-1134-018
LED
DS1
Control Fault
JUMPER
J1
Calibrate (Normal Operation*)
*As shipped (for factory use only)
C.1
1640-IN-031-C-08
WARNING:
Hazardous extraneous voltage capable of causing severe injury or death may exist
between sensor leads and ground. Disconnecting the instrument power may not
remove this voltage. Measure for the presence of voltage between each sensor
lead and ground before servicing. Do NOT place power wiring in the same conduit
or wiring trough with sensor wiring.
Eurotherm/Barber-Colman
Page 26 of 104
MACO Series Controller Installation
Figure 2.3 A-60063-2XX or A-60133-2XX 6 Zone Analog Input / 6 Zone T/C Input Board
EPROM 1
(U2)
DS1
P1
P2
P3
P4
P14
P15
P5
P6
P7
P8
P9
P10
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P15
Function A
(Zones 1A-6A)
(Jumper Pin 1 & 2)
(Jumper Pin 1 & 2)
Zone 1 (-)
Zone 1 (+)
Zone 2 (-)
Zone 2 (+)
Zone 3 (-)
Zone 3 (+)
Zone 4 (-)
Zone 4 (+)
Zone 5 (-)
Zone 5 (+)
Zone 6 (-)
Zone 6 (+)
Not Used
Not Used
Chassis**
Chassis**
0
1
2
3
4
5
6
7
8
POWER SUPPLY
OUTPUTS TO BUS
J1
See Cable Assemblies for
Wire Description
Function B
(Zones 1B-6B)
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
8
Not Used
Not Used
Zone 1 T/C (-)
Zone 1 T/C (+)
Zone 2 T/C (-)
Zone 2 T/C (+)
Zone 3 T/C (-)
Zone 3 T/C (+)
Zone 4 T/C (-)
Zone 4 T/C (+)
Zone 5 T/C (-)
Zone 5 T/C (+)
Zone 6 T/C (-)
Zone 6 T/C (+)
Balco 2 (Jumper Pin 15 & 16)
Balco 2 (Jumper Pin 15 & 16)
Chassis**
Chassis**
Note that a wire jumper is
used in place of the Balco
on the terminal block (the
Balcos are located on the
PCB). A Balco failure error
will occur if Balcos are used
on the terminal block.
Note also that the wire
jumper remains in place
for analog inputs.
**At the factory, Pin 18 of P14 is connected to Pin 17 of P15 and Pin 18 of P15 is connected to
the EMC bond rail.
CONNECTOR
(ON CARD)
MATING
CONNECTOR
NO FUSES
E24-1135-018
E24-1134-018
LED
DS1
Control Fault
JUMPER
J1
Calibrate (Normal Operation*)
*As shipped (for factory use only)
C.1
1640-IN-031-C-08
WARNING:
Hazardous extraneous voltage capable of causing severe injury or death may exist
between sensor leads and ground. Disconnecting the instrument power may not
remove this voltage. Measure for the presence of voltage between each sensor
lead and ground before servicing. Do NOT place power wiring in the same conduit
or wiring trough with sensor wiring.
Eurotherm/Barber-Colman
Page 27 of 104
MACO Series Controller Installation
Figure 2.4 A-60063-3XX or A-60133-3XX 6 Zone T/C Input Board
EPROM 1
(U2)
DS1
P1
P2
P3
P4
J1
P15
See Cable Assemblies for
Wire Description
P5
P6
P7
P8
P9
P10
POWER SUPPLY
OUTPUTS TO BUS
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P15
PIN
NUMBER
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
1
1
Note that in MOST cases this board can
be used as a "drop in" replacement for
the original 6 zone temperature board
(A-13398). No programming changes
are necessary. See the note at the front
of the t/c-analog wiring section.
0
1
2
3
4
5
6
7
8
Function B
(Zones 1B-6B)
Not Used
Not Used
Zone 1 T/C (-)
Zone 1 T/C (+)
Zone 2 T/C (-)
Zone 2 T/C (+)
Zone 3 T/C (-)
Zone 3 T/C (+)
Zone 4 T/C (-)
Zone 4 T/C (+)
Zone 5 T/C (-)
Zone 5 T/C (+)
Zone 6 T/C (-)
Zone 6 T/C (+)
Balco 2 (Jumper Pin 15 & 16)
Balco 2 (Jumper Pin 15 & 16)
Chassis**
Chassis**
Note that a wire jumper is
used in place of the Balco
on the terminal block (the
Balcos are located on the
PCB). A Balco failure error
will occur if Balcos are used
on the terminal block.
**At the factory, Pin 18 of P15 is connected to the EMC bond rail.
CONNECTOR
(ON CARD)
MATING
CONNECTOR
NO FUSES
E24-1135-018
E24-1134-018
LED
DS1
Control Fault
JUMPER
J1
Calibrate (Normal Operation*)
*As shipped (for factory use only)
C.1
1640-IN-031-C-08
WARNING:
Hazardous extraneous voltage capable of causing severe injury or death may exist
between sensor leads and ground. Disconnecting the instrument power may not
remove this voltage. Measure for the presence of voltage between each sensor
lead and ground before servicing. Do NOT place power wiring in the same conduit
or wiring trough with sensor wiring.
Eurotherm/Barber-Colman
Page 28 of 104
MACO Series Controller Installation
Figure 2.5 Wiring T/C Inputs using the T/C-Analog Card
Pin 18
Zone 1 T/C Zone 1 T/C +
Zone ...
Zone ...
Chassis
Pin 17
Pin 18 bonded to EMC bond rail at factory
Bond to
Chassis
(Shielded T/C Cable)
Figure 2.6 Wiring Analog Inputs using the T/C-Analog Card
Pin 18
Zone 1 ( -)
Zone 1 (+)
Zone ...
Zone ...
Chassis
Pin 17
Pin 18 bonded to EMC bond rail at factory
(Braided Shield)
Bond to
Chassis
Bond to
Chassis
(Braided Shield and Overbraid)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 29 of 104
MACO Series Controller Installation
3. Installing & Wiring the Communications Board
Check the following:
1.Make sure that the RS-232 daughterboard (A-60055-XXX) is in Slot 1 or Slot 2
of the Communications motherboard.
2.Make sure that the RS-485 daughterboard (A-60062-XXX) is in Slot 2 or Slot 3
of the Communications motherboard.
3.Refer to Figures 15 and 16 for part numbers of available cable assemblies and
pin connections.
The A-60050-XXX version of the motherboard has two connectors for the
backplane which connect to both the communications bus (the lower bus) and
the control data bus (the middle bus). These boards work in all systems.
Note that the communications slots of the A-60205 communications/power supply
board (used in 7 slot controllers) should be wired exactly as shown here - except
that Slot 3 is not available (that is where the 24 Vdc power supply for system power
resides) and no ground strap is required to the chassis.
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 30 of 104
MACO Series Controller Installation
Figure 3. A-60050 Communications Motherboard
Slot 3 is reserved
for RS-485 Daughter Board
Slot 3
Slot 2 may be used
for either RS-232 or RS-485
Slot 2
Slot 1 is reserved
for RS-232 Daughter Board
Slot 1
J2
J1
EPROM 1
(U10)
DS1
P5
P6
P7
P8
P9
P10
P3
PIN 9
PIN 8
PIN 7
PIN 6
P3
PIN
NUMBER
1
2
3
4
5
6
7
8
9
Data (+)
Data (-)
Common
Shield
CONNECTOR E24-1135-004
(ON CARD)
E24-1134-004
MATING
CONNECTOR
JUMPERS
J1
Line Terminator (in for last RS-485 Bd*)
J2
Line Terminator (in for last RS-485 Bd*)
*As shipped
DS1
PIN 5
PIN 4
PIN 3
PIN 2
PIN 1
(Viewed as shown - installed )
P3
LEDs
A-60055
RS-232 Board
DS1
PIN 4
PIN 3
PIN 2
PIN 1
(Viewed as shown - installed )
PIN
NUMBER
1
2
3
4
POWER SUPPLY
OUTPUTS TO BUS
+5 Vdc Common
P1
+5 Vdc
P2
+5 Vdc Common
P3
+5 Vdc
P4
+5Vdc Common
P5
Not Used
P6
28 Vac ØA
P7
28 Vac ØB
P8
Not Used
P9
P 1 0 Guard
KEY
EPROM 1
(U10)
A-60062
RS-485 Board
P3
P1
P2
P3
P4
DCD (Data Carrier Detect)
RXD (Receive Data)
TXD (Transmit Data)
DTR (Data Transfer Ready)
SGND (Signal Ground)
DSR (Data Set Ready)
RTS (Request to Send)
CTS (Clear to Send)
RI (Ring Indicator)
CONNECTOR E24-1118
(ON CARD)
MATING
71-761 (Kit)
CONNECTOR
LEDs
Communications Busy
NO FUSES
1640-IN-031-C-08
DS1
Communications Busy
NO FUSES (motherboard)
NO JUMPERS (motherboard)
Eurotherm/Barber-Colman
Page 31 of 104
MACO Series Controller Installation
Figure 3.1 Wiring Communications Daughterboards
...
Common
Data Data +
SGND
DTR
TXD
RXD
DCD
RI
CTS
RTS
DSR
(Installed at Factory)
(Braided Shield)
Bond to
Chassis
Standard Cable Assembly
(no bonding required)
Bond to
Chassis
(Braided Shield and Overbraid)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 32 of 104
MACO Series Controller Installation
4. Installing & Wiring the Data Handler Board
The A-60010 assemblies support the following:
7, 9, 12 or 16 Slot Chassis
72 Zones of T/C-Analog Control Maximum
2 Sequence & Hydraulic Cards
2 Analog I/O Cards
Standard or High Density T/C-Analog Cards
Standard or High Density Logic I/O Cards
5, 6, 7, or 8 Logic I/O Cards
RLD Editor Version 3 or later
SPC
Math Functions
Process Control and SPC Line Graphs
Line Graphs for Parison
Setpoint Profile Entry Screen
Internal Storage of Parison Profiles
Transfer of Parison Profiles to Cartridge
Multi-Rack
Check the following:
1.Make sure that all jumpers are located as described in Figure 4. On multi-chassis
installations, pay particular attention to the line terminator jumpers.
2.Make sure that the cable connector is firmly seated on the board connector (the
other end of this cable terminates at the operator station).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 33 of 104
MACO Series Controller Installation
Figure 4.0 A-60010 Data Handler Board
DS1
DS3
DS5
NO FUSES
EPROM 1
(U26)
P1
P2
P3
P4
EPROM 3
(U25)
DS2
See Cable Assemblies for
Wire Description
DS4
POWER SUPPLY
OUTPUTS TO BUS
BT1 (+)
EEPROM
(U24)
DS6
SRAM
(U23)
J9
J7
J6
J5
KEY
KEY
†S1
† Switch S1 is Not Used
LEAVE IN OFF
S2
EPROM 2
(U46)
P14
J19
J20
P5
P6
P7
P8
P9
P10
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P1
PIN
NUMBER
4
3
2
1
JUMPER
Iso Common (Data)
No Connection**
Data Minus (-)
Data Plus (+)
J5
J6
J7
J8
(Pins
(Pins
(Pins
(Pins
1-2*)
1-2*)
1-2*)
2-3*)
*As shipped
**DO NOT Connect Shield to this Terminal
CONNECTOR E24-1135-004
(ON CARD)
MATING
E24-1134-004
CONNECTOR
Switch S2
Single Rack
Ctlr 1
Ctlr 2
Ctlr 3
Ctlr 4
A-60010-0xx
Sw1
Sw2
Sw3
Off
On
Off
On
Off
Off
Off
On
On
Off
Off
Off
Off
Off
On
A-60010-0xx
A-60010-1xx
A-60010-2xx
A-60010-3xx
A-60010-4xx
A-60010-5xx
A-60010-6xx
A-60010-7xx
Line Graphs
SPC
SPC/Line Graphs
Math
Math/Line Graphs
Math/SPC
Math/SPC/Line Graphs
Battery BT1 is BC Pt. No. E17-157
Field Replaceable (1/2 AA Lithium)
LED
DS1
DS2
DS3
DS4
DS5
DS6
Control Fault
Control Connect
Comm Fault (bus)
Comm Connect (bus)
Display Handler Fault (Flatpanel)
Display Handler Connect (Flatpanel)
D.1
1640-IN-031-C-08
WARNING:
Use of improper battery could present a risk of fire or explosion of the battery.
Eurotherm/Barber-Colman
Page 34 of 104
MACO Series Controller Installation
Figure 4.1 Wiring the Data Handler Board (Overbraid in Conduit to Op Station)
ISO Com
N/C
Data Data +
Overbraid in Conduit
to Operator Station
(Braided Shield)
Bond to
Chassis
Figure 4.2 Wiring the Data Handler Board (Overbraid to Op Station)
ISO Com
N/C
Data Data +
Overbraid to
Operator Station
Bond to
Chassis
1640-IN-031-C-08
(Braided Shield)
Eurotherm/Barber-Colman
Page 35 of 104
MACO Series Controller Installation
5. Installing & Wiring the Analog I/O Board
Important! Note that depending on the application, not all sensors need be used.
