Max

maxPAC Hardware Reference Guide
278596 Rev. A7
Refer to this publication for complete and accurate information that helps you better operate and service Metso Automation equipment. Your comments and suggestions are welcome. Metso Automation 1180 Church Road Lansdale, PA 19446 Attention: Manager, Technical Publications
Copyright 2005 by Metso Automation MAX Controls, Inc. Printed in the United States of America All Rights Reserved
Metso Automation 278596
Contents
PREFACE ............................................................................................................................III CHAPTER 1 ...................................................................................................................... 1-1
maxPAC Input/Output Subsystem ............................................................................................................................1-1 Overview ...................................................................................................................................................................1-1 Model IOP I/O Subsystem.....................................................................................................................................1-1 Cabinet...............................................................................................................................................................1-1 Chassis Assembly ..............................................................................................................................................1-2 DPU Mounting ..................................................................................................................................................1-4 I/O Modules.......................................................................................................................................................1-4 I/O Module Types..............................................................................................................................................1-5 Power Supply.........................................................................................................................................................1-6 Field Termination Options.....................................................................................................................................1-7 Local Terminations (standard)...........................................................................................................................1-7 Remote Terminations (option)...........................................................................................................................1-7 Termination Assemblies ....................................................................................................................................1-7 Installing Model IOP I/O Equipment ....................................................................................................................1-8 Sequence of Mounting Operations ........................................................................................................................1-8 Mounting I/O Chassis Assemblies.........................................................................................................................1-9 Cabling, Power, and Ground Wiring .....................................................................................................................1-9 Supplying 24V Power to the I/O Modules ......................................................................................................1-10 Interconnecting I/O Racks ...............................................................................................................................1-10 Summary of Cabling Rules for maxPAC I/O ..................................................................................................1-14 maxPAC I/O Bus Cables .................................................................................................................................1-14 Module Mounting Considerations .......................................................................................................................1-16 I/O Modules ...................................................................................................................................................1-16 DPU Modules ..................................................................................................................................................1-16 Module Addressing .............................................................................................................................................1-17 Backup Configuration Options............................................................................................................................1-17 Shared Configuration.......................................................................................................................................1-17 Redundant Configuration ................................................................................................................................1-18 Mixed Configuration .......................................................................................................................................1-19 Remote I/O ..........................................................................................................................................................1-20 Specifications.......................................................................................................................................................1-22 Environment ....................................................................................................................................................1-22 I/O Bus.............................................................................................................................................................1-22 Inputs/Outputs .................................................................................................................................................1-22
CHAPTER 2 ...................................................................................................................... 2-1

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

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

Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305 ................................... 3-1 Overview .................................................................................................................................................................. 3-1 LED Indication ..................................................................................................................................................... 3-1 Bus Address .......................................................................................................................................................... 3-2 Jumper Configuration ........................................................................................................................................... 3-2 Module Operation................................................................................................................................................. 3-2 Diagnostics ........................................................................................................................................................... 3-4 Module Specifications .......................................................................................................................................... 3-4 Field Wiring for IOP302....................................................................................................................................... 3-5 Field Wiring IOP 305 Analog Input Module..................................................................................................... 3-6 Field Wiring For Redundant Modules with Common Transmitter....................................................................... 3-7
CHAPTER 4 ...................................................................................................................... 4-1

Analog Input Modules 3 Wire RTD Module IOP303.............................................................................................. 4-1 Overview .................................................................................................................................................................. 4-1 LED Indication ..................................................................................................................................................... 4-1 Bus Address .......................................................................................................................................................... 4-2 Jumper Configuration ........................................................................................................................................... 4-2 Module Operation................................................................................................................................................. 4-2 Diagnostics ........................................................................................................................................................... 4-4 Module Specifications .......................................................................................................................................... 4-4 Field Wiring.......................................................................................................................................................... 4-5 Field Wiring For Redundant Modules with Common RTD ................................................................................. 4-6
CHAPTER 5 ...................................................................................................................... 5-1

