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Transcript
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