Refer to the "Application Guide for Sensors & Analog I/O Signals" at the back of
the Controller Installation & Wiring section.
1. Make sure the jumpers are correctly positioned.
2.For ease of wiring, remove the daughterboard (connector assembly) from the
motherboard by removing the four screws.
3. Use braided shield cables and connect as shown in Figures 5.1, 5.2 and 5.3. To
avoid overcrowding, strip cable jackets about 1/2" below the edge of the board,
make the connections and then heat shrink the wires. Add strain relief as required.
If overbraid has been used, terminate both the internal braided shield and the
overbraid at the ground distribution block (see Figure 5.3).
4.Reconnect the daughterboard and secure with the four screws.
NOTE: Signal conditioners may be required to convert signals to the proper analog
voltages. These signal conditioners must be powered from an external regulated
supply and provide a nominal 0-10 Vdc output.
Analog I/O Card Specifications
Input Resolution:
12 Bits
Inputs (6)
Voltage:
0 to +10 Vdc (Nominal)
Outputs (4)
Maximum Input:
± 15 Vdc without damage
Voltage:
0 to +10 Vdc or 0 to -10 Vdc
(Control Relay Selectable)
Offset:
-2 to +10 Vdc
Load Impedance:
3500 Ohms Minimum
Type (3 Inputs):
0 to +10 Vdc; Position, Potentiometer,
LVDT, Ultrasonic devices, or High Level
Pressure Transducers
Output Resolution:
13 Bits
Excitation Voltage:
+10 Vdc @ 20 mA
for potentiometers
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
Potentiometer Resistance:
2k to 10k Ohms
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Type (2 Inputs):
Pressure: 0 to +10 Vdc (Nominal) from
high level output pressure transducer
Type (1 Input):
Tachometer: +15 Vdc maximum input at 1 kHz,
+12 Vdc excitation at 10 mA provided (see application guide)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 36 of 104
MACO Series Controller Installation
Figure 5.0 A-60051 Analog I/O Motherboard
KEY
P1
P2
P3
P4
D28
EPROM 1
(U35)
J2
J1
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
P1
P1
P3
P2
P5
P6
P7
P8
P9
P10
A-13637
A-60051
P3
PIN
NUMBER
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
P2
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Analog Output #3
Analog Common
Analog Output #4
Shield (open)
Tach Input (15 Vdc max., 1KHz max.)
12 Vdc Common
12 Vdc Regulated (10 mA max. load)
Analog Common
Ejector Position Input /Ana In_3
Ejector Excitation (+)/Ana In_3 EX+
Shield (open)
Shunt Cal Hydraulic 2A/Cal Ana In_4A
Shunt Cal Hydraulic 2B/Cal Ana In_4B
Clamp Hydraulic Input/Ana In_4
Analog Common
Shield (open)
CONNECTOR E24-1129-016
(ON CARD)
CONNECTOR E24-1129-016
(ON CARD)
LEDs
JUMPERS
J1
J2
Analog Output #1
Analog Common
Analog Output #2
Shield (open)
Ram Excitation (+)/Ana In_2 EX+
Ram Position Input/Ana In_2
Analog Common
Clamp Position Input/Ana In_1
Clamp Excitation (+)/Ana In_1 EX+
Shield (open)
Shunt Cal Hydraulic 1A/Cal Ana In_5A
Shunt Cal Hydraulic 1B/Cal Ana In_5B
Ram Hydraulic Input/Ana In_5
Analog Common
Shield (open)
Shield (open)
Board Select (Analog I/O #1* or #2)
Factory Cal (Not in place*)(factory use only)
D28
Control Fault
NO FUSES
*As shipped. Note that presently each Analog I/O card requires
its own Seq/Hyd board and ALL Analog I/O's must be set to #1.
See Cable Assemblies for
Wire Description
N o t e : To avoid possible overcrowding of wires, strip cable jacket approximately
1/2" below edge of board and heat shrink leads.
Add Cable Ties for strain relief.
1/2"
Daughter Board MUST be held in place using 4 screws provided.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 37 of 104
MACO Series Controller Installation
Figure 5.1 Analog I/O Wiring (Connector P2)
ANALOG I/O CARD
CONNECTOR ASSEMBLY
P2
Analog Outputs can be either 0 to -10 Vdc or 0 to +10 Vdc
(by Hydraulics Control Relay - see Programming and Setup)
Output current limited to approx. 3mA.
Analog Output #1
1
Valve Driver/
Servo Amplifier
Analog Common
2
Valve Driver/
Servo Amplifier
Analog Output #2
Refer to I/O Specs
for detailed description
of I/O devices.
No Connection
3
4
Mechanical
link to RAM
Ram Excitation (+)/Ana In_2 EX+
Input (+)
0-10 Vdc
Common
Common
0-10 Vdc
Input (+)
2K to 10K
Pot.
Ram Position Input/Ana In_2
6
Analog Common
7
6
7
8
or
or
2K to 10K
Pot.
Analog Inputs must have minimum
Span of 8 Vdc to maintain max. resolution.
See Programming and Setup for 5 Vdc Spans.
Clamp Position Input/Ana In_1
8
Clamp Excitation (+)/Ana In_1
9
No Connection
Mechanical
link to CLAMP
(built-in)
or
SIG (+)
Shunt Cal Hydraulic 1A/Cal Ana In_5A
11
Shunt Cal Hydraulic 1B/Cal Ana In-5B
12
Ram Hydraulic Input/Ana In_5
13
Analog Common
14
opto-isolator
EX(+)
10
(external)
EX(-)
SIG (-)
5
No Connection
No Connection
High Level Transducer
15
16
High Level Excitation is from external regulated supply.
If transducer does not have built-in Cal resistor, insert resistor
shown between EX (-) and Terminal 11.
If resistor is NOT built-in, use value specified by manufacturer.
Note that certain transducers
may require the installation of an
optical isolator between the transducer
output and analog input terminals.
Note that ALL Analog Common Terminals are common to each other.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 38 of 104
MACO Series Controller Installation
Figure 5.2 Analog I/O Wiring (Connector P3)
ANALOG I/O CARD
CONNECTOR ASSEMBLY
P3
16
Analog Output #3
Analog Outputs can be either 0 to -10 Vdc or 0 to +10 Vdc
(by Hydraulics Control Relay - see Programming and Setup)
Output current limited to approx. 3mA.
Valve Driver/
Servo Amplifier
15
Analog Common
Valve Driver/
Servo Amplifier
14
13
Analog Output #4
Refer to I/O Specs
for detailed description
of I/O devices.
No Connection
12
Tach Input
11
12 Vdc Common
10
12 Vdc Regulated
9
Analog Common
8
Ejector Position Input/Ana In_3
7
Ejector Excitation (+)/Ana In_3 EX+
6
No Connection
12 Vdc regulated supply load must be limited to
maximum current of 10 mA.
If external supply is used, tie supply minus (-)
to 12 Vdc Common.
9
2K to 10K
Pot.
Mechanical
link to EJECTOR
Shunt Cal Hydraulic 2A/Cal Ana In_4A
4
Shunt Cal Hydraulic 2B/Cal Ana In_4B
3
Clamp Hydraulic Input/Ana In_4
2
Analog Common
8
Common
0-10 Vdc
Input (+)
Analog Inputs must have minimum
Span of 8 Vdc to maintain max. resolution.
See Programming and Setup for 5 Vdc Spans.
(external)
5
or
or
(built-in)
EX(-)
SIG(+)
1
No Connection
SIG(-)
opto-isolator
EX(+)
High Level Transducer
High Level Excitation is from external regulated supply.
Note that certain transducers
may require the installation of an
optical isolator between the transducer
output and analog input terminals.
If transducer does not have built-in Cal resistor, insert resistor
shown between EX (-) and Terminal 5.
If resistor is NOT built-in, use value specified by manufacturer.
Note that ALL Analog Common Terminals are common to each other.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 39 of 104
MACO Series Controller Installation
Figure 5.3 Wiring the Analog I/O Board
Do NOT connect
shields at this end
(Braided Shield)
Bond to
Chassis
Bond to
Chassis
(Braided Shield and Overbraid)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 40 of 104
MACO Series Controller Installation
6. Installing & Wiring the High Speed Ana Sig Processor (Parison) Board
6.1 Introduction
The high speed analog signal processor card can be specified with 1, 2, or 4
channels of control. The number of channels required will depend on the amount
of control needed by the process. Regardless of the number of channels specified,
wiring from one channel to another will be similar (the difference being the type of
sensor used to provide the input). Current or voltage inputs can be used. Outputs
are voltage only and are intended for use with a drive package or amplifier.
6.2 Wiring of All Analog Inputs & Outputs
6.2.1 Input/Output Specifications
The following is a list of specifications that should be observed when installing and
wiring the high speed analog signal processor card. The specifications apply to all
functions of the same type.
Analog Inputs
Input Signal:
±10 Vdc (nominal) or ±20 mA (nominal)(jumper selectable)
Input Impedance:
100kΩ minimum voltage input: 500Ω current input
Input Function:
Accumulator Position, Die Position, or Hydraulic Pressure (user configurable)
Analog Outputs
Output Signal:
±10 Vdc
Output Current:
4.5 mA maximum into a 2.2k ohm load
Input/Output Isolation:
Each Input/Output pair is isolated from all other pairs
DC Discrete Logic Inputs/Outputs
DC Inputs
DC Outputs (Requires External Supply)
Input Voltage:
-0.6 (minimum)
to 40 Vdc (maximum)
Voltage:
24 Vdc maximum
switched voltage
On Voltage:
10 Vdc
Current:
20 mA maximum
switched current
Off Voltage:
5 Vdc
Input Current
Less than 10 mA
at 24 Vdc
1640-IN-031-C-08
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 41 of 104
MACO Series Controller Installation
6.2.2 Analog Input/Output Wiring Guidelines
1. Use braided shield cables on ALL analog inputs and outputs. Use separate
cables for each function and keep cables less than 3 meters in length. If cables
are over 3 meters long, an overbraid is required. If overbraid has been used,
terminate both the internal braided shield and the overbraid at the ground
distribution block (see figures 6.3 and 6.4).
2. Analog Input (-) must be connected to Analog Common at the sensing device
to prevent ground loop currents.
3. Excitation voltage for potentiometers is provided by the card. Excitation voltage
is +10 Vdc @ 20 mA. Potentiometer resistance should be 500Ω to 2kΩ.
6.2.3 Analog I/O Applications Wiring
Figures 6.3 and 6.4 illustrate typical analog I/O wiring for the control card. Note that
this drawing is "typical" only. Actual wiring will depend on the sensors and control
elements used.
6.3 Wiring of DC Inputs & Outputs
The DC Input and Output functions require an external, regulated DC power supply
capable of providing a nominal voltage of plus (+) 24 Vdc. The power supply must
be CE recognized. The power supply and its ground distribution block must be
located within 30 cm of the bottom of the controller chassis. There must be NO
other (external) devices powered from the supply. The current rating of the power
supply will depend on the loads being driven. Note that there are only four input and
output functions and they are shared by all four channels if the card is so specified.
1. Connect (+)DC to Pin 5 of the top connector (P14). This supplies the voltage for
the output circuits.
2. Connect (-)DC to Pin 6 of the same connector. This supplies DC Common for
both the input and output circuits.
3. Connect the outputs to one side of the loads. Connect the other side of the loads
to (-)DC.
18 gauge wire is recommended as a minimum, but make certain to satisfy all local
and national code requirements.
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 42 of 104
MACO Series Controller Installation
Figure 6.0 A-13815 High Speed Ana Sig Processor (Parison) Board
4 S1
P14
JUMPER
DETAIL
CURRENT
1
KEY
EPROM 1
P1
P2
P3
P4
(U212)
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
DS3
VOLTAGE
DS4
P15
J10
P16
J20
P17
J30
P18
J40
P5
P6
P7
P8
P9
P10
P15
Chnl 1
P17
Chnl 3
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
P16
Chnl 2
PIN
NUMBER
1
2
3
4
5
6
7
DC Input 1
DC Input 2
DC Input 3
DC Input 4
+DC for Outputs
DC Input/Output Common
DC Output 1
DC Output 2
DC Output 3
DC Output 4
P18
Chnl 4
Analog In Plus (+)
Analog In Minus (-)
Analog Out (+)
Excitation (+)
Analog Common (-)
Cal A
Cal B
CONNECTOR E24-1135-007
(ON CARD)
E24-1134-007
MATING
CONNECTOR
CONNECTOR E24-1135-010
(ON CARD)
E24-1134-010
MATING
CONNECTOR
NO FUSES
See Cable Assemblies for
Wire Description
S1 Settings
JUMPERS
J10
J20
J30
J40
*As shipped
Chnl 1 Analog In: ±10Volts* or ±20mA
Chnl 2 Analog In: ±10Volts* or ±20mA
Chnl 3 Analog In: ±10Volts* or ±20mA
Chnl 4 Analog In: ±10Volts* or ±20mA
SWITCH
NUMBER
4
3
2
1
LEDs
DS3
DS4
1640-IN-031-C-08
Open = Run; Closed = Factory Cal*
Undefined
Brd 1
Brd 2
Brd 3
Brd 4
Closed
Closed
Closed
Open
Open
Closed
Open
Open
*Factory use only
Control Fault
Parison Communications Busy
Eurotherm/Barber-Colman
Page 43 of 104
MACO Series Controller Installation
Figure 6.1 High Speed Analog (Parison) Sensor Wiring
Notes: 1. Excitation voltage from the parison card is limited to +10 Vdc @ 20 mA.