Analog Input Modules TC Module IOP304 ............................................................................................................. 5-1 Overview .................................................................................................................................................................. 5-1 LED Indication ..................................................................................................................................................... 5-1 Bus Address .......................................................................................................................................................... 5-2 Jumper Configuration ........................................................................................................................................... 5-2 Cold Junction Compensation ................................................................................................................................ 5-2 Module Operation................................................................................................................................................. 5-2 Diagnostics ........................................................................................................................................................... 5-3 Module Specifications .......................................................................................................................................... 5-4 Field Wiring.......................................................................................................................................................... 5-5 Field Wiring For Redundant Modules with Common TC .................................................................................... 5-6
Contents
CHAPTER 6 ...................................................................................................................... 6-1
Analog Output Modules 4-20 mA Output Module IOP320.....................................................................................6-1 LED Indication ......................................................................................................................................................6-1 Bus Address...........................................................................................................................................................6-2 Jumper Configuration ............................................................................................................................................6-2 Module Operation..................................................................................................................................................6-3 Diagnostics ............................................................................................................................................................6-4 Module Specifications ...........................................................................................................................................6-5 Field Wiring...........................................................................................................................................................6-6 Field wiring for redundant modules with common end element ...........................................................................6-7
CHAPTER 7 ...................................................................................................................... 7-1

Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331..................7-1 Overview ...................................................................................................................................................................7-1 LED Indication ......................................................................................................................................................7-1 Bus Address...........................................................................................................................................................7-2 Module Operation..................................................................................................................................................7-2 Module specifications............................................................................................................................................7-3 Field Wiring...........................................................................................................................................................7-4 Field Wiring For Redundant Modules with Common DI......................................................................................7-5
CHAPTER 8 ...................................................................................................................... 8-1

Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333 ...........................................................................................................8-1 Overview ...................................................................................................................................................................8-1 LED Indication ......................................................................................................................................................8-1 Bus Address...........................................................................................................................................................8-2 Jumper Configuration ............................................................................................................................................8-2 Module Operation..................................................................................................................................................8-2 Module Specifications ...........................................................................................................................................8-3 Field Wiring...........................................................................................................................................................8-4 Field Wiring For Redundant Modules with Isolated DI ........................................................................................8-5
CHAPTER 9 ...................................................................................................................... 9-1

Digital Input Modules Counter Timer Module IOP335 ..........................................................................................9-1 LED Indication ......................................................................................................................................................9-1 Bus Address...........................................................................................................................................................9-2 Jumper Configuration ............................................................................................................................................9-2 Module Operation..................................................................................................................................................9-3 Diagnostics ............................................................................................................................................................9-4 Module specifications............................................................................................................................................9-4 Field Wiring...........................................................................................................................................................9-5
CHAPTER 10 .................................................................................................................. 10-1

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

Bus Address ........................................................................................................................................................ 10-2 Jumper Configuration ......................................................................................................................................... 10-2 Module Operation............................................................................................................................................... 10-2 Module Specifications ........................................................................................................................................ 10-3 Field Wiring IOP 351 ...................................................................................................................................... 10-5 Wiring IOP350 ................................................................................................................................................ 10-6 Field Wiring For Redundant Modules with Common End Element................................................................... 10-7
CHAPTER 11 ................................................................................................................. 11-1

Bus Extender Unit Module IOP371 ....................................................................................................................... 11-1 Overview ................................................................................................................................................................ 11-1 BEM Front Panel ............................................................................................................................................ 11-2 LED Indication ................................................................................................................................................... 11-2 Link Test............................................................................................................................................................. 11-2 Bus Address ........................................................................................................................................................ 11-2 Jumper Configuration ......................................................................................................................................... 11-2 DPU Compatibility ......................................................................................................................................... 11-4 I/O Bus Loading ............................................................................................................................................. 11-4 BEM Operation................................................................................................................................................... 11-5 Optical Cabling ............................................................................................................................................... 11-7 Model 564 and maxPAC I/O Compatibility ................................................................................................... 11-7 Termination Requirements.............................................................................................................................. 11-7 Redundant Configuration Approaches................................................................................................................ 11-8 Four Configuration Approaches ..................................................................................................................... 11-8 Configuring Remote I/O only ......................................................................................................................... 11-8 Configuring Local Common I/O..................................................................................................................... 11-8 Configuring Mixed Common and Redundant I/O .......................................................................................... 11-9 Single DPU Configurations .......................................................................................................................... 11-10 BEM Configuration Considerations ................................................................................................................. 11-12 Calculating Link Capacities.......................................................................................................................... 11-12 Ensuring Link Availability ............................................................................................................................... 11-13 Detecting Failover Conditions ...................................................................................................................... 11-13 Cabling Recommendations ........................................................................................................................... 11-13 Specifications.................................................................................................................................................... 11-14
CHAPTER 12 ................................................................................................................. 12-1