2. All shields must be connected directly to panel earth ground at one end only.
3. Input minus (-) must be connected to Analog Common at the sensing device - NOT at the parison card.
Potentiometer
Analog In Plus (+)
Analog In Minus (-)
Analog Out (+)
Excitation (+)
Analog Common (-)
Cal A
Cal B
500 Ω
to
2k Ω
Wire shield directly to
panel earth ground
Other Position Devices (such as Temposonics)
Analog In Plus (+)
Analog In Minus (-)
Analog Out (+)
Excitation (+)
Analog Common (-)
Cal A
Cal B
Position
Detection
System
Wire shield directly to
panel earth ground
Power
To external power supply
DC LVDT
Analog In Plus (+)
Analog In Minus (-)
Analog Out (+)
Excitation (+)
Analog Common (-)
Cal A
Cal B
1640-IN-031-C-08
Signal
LVDT
Power
Wire shield directly to
panel earth ground
Eurotherm/Barber-Colman
To external power supply
Page 44 of 104
MACO Series Controller Installation
Figure 6.2 High Speed Analog (Parison) Card Pressure Transducer Wiring
Analog In Plus (+)
Analog In Minus (-)
Analog Out (+)
Excitation (+)
Analog Common (-)
Cal A
Cal B
EX+
Sig+
Wire shield directly to
panel earth ground
external
Notes:
SigEX-
or
internal
1. High level excitation is from an external regulated power supply.
2. If the transducer does not have a built-in calibration resistor, insert resistor
as shown between EX(-) and CAL terminal.
3. If resistor is not built-in, use value specified by manufacturer.
Figure 6.3 High Speed Analog (Parison) Card DC Input and Output Wiring
DC Input 1
DC Input 2
DC Input 3
DC Input 4
VBIAS (+DC for Outputs)
DC Input/Output Common
DC Output 1
DC Output 2
DC Output 3
DC Output 4
1640-IN-031-C-08
+ External
Supply
– (24 Vdc max)
Loads
Eurotherm/Barber-Colman
Page 45 of 104
1640-IN-031-C-08
PARISON PCB
Rotation Detector
P14
DC Input 1
DC Input 2
DC Input 3
DC Input 4
VBIAS (+DC for Outputs)
DC Input/Output Common
DC Output 1
DC Output 2
DC Output 3
DC Output 4
Count Pulse
Home Pulse
+
–
A-13441 SERVO AMP
Servo Assembly
EX+
EX+
EXEX-
P15
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
LVDT
Excitation
Input
LVDT
Position
Output
Input 1+
Input 1-
Output 1+
Output 1-
Servo Control
Input
Page 46 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
External
DC Supply
Figure 6.4 One-Head Time-Based Machine with B-C Servo Amp
DC Common
1640-IN-031-C-08
A-13441 SERVO AMP
PARISON PCB
Servo Assembly #1
P15
LVDT
Position
Output
Input 1+
Input 1-
Output 1+
Output 1-
Servo Control
Input
Servo Assembly #2
P16
Analog In 2 Plus (+)
Analog In 2 Minus (-)
Analog Out 2 (+)
Excitation 2 (+)
Analog Common 2 (-)
Cal 2 A
Cal 2 B
Input 2+
Input 2-
Output 2+
Output 2-
Servo Control
Input
LVDT
Position
Output
LVDT
Excitation
Input
Page 47 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
LVDT
Excitation
Input
Figure 6.5 Two-Head Time-Based Machine with B-C Servo Amp
EX+
EX+
EXEX-
1640-IN-031-C-08
A-13441 SERVO AMP
PARISON PCB
Servo Assembly #1
P15
LVDT
Position
Output
Input 1+
Input 1-
Output 1+
Output 1-
Servo Control
Input
Position Detection
P17
Analog In 3 Plus (+)
Analog In 3 Minus (-)
Analog Out 3 (+)
Excitation 3 (+)
Analog Common 3 (-)
Cal 3 A
Cal 3 B
EX+
500 Ω
Position
to
2k Ω Output
Page 48 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
LVDT
Excitation
Input
Figure 6.6 Two-Head Position-Based Machine with B-C Servo Amp
EX+
EX+
EXEX-
1640-IN-031-C-08
A-13441 SERVO AMP
PARISON PCB
Servo Assembly #1
P15
LVDT
Position
Output
Input 1+
Input 1-
Output 1+
Output 1-
Servo Control
Input
Position Detection
P17
Analog In 3 Plus (+)
Analog In 3 Minus (-)
Analog Out 3 (+)
Excitation 3 (+)
Analog Common 3 (-)
Cal 3 A
Cal 3 B
EX+
500 Ω
Position
to
2k Ω Output
Valve or Valve Amplifier
(for Pushout Control)
Page 49 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
LVDT
Excitation
Input
Figure 6.7 Two-Head Position-Based Machine with Pushout and B-C Servo Amp
EX+
EX+
EXEX-
1640-IN-031-C-08
Position Detection
500 Ω
Position
to
2k Ω Output
Input 1+
Input 1-
Output 1+
Output 1-
Input to
Flow Valve
Page 50 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
EX+
P15
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
Figure 6.8 Accumulator Machine (Velocity Control) with B-C Servo Amp
A-13441 SERVO AMP
PARISON PCB
1640-IN-031-C-08
EX+
P15
Analog In 1 Plus (+)
Analog In 1 Minus (-)
Analog Out 1 (+)
Excitation 1 (+)
Analog Common 1 (-)
Cal 1 A
Cal 1 B
500 Ω
Position
to
2k Ω Output
Excitation (+) 11
Excitation (-) 13
Input (+) 4
Input (-) 5
Output (+) 7
Output (-) 8
Servo
Control In
Page 51 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Position Detection
Figure 6.9 Two-Head Position-Based Machine with Moog Servo Amp
MOOG 121-105 SERVO AMP
PARISON PCB
MACO Series Controller Installation
Figure 6.10 Wiring the High Speed Analog Signal Processor (Parison) Board DC Inputs
DC In 1
DC In 2
DC In 3
DC In 4
DC Common
Note that DC Inputs and Outputs
have a shared common.
24 Vdc
Supply
+
-
DC Common
Bond to
Chassis
(Overbraid)
Figure 6.11 Wiring the High Speed Analog Signal Processor (Parison) Board DC Outputs
+DC for Outs
DC I/O Common
DC Out 1
DC Out 2
DC Out 3
DC Out 4
Note that DC Inputs and Outputs
have a shared common.
24 Vdc
Supply
+
-
DC Common
Power Supply outputs MUST have
ferrite beads capable of filtering
30 MHZ to 100 MHZ
Bond to
Chassis
(Overbraid)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 52 of 104
MACO Series Controller Installation
Figure 6.12 Wiring the High Speed Analog Signal Processor (Parison) Board Analog Inputs
Ana In +
Ana In Ana Common
(Braided Shield)
Bond to
Chassis
Bond to
Chassis
(Braided Shield and Overbraid)
Connect Input minus to Analog
Common at the sensor
Figure 6.13 Wiring the High Speed Analog Signal Processor (Parison) Board Analog Outputs
Ana Out+
Ana Common
(Braided Shield)
Bond to
Chassis
Bond to
Chassis
(Braided Shield and Overbraid)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 53 of 104
MACO Series Controller Installation
7. Installing & Wiring the Seq/Hydraulics Board
Different versions of Sequence/Hydraulics board assembly A-60012/A-60083 are
meant for 9-slot, 12-slot or 16-slot control systems (see the table).
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 54 of 104
MACO Series Controller Installation
Figure 7. A-60012 or A-60083 Seq/Hydr Board
DS3
P1
P2
P3
P4
J4
DS4
EPROM 2
(U67)
DS1
DS2
EPROM 1
(U11)
(U13)
P5
P6
P7
P8
P9
P10
KEY
POWER SUPPLY
OUTPUTS TO BUS
+5 VDC Common
P1
+5 VDC
P2
+5 VDC Common
P3
+5 VDC
P4
+5 VDC Common
P5
Not Used
P6
28 VAC ØA
P7
28 VAC ØB
P8
Not Used
P9
Guard
P10
LEDs
DS1
DS2
DS3
DS4
Sequence Fault
Sequence Communications Active
Hydraulic Fault
Hydraulic Communications Active
NO FUSES
A-60012-0xx
A-60012-1xx
A-60083-0xx
A-60083-1xx
A-60201-0xx
A-60201-1xx
A-60201-90x
A-60201-91x
12-Slot
9 or 16-Slot
12-Slot (5K RLD)
7, 9 or 16-Slot (5K RLD)
12-Slot (9K RLD)
7, 9 or 16-Slot (9K RLD)
Note that 9K RLD requires U13
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 55 of 104
MACO Series Controller Installation
8. Installing & Wiring the Power Supply Board
Note that the 7 Slot System is a 24 Vdc system ONLY.
DO NOT CONNECT AC POWER TO A 7 SLOT SYSTEM!
AC Power Supplies (9 Slot, 12 Slot and 16 Slot Systems)
1. Connect the board to a suitable AC power source as shown in Figure 8.2, 8.3
or 8.4. Connect Pin 5 on the power connector directly to "Ground" or to the system
ground block.
WARNING:
For safety reasons, if replacing an A-13395 power supply with an A-60045 power
supply on 9 and 16 slot systems, you MUST add a ground wire from Pin 5 of P12
directly to Earth Ground or an Earth Ground Distribution Block! If the power supply
is being installed in a control system which includes a "bonding bar," then instead
of adding the ground wire, simply attach the free end of the bond strap (on the
power supply) to the bond bar.
E.1
2.Connect the 15 Vdc output from the power supply board to the operator station as
shown in Figure 8.2, 8.3 or 8.4. Refer to Figure 16 for cable part numbers & pinouts.
DC Power Supplies (7 Slot Systems)
1. Connect the board to a suitable DC power source as shown in Figure 8.5. Note
that 7 Slot systems achieve a ground connection by bonding the rack to a grounded
panel by means of the rack's mounting screw.
2. Note that a an external 15 Vdc supply is required for the operator station. Refer
to the Operator Station I&W for details.
Power Supply Specifications
AC Supply Voltage (for 9 Slot, 12 Slot and 16 Slot Systems):
100/250 Vac; 50/60 Hz, ±3 Hz; 200 VA maximum.
DC Supply Voltage (for 7 Slot Systems):
Class 2 supply capable of 24 Vdc, 2.0 Amps (minimum), 24 Vdc, 3.0 Amps
(recommended).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
For supply connections, use No. 18 AWG or
larger wires rated for at least 75°C (165°F).
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 56 of 104
MACO Series Controller Installation
Figure 8.0 A-13395 Power Supply Board
P11
See Cable Assemblies
for Wire Description
P1
P2
P3
P4
F3
F1
SPARE FUSES
(1 each)
DS1
P5
P6
P7
P8
P9
P10
F4
P12
POWER SUPPLY
OUTPUTS TO BUS
+5 Vdc Common
P1
+5 Vdc
P2
+5 Vdc Common
P3
+5 Vdc
P4
+5 Vdc Common
P5
Not Used
P6
28 Vac ØA
P7
28 Vac ØB
P8
Not Used
P9
P 1 0 Guard
KEY
P11
PIN
NUMBER
1
2
3
P12
+15 Vdc (to Flatpanel)
No Connection
Flatpanel Common
CONNECTOR E24-1135-003
(ON CARD)
MATING
E24-1134-003
CONNECTOR
PIN
NUMBER
1
2
3
4
5
L1 (100 to 250 Vac IN)
No Connection
L2 Vac IN
No Connection
Earth Ground
CONNECTOR E24-1446-005
(ON CARD)
E24-1134-005
MATING
CONNECTOR
LEDs
DS1
FUSES
F1
F3
F4
Line Voltage in ON
BC
Part No.
E15-114
E15-107
E15-107
4 Amp, 250V
3 Amp, 250V*
3 Amp, 250V*
5 Vdc Supply
15 Vdc Supply
Line Voltage In (P12, No. 1)
*5X20mm "fast acting," Littelfuse 235-003 ONLY!
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 57 of 104
MACO Series Controller Installation
Figure 8.1 A-60045 Power Supply Board
P11
P1
P2
P3
P4
See Cable Assemblies
for Wire Description
SPARE FUSE
DS1
P5
P6
P7
P8
P9
P10
F1
P12
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
KEY
P11
PIN
NUMBER
1
2
3
P12
+15 Vdc (to Flatpanel)
No Connection
Flatpanel Common
CONNECTOR E24-1135-003
(ON CARD)
MATING
E24-1134-003
CONNECTOR
PIN
NUMBER
1
2
3
4
5
L1 (100 to 250 Vac IN)
No Connection
L2 Vac IN
No Connection
Earth (Safety Ground)
CONNECTOR E24-1446-005
(ON CARD)
MATING
E24-1134-005
CONNECTOR
LEDs
DS1
FUSES
F1
Line Voltage in ON
BC
Part No.
E15-107
3 Amp, 250V*
Line Voltage In (P12, No. 1)
*5X20mm "fast acting," Littelfuse 235 003 ONLY!
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 58 of 104
MACO Series Controller Installation
Figure 8.2 Wiring the Power Supply Board in 9 Slot Systems
Overbraid in Conduit
to Operator Station
or
Overbraid
to Operator Station
+15 Vdc
Flatpanel Common
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
Bond to Chassis
within 10 cm of controller
Earth (Safety Earth)
L2
L1
(Braided Shield)
Bond to
Chassis
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Local
Ground Rod
Figure 8.3 Wiring the Power Supply Board in 12 Slot Systems
Overbraid in Conduit
to Operator Station
or
Overbraid
to Operator Station
+15 Vdc
Flatpanel Common
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Bond to Chassis
within 10 cm of controller
L1
L2
Earth (Safety Earth)
(Braided Shield)
Bond to
Chassis
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
1640-IN-031-C-08
Local
Ground Rod
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Eurotherm/Barber-Colman
Page 59 of 104
MACO Series Controller Installation
Figure 8.4 Wiring the Power Supply Board in 16 Slot Systems
Overbraid in Conduit
to Operator Station
or
Overbraid
to Operator Station
+15 Vdc
Flatpanel Common
Use the bond strap provided
or one that maintains a 5:1
length to width ratio
Power supply bond strap
is installed at the factory
for CE EMC compliant
systems.
Bond to Chassis
within 10 cm of controller
Earth (SafetyEarth)
L2
L1
(Braided Shield)
Bond to
Chassis
Distribution Blocks
Twist L1, L2 and Safety Earth at least 1 turn per inch.
Safety Earth
Bond to
Chassis
L1
L2
Local
Ground Rod
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
Figure 8.5 Wiring the Power Supply Board in 7 Slot Systems
+24V
N/C
COM
+
-
24 Vdc
Supply
Power Supply outputs MUST have
ferrite beads capable of filtering
30 MHZ to 100 MHZ
A Class 2 Supply is required
24 Vdc, 2.0 Amps (minimum)
24 Vdc, 3.0 Amps (recommended)
Note that this assembly
achieves a ground connection by
bonding the rack to a grounded panel
by means of the rack's mounting screw.
DC Power ONLY!
Include a switch or circuit breaker in the installation. It must be placed in
close proximity to the equipment, within easy reach of the operator and
must be marked as the disconnecting device for the equipment.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 60 of 104
MACO Series Controller Installation
9. Installing & Wiring AC Output Boards
AC output boards have NOT been validated for conformance with the CE EMC
directive. Additional measures beyond those specified here may be needed in
order to demonstrate EMC compliance at the machine level. Proof of EMC
conformance lies with the machine manufacturer.
18 gauge wire is recommended as a minimum, but make certain to satisfy all local
and national code requirements.
1.Connect L1 to the input side of the output board. There are four pins (Connector P12, Pins 3, 4, 5 and 6) where L1 must be connected. Each L1 input supplies
power to four outputs. Pin 3 powers Outputs 1 - 4; Pin 4 powers Outputs 5 - 8; Pin
5 powers Outputs 9 - 12; and Pin 6 powers Outputs 13 - 16.
Connect L2 to the input side of the output board. There are two pins (Connector
P12, Pins 1 and 2) where L2 must be connected. Each L2 supplies a common for
eight of the neon indicator lights (NOT the outputs).
2.Connect the outputs to the loads. Each output has a single, separate connection
(P13, Pins 1 - 16) from the board. Connect the other side of each of the loads to
L2. Note that each load must draw a minimum of 50 mA and a maximum of 1 Amp.
AC Outputs Operating Specifications
Output Points per Card:
16 (standard density), 24 (high density)
Supply Voltage:
100 to 240 Vac external
Minimum Load:
50 mA
Maximum Load:
1 Amp, 120/240 Vac, 125/250 VA, (pilot duty)
Maximum Leakage:
5 mA
Fused:
2 Amp fuse per output (load side)
Indicator:
Neon per output
Maximum Output Current per Card
(Enclosed Systems):
16 Amps
(Open Frame Systems):
8 Amps
Isolation:
Optically isolated (in groups of 4)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 61 of 104
MACO Series Controller Installation
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
For supply connections, use No. 18 AWG or
larger wires rated for at least 75°C (165°F).
In order to insure that triac outputs will fully turn on, the load
must draw a minimum of 50 mA AC rms current when
conducting. If a load is suspected or known to require less
than 50 mA, one of the resistors below should be used. The
resistor is meant to be wired in parallel with the load and will
serve to increase load current above the 50 mA minimum.
Kit Number 71-934-000 (120 Vac)
2k Ω, 10 W, leaded, wire-wound resistor.
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Kit Number 71-934-100 (240 Vac)
4k Ω, 20 W, leaded, wire-wound resistor.
L1
L
O
A
D
Caution: Resistor gets "hot" when powered.
Keep away from wiring, case, etc.
L2
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 62 of 104
MACO Series Controller Installation
Figure 9.0 A-13402 Standard Density AC Output Board
F1
to
F16
DS1
to
DS16
P1
P2
P3
P4
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
KEY
P12
P5
P6
P7
P8
P9
P10
P13
P12
PIN
NUMBER
1
2
3
4
5
6
P13
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
L2 (for Neons)
L2 (for Neons)
L1A (Out 1 - Out 4)
L1B (Out 5 - Out 8)
L1C (Out 9 - Out 12)
L1D (Out 13 - Out 16)
CONNECTOR E24-1135-006
(ON CARD)
E24-1134-006
MATING
CONNECTOR
AC Output 1
AC Output 2
AC Output 3
AC Output 4
AC Output 5
AC Output 6
AC Output 7
AC Output 8
AC Output 9
AC Output 10
AC Output 11
AC Output 12
AC Output 13
AC Output 14
AC Output 15
AC Output 16
NEONs
DS1
to
DS16
Output 1
to
Output 16
FUSES
BC
Part No.
F1
to
F16
E15-103
ON
CONNECTOR E24-1135-016
(ON CARD)
E24-1134-016
MATING
CONNECTOR
ON
2A, 250 V*
Output 1
to
Output 16
See Cable Assemblies for
Wire Description
*5X20mm fast acting, Littlefuse 235002 or equivalent
NO JUMPERS
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 63 of 104
MACO Series Controller Installation
Figure 9.1 A-13904 High Density AC Output Board
P1
P2
P3
P4
F1
to
F24
DS1
to
DS24
POWER SUPPLY
OUTPUTS TO BUS
+5 Vdc Common
P1
+5 Vdc
P2
+5 Vdc Common
P3
+5 Vdc
P4
+5 Vdc Common
P5
Not Used
P6
28 Vac ØA
P7
28 Vac ØB
P8
Not Used
P9
P 1 0 Guard
P12
1-16
P5
P6
P7
P8
P9
P10
17-32
P12
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
L2 (for Neons)
L1A (Out 1 - Out 4)
L1B (Out 5 - Out 8)
L1C (Out 9 - Out 12)
AC Output 1
AC Output 2
AC Output 3
AC Output 4
AC Output 5
AC Output 6
AC Output 7
AC Output 8
AC Output 9
AC Output 10
AC Output 11
AC Output 12
CONNECTOR E24-1220-016 (1 each)
(ON CARD)
E24-1134-016 (2 each)
MATING
CONNECTOR
See Cable Assemblies for
Wire Description
PIN
NUMBER
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
L2 (for Neons)
L1D (Out 13 - Out 16)
L1E (Out 17 - Out 20)
L1F (Out 21 - Out 24)
AC Output 13
AC Output 14
AC Output 15
AC Output 16
AC Output 17
AC Output 18
AC Output 19
AC Output 20
AC Output 21
AC Output 22
AC Output 23
AC Output 24
LEDs
DS1
to
DS24
Output 1
to
Output 24
FUSES
BC
Part No.
F1
to
F24
E15-103
ON
ON
2A, 250 V*
Output 1
to
Output 24
*5X20mm fast acting, Littlefuse 235002 or equivalent
NO JUMPERS
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 64 of 104
MACO Series Controller Installation
Figure 9.2 AC Output Wiring
Field Wiring
Simplified Circuit
2 Amp
L1A
100/240 Vac
(Outputs 1, 2, 3, 4)
2 Amp
L2
Common for
Output Lights
2 Amp
Field Wiring
OUT 1
OUTPUT #1
LOAD
OUT 2
OUTPUT #2
LOAD
OUT 3
2 Amp
OUT 4
OUT 5
OUT 6
L1B
100/240 Vac
(Outputs 5, 6, 7, 8)
Output Circuitry
Same as Above
OUT 7
OUT 8
OUT 9
OUT 10
L1C
100/240 Vac
(Outputs 9, 10, 11, 12)
Output Circuitry
Same as Above
OUT 11
OUT 12
OUT 13
OUT 14
L1D
100/240 Vac
(Outputs 13, 14, 15, 16)
1640-IN-031-C-08
Output Circuitry
Same as Above
OUT 15
OUT 16
Eurotherm/Barber-Colman
L2
OUTPUT #3
LOAD
OUTPUT #4
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
Page 65 of 104
MACO Series Controller Installation
10. Installing & Wiring DC Output Boards
Note that DC Output Boards require an external, regulated DC supply capable of
providing a voltage of plus (+) 16 Vdc to plus (+) 24 Vdc. The power supply must
be CE recognized. The power supply and its ground distribution block must be
located within 30 cm of the bottom of the controller chassis. There must be NO
other (external) devices powered from the supply. The current rating of the supply
will depend on the loads being driven.
18 gauge wire is recommended as a minimum, but make certain to satisfy all local
and national code requirements.
For 24 Output (A-60068) Boards:
1.Connect +DC to the input side of the output board. There are six pins (Connector
P12, Pins 2, 3, 4, 18, 19 and 20) where +DC must be connected. Each +DC input
supplies power to four outputs. Pin 2 powers Outputs 1 - 4; Pin 3 powers Outputs
5 - 8; Pin 4 powers Outputs 9 - 12; Pin 18 powers Outputs 13 - 16; Pin 19 powers
Outputs 17 - 20; Pin 20 powers Outputs 21 - 24.
Connect -DC to the input side of the output board. There are two pins (Connector
P12, Pin 1 and 17) where -DC must be connected.
2.Connect the outputs to the loads. Each output has a single, separate connection
from the board. Connect the other side of each of the loads to -DC. Each load must
draw a minimum of 5 mA and a maximum of 2 Amps.
For 16 Output (A-60107) Boards:
1.Connect +DC to the input side of the output board. There are four pins
(Connector P12, Pins 2, 3, 4 and 18) where +DC must be connected. Each +DC
input supplies power to four outputs. Pin 2 powers Outputs 1 - 4; Pin 3 powers
Outputs 5 - 8; Pin 4 powers Outputs 9 - 12; Pin 18 powers Outputs 13 - 16.
Connect -DC to the input side of the output board. There are two pins (Connector
P12, Pin 1 and 17) where -DC must be connected.
2.Connect the outputs to the loads. Each output has a single, separate connection
from the board. Connect the other side of each of the loads to -DC. Each load must
draw a minimum of 5 mA and a maximum of 2 Amps.
DC Outputs Operating Specifications
Outputs per Card:
24 (high density)
16 (standard density)
1640-IN-031-C-08
Indicator:
LED per output
Supply Voltage:
12 to 24 Vdc external
Maximum Output Current per Card
(Enclosed Systems):
32 Amp
Minimum Load:
5 mA
(Open Frame Systems):
16 Amp
Maximum Load:
2 Amp
Isolation:
Optically isolated as a group
Maximum Leakage:
2 mA
Fused:
2 Amp fuse per output (load side)
Eurotherm/Barber-Colman
Page 66 of 104
MACO Series Controller Installation
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 67 of 104
MACO Series Controller Installation
Figure 10.0 A-60068 24 Output DC Out Board
P1
P2
P3
P4
F1
to
F24
DS1
to
DS24
POWER SUPPLY
OUTPUTS TO BUS
+5 Vdc Common
P1
+5 Vdc
P2
+5 Vdc Common
P3
+5 Vdc
P4
+5 Vdc Common
P5
Not Used
P6
28 Vac ØA
P7
28 Vac ØB
P8
Not Used
P9
P 1 0 Guard
P12
1-16
P5
P6
P7
P8
P9
P10
17-32
P12
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DC - (Out 1 - Out 12)
DC + (Out 1 - Out 4)
DC + (Out 5 - Out 8)
DC + (Out 9 - Out 12)
DC Output 1
DC Output 2
DC Output 3
DC Output 4
DC Output 5
DC Output 6
DC Output 7
DC Output 8
DC Output 9
DC Output 10
DC Output 11
DC Output 12
CONNECTOR E24-1220-016 (1 each)
(ON CARD)
E24-1134-016 (2 each)
MATING
CONNECTOR
See Cable Assemblies for
Wire Description
PIN
NUMBER
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
DC - (Out 13 - 24)
DC + (Out 13 - Out 16)
DC + (Out 17 - Out 20)
DC + (Out 21 - Out 24)
DC Output 13
DC Output 14
DC Output 15
DC Output 16
DC Output 17
DC Output 18
DC Output 19
DC Output 20
DC Output 21
DC Output 22
DC Output 23
DC Output 24
LEDs
DS1
to
DS24
Output 1
to
Output 24
FUSES
BC
Part No.