QuadPAT Module IOP336..................................................................................................................................... 12-1 QuadPAT Termination Module IOP337 ............................................................................................................... 12-1 Overview ................................................................................................................................................................ 12-1 Front Panel...................................................................................................................................................... 12-2 LED Indication ................................................................................................................................................... 12-2 Jumper Configuration ......................................................................................................................................... 12-2 Bus Address ........................................................................................................................................................ 12-4 DPU Compatibility ............................................................................................................................................. 12-4 Module Operation............................................................................................................................................... 12-4 QuadPAT Termination ................................................................................................................................... 12-5 Feedback Options ............................................................................................................................................... 12-6 Output Options ................................................................................................................................................... 12-6 Limit Switch Detection ....................................................................................................................................... 12-6 Redundant Configuration.................................................................................................................................... 12-7
Contents
Diagnostics ..........................................................................................................................................................12-8 Module Field Connections...................................................................................................................................12-9 Termination Field Connections Channels 1-2 ...................................................................................................12-10 Termination Field Connections Channels 3-4 ...................................................................................................12-11 Group1 Analog I/O Configuration ....................................................................................................................12-12 Group2 Analog I/O Configuration ....................................................................................................................12-13 Digital I/O Configuration Channels 1-2 ............................................................................................................12-14 Digital I/O Configuration Channels 3-4 ............................................................................................................12-15 Digital I/O Configuration - DC Power Switches ...............................................................................................12-16 Specifications.....................................................................................................................................................12-17
CHAPTER 13 ................................................................................................................. 13-1

Turbine Valve Positioner Module IOP341 .............................................................................................................13-1 Turbine Valve Termination Module IOP342.........................................................................................................13-1 Overview .................................................................................................................................................................13-1 Positioner Front Panel .........................................................................................................................................13-2 LED Indication ....................................................................................................................................................13-3 Jumper Configuration ..........................................................................................................................................13-4 Bus Address.........................................................................................................................................................13-5 DPU Compatibility ..............................................................................................................................................13-5 Module Operation................................................................................................................................................13-5 Turbine Valve Termination .............................................................................................................................13-7 Configuration.......................................................................................................................................................13-7 Calibration ...........................................................................................................................................................13-7 Diagnostics ..........................................................................................................................................................13-8 Module Field Connections.................................................................................................................................13-10 Termination Field Connections .........................................................................................................................13-11 Group1 Analog I/O Configuration ....................................................................................................................13-12 Group2 Analog I/O Configuration ....................................................................................................................13-13 Digital I/O Configuration ..................................................................................................................................13-14 Specifications.....................................................................................................................................................13-15
CHAPTER 14 ................................................................................................................. 14-1

Overspeed Trip Module IOP345 .............................................................................................................................14-1 Overspeed Termination Module IOP346 ...............................................................................................................14-1 Overview .................................................................................................................................................................14-1 Overspeed Front Panel.....................................................................................................................................14-2 LED Indication ....................................................................................................................................................14-2 Jumper Configuration ..........................................................................................................................................14-3 Bus Address.........................................................................................................................................................14-4 DPU Compatibility ..............................................................................................................................................14-4 Module Operation................................................................................................................................................14-4 Overspeed Trip Termination...........................................................................................................................14-5 Diagnostics ..........................................................................................................................................................14-6 Module Field Connections...................................................................................................................................14-7 Termination Field Connections ...........................................................................................................................14-8 Group1 Analog I/O Configuration ......................................................................................................................14-9 Group2 Analog I/O Configuration ....................................................................................................................14-10 Digital I/O Configuration ..................................................................................................................................14-11
vii