F1
to
F24
E15-103
ON
ON
2 Amps,
250 Volts*
Output 1
to
Output 24
*5X20mm fast acting, Littlefuse 235002 ONLY!
NO JUMPERS
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 68 of 104
MACO Series Controller Installation
Figure 10.1 A-60107 16 Output DC Out Board
P1
P2
P3
P4
F1
to
F16
DS1
to
DS16
POWER SUPPLY
OUTPUTS TO BUS
+5 Vdc Common
P1
+5 Vdc
P2
+5 Vdc Common
P3
+5 Vdc
P4
+5 Vdc Common
P5
Not Used
P6
28 Vac ØA
P7
28 Vac ØB
P8
Not Used
P9
P 1 0 Guard
P12
1-16
P5
P6
P7
P8
P9
P10
17-32
P12
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DC - (Out 1 - Out 12)
DC + (Out 1 - Out 4)
DC + (Out 5 - Out 8)
DC + (Out 9 - Out 12)
DC Output 1
DC Output 2
DC Output 3
DC Output 4
DC Output 5
DC Output 6
DC Output 7
DC Output 8
DC Output 9
DC Output 10
DC Output 11
DC Output 12
CONNECTOR E24-1220-016 (1 each)
(ON CARD)
E24-1134-016 (2 each)
MATING
CONNECTOR
See Cable Assemblies for
Wire Description
PIN
NUMBER
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
DC - (Out 13 - 16)
DC + (Out 13 - Out 16)
(Not Used)
(Not Used)
DC Output 13
DC Output 14
DC Output 15
DC Output 16
(Not Used)
(Not Used)
(Not Used)
(Not Used)
(Not Used)
(Not Used)
(Not Used)
(Not Used)
LEDs
DS1
to
DS24
Output 1
to
Output 16
FUSES
BC
Part No.
F1
to
F16
E15-103
ON
ON
2 Amps,
250 Volts*
Output 1
to
Output 16
*5X20mm fast acting, Littlefuse 235002 ONLY!
NO JUMPERS
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 69 of 104
MACO Series Controller Installation
Figure 10.2 DC Output Wiring
+24 Vdc from
External Supply
2 Amp
Control
+5V
1M
390
+24 Vdc Output
6.8k
DC OUTPUT
CIRCUIT
Output
LED
15k
10k
LOAD
2.2k
Power Supply
Common
Opto-Isolator
Logic Common
(+)
+24 Vdc IN
- DC (Common)
+24 Vdc Supply
(-)
+24 Vdc Outputs
2 Amp (all)
OUT 1
+DC In
(Outputs 1, 2, 3, 4)
Output Circuits
1 thru 4
OUT 2
OUT 3
OUT 4
OUT 5
+DC In
(Outputs 5, 6, 7, 8)
Output Circuits
5 thru 8
OUT 6
OUT 7
OUT 8
OUT 9
+DC In
(Outputs 9, 10, 11, 12)
Output Circuits
9 thru 12
OUT 10
OUT 11
OUT 12
OUT 13
+DC In
(Outputs 13, 14, 15, 16)
Output Circuits
13 thru 16
OUT 14
OUT 15
OUT 16
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
-DC (Common)
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 70 of 104
MACO Series Controller Installation
Figure 10.3 Wiring the DC Output Board
DCDC+
DC Out 1
DC Out 2
DC Out ...
24 Vdc
Supply
+
-
DC Common
Power Supply outputs MUST have
ferrite beads capable of filtering
30 MHZ to 100 MHZ
Note that NO Shield or Overbraid is necessary.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 71 of 104
MACO Series Controller Installation
11. Installing & Wiring Analog Output Boards
Analog output boards have NOT been validated for conformance with the CE EMC
directive. Additional measures beyond those specified here may be needed in
order to demonstrate EMC compliance at the machine level. Proof of EMC
conformance lies with the machine manufacturer.
Note that Analog Output Boards require an external, regulated DC supply capable
of providing 24 Vdc, ±0.5 Vdc with a minimum current of at 0.6 Amps. The power
supply must be CE recognized. The power supply and its ground distribution block
must be located within 30 cm of the bottom of the controller chassis. There must
be NO other (external) devices powered from the supply.
18 gauge wire is recommended as a minimum, but make certain to satisfy all local
and national code requirements.
Sequence card setpoints are used to locate and configure the boards within a rack.
The "First Analog Out Slot" setpoint tells the system which slot contains the first
analog output board:
For 16 Slot Systems:
Count the slot on the far right as "7" and count down from right to left until you count
the analog output card farthest to the left. Enter that number.
For 12 Slot Systems:
Count the slot on the far right as "5" and count down from right to left until you count
the analog output card farthest to the left. Enter that number.
For 7 and 9 Slot Systems:
Enter the number "1"
The "# Analog Output Brds." setpoint tells the system how many (up to 3, except
9 slot systems can have only 1) analog output boards are present in the rack.
The "Analog Brd. 1-3 Out 1-12" setpoints determine the level of each output. An
entry of zero equals 4 mAdc or 0 Vdc. An entry of 32,000 equals 20 mAdc or 10
Vdc, with proportional levels in between.
1.Connect DC + to Pin 1 of P16. Connect DC - to Pin 2 of P16. Pin 3 of P16 must
be connected to directly to earth ground or the earth ground distribution block.
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
Eurotherm/Barber-Colman
Page 72 of 104
MACO Series Controller Installation
2.Connect the outputs to the loads. Each output has two separate connections
from the board.
Analog Output Operating Specifications
Outputs per Card:
2, 4 or 12
Card Supply Voltage:
24 Vdc, ±0.5 Vdc (external supply) @ 0.6 Amps minimum current.
Current Outputs:
4 to 20 mAdc, isolated, short circuit protected both leads to ground. 750 Ohm maximum
load. Up to 15 bit resolution. Accuracy of 0.25% at full scale at rated conditions.
Voltage Outputs:
0 to 10 Vdc, isolated, short circuit protected at 3.3 mA both leads to ground. 3.3k Ohm
minimum load. Up to 15 bit resolution. Accuracy of 0.25% at full scale at rated conditions.
Figure 11.0 Locating the Analog Output Boards
16 Slot Systems
This is Board 2
(enter "2" as "# Analog Output Brds." setpoint)
This is Board 1
(enter "5" as "First Analog Out Slot" setpoint)
Slot
1
Slot
2
Slot
3
Slot
4
Slot
5
Slot
6
Slot
7
Slot
8
Slot
0
Slot
1
Slot
2
Slot
3
Slot
4
Slot
5
Slot
6
Slot
7
Slot
9
Slot
10
Slot
11
Slot
12
Slot
13
Slot
14
Slot
15
Slot
16
Do NOT count like this
12 Slot Systems
This is Board 2
(enter "2" as "# Analog Output Brds." setpoint)
This is Board 1
(enter "2" as "First Analog Out Slot" setpoint)
Slot
1
Slot
2
Slot
3
Slot
4
Slot
5
Slot
6
Slot
7
Slot
1
Slot
2
Slot
3
Slot
4
Slot
5
Slot
8
Slot
9
Slot
10
Slot
11
Slot
12
Do NOT count like this
7 and 9 Slot Systems
Enter "1" as "First Analog Out Slot" setpoint.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 73 of 104
MACO Series Controller Installation
Figure 11.1 A-60033 Analog Output Board
P1
P2
P3
P4
DS1
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
P14
P15
P16
P5
P6
P7
P8
P9
P10
P16
PIN
NUMBER
1
2
3
4
5
+24 Vdc (IN)
24 Vdc COM
Earth
Spare
Spare
CONNECTOR E24-1135-005
(ON CARD)
E24-1134-005
MATING
CONNECTOR
LEDs
DS1
Fault
Switches
SW1A
thru
SW1M
Up = Current (4-20 mAdc)
Down = Voltage (0-10 Vdc)
P14 & P15
PIN
NUMBER
P14 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P15 1
2
3
4
5
6
CONNECTOR
(ON CARD)
MATING
CONNECTOR
E24-1135-018
E24-1135-006
E24-1134-018
E24-1134-006
(P14)
(P15)
(P14)
(P15)
See Cable Assemblies for
Wire Description
NO JUMPERS
1640-IN-031-C-08
Out 1+
Out 1Out 2+
Out 2Out 3+
Out 3Out 4+
Out 4Out 5+
Out 5Out 6+
Out 6Out 7+
Out 7Out 8+
Out 8Out 9+
Out 9Out 10+
Out 10Out 11+
Out 11Out 12+
Out 12-
Eurotherm/Barber-Colman
Page 74 of 104
MACO Series Controller Installation
Figure 11.2 Analog Output Wiring
P14
1
+
2
3
+
4
5
+
6
7
+
8
9
+
10
11
+
12
13
+
14
15
+
16
17
+
18
-
1
+
2
3
+
4
5
+
6
-
P15
P16
1640-IN-031-C-08
1 +
2 3
n/c
n/c
Current Outputs
750 Ω
Maximum Load
Voltage Outputs
3.3k Ω
Minimum Load
24 Vdc
External
Supply
600 mA minimum
Eurotherm/Barber-Colman
Page 75 of 104
MACO Series Controller Installation
Figure 11.3 Wiring the Analog Output Board
Out 1 +
Out 1 Out 2 +
Out 2 Out ...
DC+
DCEarth (no connection)
(Installed at Factory)
24 Vdc
Supply
+
-
Power Supply outputs MUST have
ferrite beads capable of filtering
30 MHZ to 100 MHZ
(Braided Shield)
Bond to
Chassis
Bond to
Chassis
(Overbraid)
Ground at BOTH Ends!
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 76 of 104
MACO Series Controller Installation
12. Installing & Wiring AC Input Boards
AC input boards have NOT been validated for conformance with the CE EMC
directive. Additional measures beyond those specified here may be needed in
order to demonstrate EMC compliance at the machine level. Proof of EMC
conformance lies with the machine manufacturer.
(Refer to Figures 12.0, 12.1, and 12.2) 18 gauge wire is recommended as a
minimum, but make certain to satisfy all local and national code requirements.
For Standard 24 Input (A-13900 or A-60089) Boards:
1.Connect L2 to Pin 1 of Connector P14. This connection provides a common for
all 24 of the opto-isolator input circuits (1 connection is required for all 24 inputs).
2.Connect each of the machine inputs to the board. There is a separate connection
for each of the 24 inputs (P14, Pins 2 - 9; and P15, Pins 1 - 16).
For High Density 48 Input Boards:
1.Connect L2 to Pin 1 of Connector P14 on each of the two boards. This connection
provides a common for all 24 of the opto-isolator input circuits of that board (two
connections are required for all 48 inputs).
2.Connect each of the machine inputs to the board. There is a separate connection
for each of the 48 inputs (P14, Pins 2 - 9 on each of the two boards; and P15, Pins
1 - 16 on each of the two boards).
AC Inputs Operating Specifications
Supply Voltage:
100 to 240 Vac external
Input Current:
15mA @ nominal voltage
On Voltage:
≥92 Vac
Indicator:
LED per Input
Off Voltage:
≤30 Vac
Isolation:
Optically isolated as a group
For supply connections, use No. 18 AWG or
larger wires rated for at least 75°C (165°F).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 77 of 104
MACO Series Controller Installation
Figure 12.0 A-13900 or A-60089 Standard Density AC Input Board
P1
P2
P3
P4
DS1
to
DS24
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
P14
P15
P5
P6
P7
P8
P9
P10
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
P15
L2
AC Input 1
AC Input 2
AC Input 3
AC Input 4
AC Input 5
AC Input 6
AC Input 7
AC Input 8
CONNECTOR E24-1135-009
(ON CARD)
E24-1134-009
MATING
CONNECTOR
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
AC Input 9
AC Input 10
AC Input 11
AC Input 12
AC Input 13
AC Input 14
AC Input 15
AC Input 16
AC Input 17
AC Input 18
AC Input 19
AC Input 20
AC Input 21
AC Input 22
AC Input 23
AC Input 24
LEDs
DS1
to
DS24
Input 1
to
Input 24
ON
ON
CONNECTOR E24-1135-016
(ON CARD)
E24-1134-016
MATING
CONNECTOR
NO FUSES
NO JUMPERS
See Cable Assemblies for
Wire Description
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 78 of 104
MACO Series Controller Installation
Figure 12.1 High Density AC Input Board Assembly
DS25
to
DS48
P1
P2
P3
P4
DS1
to
DS24
(Lower)
(1 - 24)
J2
(Upper)
(Upper)
P14
KEY
J4
P15
(Lower)
P15
(Upper)
L2 (Input 25 - 48)
AC Input 25
AC Input 26
AC Input 27
AC Input 28
AC Input 29
AC Input 30
AC Input 31
AC Input 32
CONNECTOR
(ON CARD)
MATING
CONNECTOR
L2 (Input 1 - 24)
AC Input 1
AC Input 2
AC Input 3
AC Input 4
AC Input 5
AC Input 6
AC Input 7
AC Input 8
E24-1135-009 (each board)
E24-1134-009 (each board)
LEDs
JUMPERS
1
2
3
4
Input 25
to
Input 48
P5
P6
P7
P8
P9
P10
P14
P14
DS1
to
DS24
J3
(Lower)
P14
P15
PIN
NUMBER
1
2
3
4
5
6
7
8
9
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P10
Guard
J1
(25 - 48)
ON
ON
Input 1
to
Input 24
ON
ON
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(Lower)
AC Input 33
ACInput 34
AC Input 35
AC Input 36
AC Input 37
AC Input 38
AC Input 39
AC Input 40
AC Input 41
AC Input 42
AC Input 43
AC Input 44
AC Input 45
AC Input 46
AC Input 47
AC Input 48
CONNECTOR
(ON CARD)
MATING
CONNECTOR
P15
(Upper)
AC Input 9
AC Input 10
AC Input 11
AC Input 12
AC Input 13
AC Input 14
AC Input 15
AC Input 16
AC Input 17
AC Input 18
AC Input 19
AC Input 20
AC Input 21
AC Input 22
AC Input 23
AC Input 24
E24-1135-016 (each board)
E24-1134-016 (each board)
(on A-13900)
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
See Cable Assemblies for
Wire Description
Check Jumper positions carefully if repositioning!
NO FUSES
Note that this assembly may consist of an A-13900 (lower) board and an A-13901 (upper) board
or an A-60089 (lower) board and an A-60090 (upper) board.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 79 of 104
MACO Series Controller Installation
Figure 12.2 AC Input Wiring
+V
Input Status
Light
IN
Common
Opto-Isolator
Typical AC Input Circuit
(120 Vac)
L1
L2
Panel I/O
Terminal Strip
AC Input Card
Connector Assembly
L2
AC IN 1
AC IN 2
AC IN 3
AC IN 4
AC IN 5
AC IN 6
AC IN 7
AC IN 8
AC IN 9 to 24
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 80 of 104
MACO Series Controller Installation
13. Installing & Wiring DC Input Boards
(Refer to Figures 13.0, 13.1, and 13.2) Note that DC Input Boards require an
external, regulated DC supply capable of providing a voltage of plus (+) 12 Vdc to
plus (+) 24 Vdc. The current rating of the supply will depend on the number of loads
being driven (and if the same supply is being used for DC Outputs). Each DC Input
draws 10 mA of current at 24 Vdc. 18 gauge wire is recommended as a minimum,
but make certain to satisfy all local and national code requirements.
For Standard 24 Input (A-60070) Boards:
1.Connect -DC to Pin 1 of Connector P14. This connection provides a common for
all 24 of the opto-isolator input circuits (1 connection is required for all 24 inputs).
2.Connect each of the machine inputs to the board. There is a separate connection
for each of the 24 inputs (P14, Pins 2 - 9; and P15, Pins 1 - 16).
For High Density 48 Input Boards:
1.Connect -DC to Pin 1 of Connector P14 on each of the two boards. This
connection provides a common for all 24 of the opto-isolator input circuits of that
board (only two such connections are required for all 48 inputs).
2.Connect each of the machine inputs to the boards. There is a separate
connection for each of the 48 inputs (P14, Pins 2 - 9 on each of the two boards;
and P15, Pins 1 - 16 on each of the two boards).
DC Inputs Operating Specifications
Supply Voltage:
12 to 24 Vdc external
Input Current:
10mA @ 24 Vdc
On Voltage:
≥10 Vdc
Indicator:
LED per Input
Off Voltage:
≤ 3 Vdc
Isolation:
Optically isolated as a group
For supply connections, use No. 18 AWG or
larger wires rated for at least 75°C (165°F).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
Yes
No
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 81 of 104
MACO Series Controller Installation
Figure 13.0 A-60070 Standard Density DC Input Board
P1
P2
P3
P4
DS1
to
DS24
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P 1 0 Guard
P14
P15
P5
P6
P7
P8
P9
P10
P14
PIN
NUMBER
1
2
3
4
5
6
7
8
9
DC Input
Input
Input
Input
Input
Input
Input
Input
P15
1
2
3
4
5
6
7
8
CONNECTOR E24-1135-009
(ON CARD)
E24-1134-009
MATING
CONNECTOR
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
LEDs
DS1
to
DS24
Input 1
to
Input 24
ON
ON
CONNECTOR E24-1135-016
(ON CARD)
E24-1134-016
MATING
CONNECTOR
NO FUSES
NO JUMPERS
See Cable Assemblies for
Wire Description
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 82 of 104
MACO Series Controller Installation
Figure 13.1 High Density DC Input Board Assembly
DS25
to
DS48
P1
P2
P3
P4
DS1
to
DS24
(Lower)
(1 - 24)
(Lower)
(Upper)
J4
P15
(Lower)
P15
(Upper)
DC- (Input 25 - 48)
DC+ Input 25
DC+ Input 26
DC+ Input 27
DC+ Input 28
DC+ Input 29
DC+ Input 30
DC+ Input 31
DC+ Input 32
DC- (Input 1 - 24)
DC+ Input 1
DC+ Input 2
DC+ Input 3
DC+ Input 4
DC+ Input 5
DC+ Input 6
DC+ Input 7
DC+ Input 8
E24-1135-009 (each board)
CONNECTOR
(ON CARD)
MATING
CONNECTOR
E24-1134-009 (each board)
LEDs
Input 25
to
Input 48
ON
ON
Input 1
to
Input 24
ON
ON
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(Lower)
DC+ Input 33
DC+ Input 34
DC+ Input 35
DC+ Input 36
DC+ Input 37
DC+ Input 38
DC+ Input 39
DC+ Input 40
DC+ Input 41
DC+ Input 42
DC+ Input 43
DC+ Input 44
DC+ Input 45
DC+ Input 46
DC+ Input 47
DC+ Input 48
CONNECTOR
(ON CARD)
MATING
CONNECTOR
P15
(Upper)
DC+ Input 9
DC+ Input 10
DC+ Input 11
DC+ Input 12
DC+ Input 13
DC+ Input 14
DC+ Input 15
DC+ Input 16
DC+ Input 17
DC+ Input 18
DC+ Input 19
DC+ Input 20
DC+ Input 21
DC+ Input 22
DC+ Input 23
DC+ Input 24
E24-1135-016 (each board)
E24-1134-016 (each board)
(on A-60070)
JUMPERS
1
2
3
4
P5
P6
P7
P8
P9
P10
P14
P14
DS1
to
DS24
J3
P14
P15
PIN
NUMBER
1
2
3
4
5
6
7
8
9
(25 - 48)
J2
(Upper)
P14
POWER SUPPLY
OUTPUTS TO BUS
P1
+5 Vdc Common
P2
+5 Vdc
P3
+5 Vdc Common
P4
+5 Vdc
P5
+5 Vdc Common
P6
Not Used
P7
28 Vac ØA
P8
28 Vac ØB
P9
Not Used
P10
Guard
J1
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
Position 1 = Low Density; Position 2 = High Density
See Cable Assemblies for
Wire Description
Check Jumper positions carefully if repositioning!
NO FUSES
Note that this assembly may consist of an A-13894 (lower) board and an A-13895 (upper) board
or an A-60070 (lower) board and an A-60071 (upper) board.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 83 of 104
MACO Series Controller Installation
Figure 13.2 DC Input Wiring
+V
IN
Common
Opto-Isolator
Typical DC Input Circuit
12 - 24 Vdc nominal
40 Vdc maximum
(10 mA each @ 24 Vdc)
Panel I/O
Terminal Strip
DC Input Card
Connector Assembly
24 Vdc Supply
(+)
DC (-)
(-)
DC+ IN 1
DC+ IN 2
DC+ IN 3
DC+ IN 4
DC+ IN 5
DC+ IN 6
DC+ IN 7
DC+ IN 8
DC+ IN 9 to 24
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 84 of 104
MACO Series Controller Installation
Figure 13.3 Wiring the DC Input Board
DC Common
DC In 1
DC In 2
DC In 3
DC In ...
DC Common
Note that NO Shield or Overbraid is necessary.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 85 of 104
MACO Series Controller Installation
14. Installing & Wiring AC/DC Input Boards
AC input boards have NOT been validated for conformance with the CE EMC
directive. Additional measures beyond those specified here may be needed in
order to demonstrate EMC compliance at the machine level. Proof of EMC
conformance lies with the machine manufacturer.
Note that there are 2 different AC/DC input board assemblies available: the A13991 is made up of the A-13901 AC board (upper) and the A-60070 DC board
(lower). The A-13991-100 assembly is made up of the A-13900 AC board (lower)
and the A-60071 DC board (upper).
READ THE WIRING LABEL CAREFULLY BEFORE APPLYING POWER TO
THESE BOARDS!
18 gauge wire is recommended as a minimum, but make certain to satisfy all local
and national code requirements.
For the DC Input Board:
Note that DC Input Boards require an external, regulated DC supply capable of
providing a voltage of plus (+) 12 Vdc to plus (+) 24 Vdc. The current rating of the
supply will depend on the number of loads being driven (and if the same supply is
being used for DC Outputs). Each DC Input draws 10 mA of current at 24 Vdc.
1.Connect -DC to Pin 1 of Connector P14. This connection provides a common for
all 24 of the opto-isolator input circuits (1 connection is required for all 24 inputs).
2.Connect each of the DC machine inputs to the board. There is a separate
connection for each of the 24 inputs (P14, Pins 2 - 9; P15, Pins 1 - 16).
For the AC Input Board:
1.Connect L2 to Pin 1 of Connector P14. This connection provides a common for
all 24 of the opto-isolator input circuits of that board.
2.Connect each of the AC machine inputs to the board. There is a separate
connection for each of the 24 inputs (P14, Pins 2 - 9; and P15, Pins 1 - 16).
DC Inputs Operating Specifications
Supply Voltage:
12 to 24 Vdc external
On Voltage:
≥10 Vdc
Off Voltage:
≤ 3 Vdc
Input Current:
10mA @ 24 Vdc
Indicator:
LED per Input
Isolation:
Optically isolated as a group
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 86 of 104
MACO Series Controller Installation
AC Inputs Operating Specifications
Supply Voltage:
100 to 240 Vac external
On Voltage:
≥92 Vac
Off Voltage:
≤30 Vac
Input Current:
15mA @ nominal voltage
Indicator:
LED per Input
Isolation:
Optically isolated as a group
For supply connections, use No. 18 AWG or
larger wires rated for at least 75°C (165°F).
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen programming) count each control rack separately.
If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and
route straight down through the wiring trough in order to meet minimum spacing requirements.
No
1640-IN-031-C-08
Yes
Eurotherm/Barber-Colman
Page 87 of 104
MACO Series Controller Installation
Figure 14. High Density AC/DC Input Board Assembly
DS25
to
DS48
P1
P2
P3
P4
DS1
to
DS24
A-60070
(DC Lower)
A-60070
(Lower)
J2
P14
P14
PIN
NUMBER
P5
P6
P7
P8
P9
P10
J4
P15
PIN
NUMBER
DC- (Input 25 - 48) L2 (Input 1 - 24)
DC+ Input 25
L1 Input 1
DC+ Input 26
L1 Input 2
DC+ Input 27
L1 Input 3
DC+ Input 28
L1 Input 4
DC+ Input 29
L1 Input 5
DC+ Input 30
L1 Input 6
DC+ Input 31
L1 Input 7
DC+ Input 32
L1 Input 8
CONNECTOR
(ON CARD)
MATING
CONNECTOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
E24-1135-009 (each board)
E24-1134-009 (each board)
LED
DS1
to
DS24
Input 25
to
Input 48
ON
ON
A-60070
(Lower)
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
CONNECTOR
(ON CARD)
MATING
CONNECTOR
ON
ON
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
A-13901
(Upper)
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
E24-1135-016 (each board)
E24-1134-016 (each board)
(on A-60070)
JUMPER
1
2
3
4
Input 1
to
Input 24
P15
P15
A-13901
(Upper)
A-60070
(Lower)
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
J3
P14
P15
1
2
3
4
5
6
7
8
9
(25 - 48)
A-13901
(Upper)
A-13901
(AC Upper)
P14
POWER SUPPLY
OUTPUTS TO BUS
J1
(1 - 24)
Position
Position
Position
Position
1
1
1
1
=
=
=
=
Low
Low
Low
Low
Density;
Density;
Density;
Density;
Position
Position
Position
Position
2
2
2
2
=
=
=
=
High
High
High
High
Density
Density
Density
Density
See Cable Assemblies for
Wire Description
Check Jumper positions carefully if repositioning!
NO FUSES
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 88 of 104
MACO Series Controller Installation
Figure 14.1 A-13991-100 High Density DC/AC Input Board Assembly
DS25
to
DS48
P1
P2
P3
P4
DS1
to
DS24
A-13900
(AC Lower)
PIN
NUMBER
L2
L1
L1
L1
L1
L1
L1
L1
L1
A-60071
(Upper)
PIN
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
E24-1135-009 (each board)
E24-1134-009 (each board)
LED
Input 25
to
Input 48
ON
ON
P15
P15
(Input 25 - 48) DC- (Input 1 - 24)
Input 25
DC+ Input 1
Input 26
DC+ Input 2
Input 27
DC+ Input 3
Input 28
DC+ Input 4
Input 29
DC+ Input 5
Input 30
DC+ Input 6
Input 31
DC+ Input 7
Input 32
DC+ Input 8
CONNECTOR
(ON CARD)
MATING
CONNECTOR
Input 1
to
Input 24
A-13900
(Lower)
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
L1
CONNECTOR
(ON CARD)
MATING
CONNECTOR
ON
ON
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
A-60071
(Upper)
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
DC+
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
Input
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
E24-1135-016 (each board)
E24-1134-016 (each board)
(on A-13900)
JUMPER
1
2
3
4
P5
P6
P7
P8
P9
P10
P14
A-13900
(Lower)
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
J3
J4
P15
P14
DS1
to
DS24
J2
A-13900
(Lower)
P14
P15
1
2
3
4
5
6
7
8
9
(25 - 48)
A-60071
(Upper)
A-60071
(DC Upper)
P14
POWER SUPPLY
OUTPUTS TO BUS
J1
(1 - 24)
Position
Position
Position
Position
1
1
1
1
=
=
=
=
Low
Low
Low
Low
Density;
Density;
Density;
Density;
Position
Position
Position
Position
2
2
2
2
=
=
=
=
High
High
High
High
Density
Density
Density
Density
See Cable Assemblies for
Wire Description
Check Jumper positions carefully if repositioning!
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 89 of 104
MACO Series Controller Installation
15. Wiring the 32 In/32 Out or 24 In/24 Out Digital I/O Boards
15.1 Introduction
The 32 In/32 Out Digital I/O board is capable of (both) 32 inputs and 32 outputs.
Outputs are sourced in groups of 4, with Vcc 1-4 supplying Output 1 through Output
4, Vcc 5-8 supplying Output 5 through 8, etc.
Each output circuit is thermally and over-current protected. Output groups need to
be externally fused. The size of the fuse must be determined based on actual load
usage, power supply and wire size.
15.2 Specifications
Power Supply
Power must come from a Class 2 power supply, 18 to 32 Vdc.
Outputs
Outputs are rated for 2 Amp loads at 24 Vdc. Maximum leakage current is 1 mA.
At 55°C ambient and 24 Vdc, these outputs MUST be limited to 2 Amps maximum
per output, 8 Amps maximum per group and 64 Amps maximum per card (48 Amps
for the 24 In/24 Out version).
Inputs
Inputs represent a 3 mA load, with a guaranteed turn on voltage of 16 Vdc and a
guaranteed turn off voltage of 5 Vdc.
Class 2 Wiring must be separated a minimum of
1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 90 of 104
MACO Series Controller Installation
Figure 15.1 32 In/32 Out or 24 In/24 Out A-60150-x
Pin Number
Upper
Connector
Lower
Connector
Assignment
Assignment
1
Output 1
Input 1
2
Output 2
Input 2
3
Output 3
Input 3
Vcc Connector
Pin Number
Assignment
1
Vcc 1-4
2
4
Output 4
Input 4
5
Output 5
Input 5
6
Output 6
Input 6
7
Output 7
Input 7
8
Output 8
Input 8
9
Output 9
Input 9
10
Output 10
Input 10
Output 17
Output 18
Output 19
Output 20
Output 21
Output 22
Output 23
Output 24
Output 25
Output 26
Output 27
Output 28
Output 29
Output 30
Output 31
Output 32
Input 17
Input 18
Input 19
Input 20
Input 21
Input 22
Input 23
Input 24
Input 25
Input 26
Input 27
Input 28
Input 29
Input 30
Input 31
Input 32
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
Output 9
Output 10
Output 11
Output 12
Output 13
Output 14
Output 15
Output 16
Bottom Row
Vcc 1-4
Vcc 5-8
Vcc 9-12
Vcc 13-16
Vcc 17-20
Vcc 21-24
Vcc 25-28
Vcc 29-32
Common
Top Row
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7
Input 8
Input 9
Input 10
Input 11
Input 12
Input 13
Input 14
Input 15
Input 16
(bottom)
Vcc 5-8
3
Vcc 9-12
4
Vcc 13-16
5
Vcc 17-20
6
Vcc 21-24
7
Vcc 25-28*
8
Vcc 29-32*
9
Pin Number
Upper
Connector
Lower
Connector
Assignment
Assignment
1
Output 17
Input 17
2
Output 18
Input 18
3
Output 19
Input 19
4
Output 20
Input 20
5
Output 21
Input 21
6
Output 22
Input 22
Input 23
7
Output 23
8
Output 24
Input 24
9
Output 25*
Input 25*
Common
Mating Connector
*N/A on 24 In/24 Out
11
Output 11
Input 11
10
Output 26*
Input 26*
11
Output 27*
Input 27*
12
Output 12
Input 12
12
Output 28*
Input 28*
13
Output 13
Input 13
13
Output 29*
Input 29*
14
Output 14
Input 14
14
Output 30*
Input 30*
15
Output 15
Input 15
15
Output 31*
Input 31*
16
Output 16
Input 16
16
Output 32*
Input 32*
Mating Connector
Mating Connector
*N/A on 24 In/24 Out
C.1
1640-IN-031-C-08
WARNING:
Hazardous extraneous voltage capable of causing severe injury or death may exist
between sensor leads and ground. Disconnecting the instrument power may not
remove this voltage. Measure for the presence of voltage between each sensor
lead and ground before servicing. Do NOT place power wiring in the same conduit
or wiring trough with sensor wiring.
Eurotherm/Barber-Colman
Page 91 of 104
MACO Series Controller Installation
Figure 15.2 32 In/32 Out or 24 In/24 Out Digital I/O Wiring
Vcc 1-4
Output 1-4
Common
Locate as close
as possible to ASB
Input 1-4
Note that DC Inputs and Outputs
have a shared common.
24 Vdc
Class 2
Supply
-
DC Common
+
For CE EMC compliance,
power supply outputs may require
ferrite beads capable of filtering
30 MHZ to 100 MHZ
Outputs
1640-IN-031-C-08
Eurotherm/Barber-Colman
Inputs
Page 92 of 104
MACO Series Controller Installation
Figure 15.3 32 In/32 Out or 24 In/24 Out Sample Wiring
Outputs
Load
Upper
Connector
Inputs
Lower
Connector
1
1
2
2
Load
3
4
3
4
Load
5
6
5
6
Load
7
7
8
8
Load
Load
9
9
Load
10
10
Load
11
12
11
12
Load
13
14
13
14
Load
15
15
Load
16
16
Load
Load
Load
Load
Load
See text for fuse and load limits
Fuse
–
+
24 Vdc
Power Supply MUST be
24 Vdc Class 2 SELV
Fuse
1 Vcc 1-4
2 Vcc 5-8
Fuse
3 Vcc 9-12
Fuse
Fuse
Fuse
Fuse
4 Vcc 13-16
Fuse
8 Vcc 29-32*
9 Common
5 Vcc 17-20
6 Vcc 21-24
7 Vcc 25-28*
Load
Load
Load
Load
Load
Load
17
17
Load
18
18
Load
19
20
19
20
Load
21
22
21
22
Load
23
23
Load
24
24
25*
25*
Load
26*
26*
Load
27*
28*
27*
28*
Load
29*
30*
29*
30*
31*
31*
32*
32*
Load
Load
*N/A on 24 In/24 Out
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 93 of 104
MACO Series Controller Installation
Figure 16. Communications Cable Pinouts
DB9
DB9
1
2
3
4
5
6
7
8
9
Shield
DCD
RXD
TXD
DTR
SG
DSR
RTS
CTS
RI
Black
White
Red
Green
Brown
Blue
Orange
Yellow
Purple
1
2
3
4
5
6
7
8
9
Shield
DCD
RXD
TXD
DTR
SG
DSR
RTS
CTS
RI
Chassis Gnd
Black
DCD
White
TXD
Red
RXD
Green
DSR
Brown
SG
Blue
DTR
Orange CTS
Yellow
RTS
Purple
RI
1
2
3
4
5
6
7
8
9
Shield
DCD
RXD
TXD
DTR
SG
DSR
RTS
CTS
RI
Female DB9 to Female DB9
PC to MACO
DCD
TXD
RXD
DSR
SG
DTR
CTS
RTS
RI
DB9
1
3
2
6
5
4
8
7
9
DB25
Female DB9 to Female DB25
1
8
2
3
6
7
20
5
4
22
MACO to Printer
DB9
Female DB9 to Male 6 Pin DIN
(Epson Printer)
5
6
1
2
4
3
Solder Pad View
6 Pin DIN
Chassis Gnd 6
Black
White
TXD
RXD
1
3
Red
Green
Signal Gnd
DTR
Not Used
5
2
4
Stub these
Wires:
Brown
Blue
Orange
Yellow
Purple
MACO to Epson Printer
DB9
Female DB9 to Male DB25
(Serial to Parallel Converter)
DB25
1
2
3
4
5
6
7
8
9
Shield
DCD
RXD
TXD
DTR
SG
DSR
RTS
CTS
RI
Chassis Gnd 1
Red
RXD 3
Black
Green
SG 7
DTR 20
MACO to Parallel Converter
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 94 of 104
MACO Series Controller Installation
Figure 17. Communications Cable Part Numbers
DB9 Connector Kit, Female
9 Pin Female D Connector
Jack Screws (2)
9 Pin Connector Housing
71-761
19-16-352
50-1628
E24-1147
DB25 Connector Kit, Male
25 Pin Male D Connector
Jack Screws (2)
25 Pin Connector Housing
71-776
E24-22
50-1628
E24-1148
DB25 Connector Kit, Female
25 Pin Female D Connector
Jack Screws (2)
25 Pin Connector Housing
71-762
E24-175
50-1628
E24-1148
Cables:
RS-232 Communications
RS-232 to Black Box Serial to Parallel Converter
RS-485 Communications
or
Operator Station to Data Handler
9 Conductor RS-232 Cable
(Belden Type 9539)
4 Conductor RS-232 Cable
(Belden Type 9534)
3 Conductor Cable
(Alpha Type 1737)
E26-210
E26-106
46-24
Note that all E24-1134-XXX Mating Connectors, as well as E24-1129 (on the Analog I/O Board)
are capable of 14 to 22 AWG wire.
For ease of wiring, use 18 AWG where loads permit. In any case, wire sizes must be large
enough to meet any code requirements that apply.
For supply connections, use No. 18 AWG or larger wires rated for at least 75°C (167°F).
Class 2 wiring must be separated a minimum of 1/4 inch from any Class 1 conductors.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 95 of 104
MACO Series Controller Installation
Figure 18. Firmware Model Numbers
4S
0
Specials
Location on Assembly
Checksum
Firmware Revision No.
Firmware Version No.
Reserved for Factory Use
Firmware
01
02
03
04
1B
20
25
27
28
30
38
40
Type
Sequence
Temperature (T/C-Analog)
Hydraulic, Ana I/O
Parison, Hi Speed Ana
Analog I/O (Hardware)
Display Handler
Display CPU
Display Communications
Display Keyboard
RS-232
RS-485 SPI
Data Handler
1640-IN-031-C-08
Location
Sequence/Hydraulic (Ana I/O) Board
Temperature Board
Sequence/Hydraulic (Ana I/O) Board
Parison (Hi Speed Ana) Board
Analog I/O (Hardware) Board
Data Handler Board
Operator Panel
Operator Panel
Operator Panel
RS-232 Communications Daughter Board
RS-485 Communications Daughter Board
Data Handler Board
Eurotherm/Barber-Colman
EPROM 1
EPROM 1
EPROM 2
EPROM 1
EPROM 1
EPROM 2
EPROM 1
EPROM 2
EPROM 3
EPROM 1
EPROM 1
EPROM 1
U11
U26
U67
U212
U35
U46
U1
U42
U53
U10
U10
U26
Page 96 of 104
MACO Series Controller Installation
16. MACO Series Specifications
Control Specifications
Process Control
Closed-loop Process Control of Drive Speed or Melt Temperature
Closed-loop process functions updated every 2.5 msec
Drive Ratio Control (Math Function)
Selectable Ramping
Line Graphs of Melt Temperature, Melt Pressure, Drive Speed, etc. (EL and Color
LCD Display)
Temperature Control
6 Zones per Card (standard density); 12 Zones per Card (high density)
Auto-Tuning or User-Selectable Manual Tuning (thermocouple inputs only)
Standby & Run Setpoints
Process High, Low, & Deviation High & Low Alarms
Sensor Break & Heater Burnout (HBO) Alarms (HBO on thermocouple inputs only)
Auto-Comp Feature on Sensor Break Detect
Auto-Start via Real Time Clock
Melt Temperature Control (Math Function)
Sequential Control
Fully Programmable Machine Control
Edited Using PC-Based RLD Editor Software
High Priority Machine Sequence Logic executed every 2.5 msec
4000 Instructions including 100 high priority instructions per Sequence Card
EEPROM Storage of Sequence Program
Timing & Counting
Sequence Card:
64 On/Off Delay Timers
• 24 On/Off Delay, range 0 to 655.35 seconds
• 16 On Delay, range 0.00 to 2.55 seconds
• 8 Off Delay, range 0.00 to 2.55 seconds
• 16 On Delay, range 0 to 655.35 seconds
10 Counters (2 non-volatile), Up or Down, range 65,535
Data Handler Card:
• 8 On Delay, range 0 to 6553.5 seconds
• 8 Event timers, range 0.00 to 655.35 seconds
• 8 Hour meters, battery backup, range 0.0 to 999,999.9 hours
Real Time Clock (seconds, minutes, hours, day, month, year) w/12 scheduled
setpoint control relays to activate internal and external control functions
Statistical Process Control (SPC)
Simultaneous calculations of any 10 User-Selected Process Variables
X-Bar, R, & Histogram charts (viewable on EL Display only, printable on EL & LCD)
Calculated X-Bar, R, Cr, & CPK values
Log of last 100 calculations for each of 10 Process Variables
Industry Standard SPC alarm CRs
User selectable sample size, time or event-based triggering, time between
readings, time between sample groups, upper and lower spec limits
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 97 of 104
MACO Series Controller Installation
Physical
Chassis Size:
Voltage (AC Systems):
Power (AC Systems):
Typical Power Xfmr:
Voltage (DC Systems):
(Refer to Figures 1.0 to 1.4)
100/264 (Low/High Line) Vac; 50/60 Hz, ±3 Hz
less than 200 VA at 120 Vac
1 kVA
24 Vdc, 1.5 Amps (nominal)
Environmental
Operating Temperature:
Storage Temperature:
Humidity:
0 to 60°C (32 to 140°F)
-40 to +85°C (-40 to +185°F)
0 to 95% Non-Condensing RH at 60°C (140°F)
Electromagnetic Compatibility
When installed according to the guidelines in this document, the MACO control
system complies with the following requirements:
Immunity
EN 61000-4-2 Electrostatic Discharge
±4 kV Contact Discharge to any user accessible metallic location
±8 kV Air Discharge to any user accessible nonmetallic location
EN 61000-4-3 Radiated Susceptibility
10 v/m from 80 to 1000 MHz, sinewave modulated at 1 kHz to 80%
ENV 50204
Radiated Susceptibility Pulsed Carrier
10 v/m at 900 MHz ±5 MHz, squarewave modulated at 200 Hz to 50%
EN 61000-4-4 Fast Transient Burst
±1 kv at 5 kHz rep rate using capacitive clamp for signal lines longer than 3 meters
±2 kv at 2.5 kHz rep rate using capacitive clamp for dc lines longer than 3 meters
±2 kv at 5 kHz rep rate using direct injection for ac lines
EN 61000-4-5 Surge
±2 kv each line to ground for ac lines
±1 kv line to line for ac lines
±1 kv line to ground for long distance signal lines
ENV 50141
Conducted Susceptibility
3 v rms from 0.15 to 80 MHz, sinewave modulated at 1 kHz to 80%, for signal
lines longer than 3 meters
3 v rms from 0.15 to 80 MHz, sinewave modulated at 1 kHz to 80%, for dc lines
longer than 3 meters
3 v rms from 0.15 to 80 MHz, sinewave modulated at 1 kHz to 80%, for ac lines
IEC 1000-4-11 Voltage Fluctuations
100% voltage dip for 1 power cycle on the ac power input only
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 98 of 104
MACO Series Controller Installation
Emissions
(reference standards CISPR 16 and CISPR 16-1)
Port
Enclosure
Frequency Range
30 MHz to 230 MHz
230 MHz to 1 GHz
AC Mains
0.15 MHz to 0.5 MHz
0.5 MHz to 5 MHz
5 MHz to 30 MHz
Limits
40 dB (mV/m) quasi-peak,
measured at 10 meters
47 dB (mV/m) quasi-peak,
measured at 10 meters
79 dB (mV) quasi-peak
66 dB (mV) average
73 dB (mV) quasi-peak
60 dB (mV) average
73 dB (mV) quasi-peak
60 dB (mV) average
Discrete Inputs (192 maximum per rack)
Points per Card:
24 (standard density)
48 (high density)
AC Inputs
Operating Specs:
On Voltage:
Off Voltage:
Input Current:
Indicator:
Isolation:
100 to 240 Vac
≥92 Vac
≤30 Vac
15 mA @ nominal voltage
LED per Input
Optically Isolated as a Group
DC Inputs
Operating Specs:
On Voltage:
Off Voltage:
Input Current:
Indicator:
Isolation:
12 to 24 Vdc
≥10 Vdc
≤ 3 Vdc
10 mA @ 24 Vdc
LED per Input
Optically Isolated as a Group
Discrete Outputs (192 maximum per rack)
Points per Card:
AC Outputs
Operating Specs:
Minimum Load:
Maximum Load:
Maximum Leakage:
Fuse:
Indicator:
Maximum Output
Current per Card:
Maximum Output
Current per Card:
Isolation:
1640-IN-031-C-08
16 (standard density)
24 (high density)
100 to 240 Vac, 125/250 VA (pilot duty)
(external voltage)
50 mA
1 Amp
5 mA
2 Amp Fuse per Output
Neon per Output (load side)
16 Amps
(Enclosed Systems)
8 Amps
(Open Frame Systems)
Optically Isolated (in groups of 4)
Eurotherm/Barber-Colman
Page 99 of 104
MACO Series Controller Installation
DC Outputs
Operating Specs:
Minimum Load:
Maximum Load:
Maximum Leakage:
Fuse:
Indicator:
Maximum Output
Current per Card:
Maximum Output
Current per Card:
Isolation:
Analog Outputs
Operating Specs:
16 to 24 Vdc (External Voltage)
5 mA
2 Amps
2 mA
2 Amp Fuse per Output
LED per Output (load side)
32 Amps
(Enclosed Systems)
16 Amps
(Open Frame Systems)
Optically Isolated (in groups of 4)
24 Vdc, ±0.5 Vdc (external supply) @ 0.5 Amps
minimum current.
Current Outputs:
4 to 20 mAdc, isolated, short circuit protected both leads to ground. 750 Ohm
maximum load. Up to 15 bit resolution. Accuracy of 0.25% at full scale at rated
conditions.
Voltage Outputs:
0 to 10 Vdc, isolated, short circuit protected at 3.3 mA both leads to ground. 3.3k Ohm
minimum load. Up to 15 bit resolution. Accuracy of 0.25% at full scale at rated conditions.
Temperature Control (72 zones maximum per rack)
Reference Accuracy:
Range:
0.25% of Span, ±1°C
Type J:
0 to 700°C (32 to 1292°F)
Type K:
0 to 950°C (32 to 1742°F)
0 to Vdc
0 to 20 mAdc
Number of Zones:
6 zones of thermocouple input
12 zones of thermocouple input
12 zones of analog input (Vdc or mAdc)
6 zones of thermocouple/6 zones of analog input
Alarms:
Control Modes:
Proc High/Low, Dev +/-, HBO, Sensor Break
Auto-Tuned PID or Manual Tune PID
(PID presently available only with thermocouple input)
Common Mode
Rejection:
Series Mode Rejection:
135 dB @ 230 Vac 60Hz
60 dB @ 150 mV 60 Hz
Analog Inputs & Outputs (Analog I/O Card, 2 cards maximum per rack)
Inputs
1640-IN-031-C-08
Number:
Voltage:
6
0 to +10 Vdc (Nominal)
Maximum Input:
± 15 Vdc without damage
Eurotherm/Barber-Colman
Page 100 of 104
MACO Series Controller Installation
Offset:
Type 1 (3 Inputs)
Excitation voltage:
Potentiometer resistance:
Type 2 (2 Inputs):
Tachometer (1 Input):
Input Resolution :
-2 to 10 Vdc
General Purpose, 0-10 Vdc (nominal)
(+10 Vdc @ 20 mA) for potentiometers
2k to 10k Ohms
Pressure 0 to +10 Vdc (nominal)
from high level output pressure transducer
+15 Vdc maximum input at 1 kHz.
+12 Vdc excitation at 10mA provided
12 Bits
Outputs
Number:
Voltage:
Load Impedance:
Output Resolution:
4
0 to +10 Vdc or 0 to -10 Vdc
(Control Relay Selectable)
3500 Ohms Minimum
13 Bits
High Speed Analog Signal Processor (Parison Card, 2 maximum per rack)
Analog Inputs
Input Signal:
Input Impedance:
±10 Vdc or ±20 mA (jumper selectable)
100k Ω minimum voltage input
500 Ω current input
Input Function:
General purpose. Signal conditioners are recommended to obtain isolation and proper signal levels
Analog Outputs
Output Signal:
±10 Vdc
Output Current:
4.5 mA maximum into a 2.2k Ohm load
Input/Output Isolation:
Each I/O Pair is Isolated from all Other Pairs
DC Discrete Logic Inputs/Outputs
(Requires External Supply)
DC Inputs
Input Voltage:
-0.6 (minimum) to 40 Vdc (maximum)
On Voltage:
10 Vdc
Off Voltage:
5 Vdc
DC Outputs
1640-IN-031-C-08
Voltage:
24 Vdc maximum switched voltage
Current:
20 mA maximum switched current
Eurotherm/Barber-Colman
Page 101 of 104
MACO Series Controller Installation
17. Application Guide for Sensors and Analog Signals
17.1 General
Machine mounted measuring sensors are required to interface with process
variables such as hydraulic pressure, plastic pressure, machine positions and
speeds. The output of these sensors is applied to inputs on the Analog I/O board
and used for display or control purposes. The following information is a general
guide to the type of transducers required by the MACO Series controllers. For the
best noise immunity, use sensors with large voltage swings and low resistance
potentiometers.
17.2 Hydraulic Pressure Transducers
The Analog I/O board has two pressure input channels (other channels may be
used for pressure input, but only two provide for calibration resistors). Typical uses
are ram hydraulic pressure and clamp hydraulic pressure (or melt pressure and die
pressure). The analog inputs on the MACO are specified at 0 to +10 Vdc, which
means that a high level output transducer is required (mV output types cannot be
used directly). An external power supply capable of providing ±14 to ±16 Vdc or
+24 to +32 Vdc at 45 mA will also be required.
17.3 Position Transducers
Position detection for the Ram, Clamp, Accumulators and Ejectors can be linear
potentiometers, magnetostrictive devices, or LVDTs. The analog inputs for these
inputs are also specified as 0 to +10 Vdc. Excitation voltage (+10 Vdc) for
potentiometers (2k to 10k Ohms) is supplied by the analog I/O board.
Operating voltage for these sensors must be provided externally. LVDTs are
generally used for short movements (up to 3 inches) and they are available from
a number of sources.
17.4 Tachometer
The tachometer input will accept up to +15 Vdc at 1kHz. Excitation voltage of +12
Vdc at 10 mA is supplied by the Analog I/O board. The measuring device will
typically put out a series of pulses proportional to the shaft RPM to which it is
mounted. Logic levels for the input are 3.1V ≤V High ≤ 15V; -0.6V ≤ Low ≤0.4V.
Pulses must not exceed +15Vdc and must not go lower than -0.6 Vdc.
17.5 Analog Outputs
The outputs from the Analog I/O board are specified as 0 to +10 Vdc or 0 to -10
Vdc. There are control relays which allow the output to be switched between the
two polarities as required. This allows the outputs to be used with a number of
different drives and devices. There are also Minimum and Maximum Output
setpoints which can be used to set the output signals to match specific drives. For
example: the maximum output can be set to 50% (5 Vdc) and the output applied
to a drive which has a full range of speed from 0 to 5 Vdc.
17.6 Extrusion/Parison Pressure Transducers
When the Analog I/O board is used in extrusion/parison applications, the same
requirements apply as for hydraulic pressure applications. The transducer must
provide a 0 to +10 Vdc output and an external regulated power supply must be used.
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 102 of 104
MACO Series Controller Installation
1640-IN-031-C-08
Eurotherm/Barber-Colman
Page 103 of 104
Barber-Colman Company / Eurotherm Controls, Inc.
741-F Miller Drive, Leesburg VA 20175
Phone: 703-443-0000
Fax: 703-669-1300
http://www.barber-colman.com http://www.eurotherm.com
An Invensys Company
Copyright © 2002 Barber-Colman Company