Specifications.................................................................................................................................................... 14-12
CHAPTER 15 ................................................................................................................. 15-1

HART Input Module IOP307 .................................................................................................................................. 15-1 HART Output Module IOP322 ............................................................................................................................... 15-1 HART Transceiver Module IOP364 ....................................................................................................................... 15-1 Overview ................................................................................................................................................................ 15-1 LED Indication ................................................................................................................................................... 15-2 Jumper Configuration ......................................................................................................................................... 15-2 Bus Address ........................................................................................................................................................ 15-2 DPU Compatibility ............................................................................................................................................. 15-3 Module Operation............................................................................................................................................... 15-3 Diagnostics ......................................................................................................................................................... 15-4 HART Analog Input Field Connections ............................................................................................................. 15-6 HART Analog Output Field Connections .......................................................................................................... 15-7 HART Transceiver Field Connections ............................................................................................................... 15-8 Transceiver to Analog Input Wiring................................................................................................................... 15-9 Transceiver to Analog Input Wiring................................................................................................................. 15-10 Transceiver to Analog Input Wiring................................................................................................................. 15-11 Transceiver to Analog Input Wiring................................................................................................................. 15-12 Transceiver to Output Driver Wiring................................................................................................................ 15-13 Transceiver to Analog Output Wiring .............................................................................................................. 15-13 HART Analog Input Wiring............................................................................................................................. 15-14 HART Analog Input Wiring............................................................................................................................. 15-15 HART Analog Input Wiring............................................................................................................................. 15-16 HART Analog Output Wiring .......................................................................................................................... 15-17 Specifications.................................................................................................................................................... 15-18
Preface
This publication, which describes the installation and operation of maxPAC, assumes familiarity with the DPU and its configuration. For additional information on related topics, refer to the following publications:
Book No. 278590 278705 278561 Book Title Model PDP Series 200 maxDPU4E Hardware Guide Model PDP Series 400 maxDPU4F Hardware Guide System Power and Grounding
Chapter 1
maxPAC Input/Output Subsystem
Overview
The maxPAC Input/Output System links the maxDNA Distributed Control System to real world process control inputs and outputs. The Input/Output system uses a compact design to provide the system with greatly enhanced I/O capacity in relatively little space. A close relationship exists, in turn, between this I/O system and the maxDNA Distributed Processing Unit (DPU) which it serves. The DPU and the I/O modules mount in an I/O chassis assembly. The backplane in the chassis assembly provides the I/O bus connection between the DPU and the I/O modules. It also provides the system power and field power connections to the modules. Multiple I/O chassis that share the I/O bus can be installed in a cabinet.
Model IOP I/O Subsystem

Cabinet
Two standard cabinet types are available for the mounting of I/O system hardware. The cabinet is available as either a NEMA (National Electrical Manufacturers Association) type 1 or 12 and consists of the following: Welded steel construction Front and Rear access I/O mounted in front and rear of cabinet (standard) I/O mounted in front and terminations in rear of cabinet (option) Other mounting arrangement options are also available Removable doors 19 rack mount rails with standard E.I.A. hole spacing Top or bottom Cable access Size 85 7/8 h x 24 w x 38 7/8d Optional Cabinet styles and sizes are also available.

The following figure shows a typical cabinet arrangement with I/O in both the front and rear of the cabinet.
Figure 1-1. Typical Cabinet Arrangement, Front and Rear Views
Chassis Assembly
Three chassis assembly types are available for the installation of the I/O module as follows: IOP382 Eight-pack assembly to accommodate up to eight maxPAC I/O modules. The DPU4F can also reside in this chassis. IOP383 Six-pack assembly to accommodate a DPU4E or a Model 564 I/O module in the right most position along with six maxPAC I/O modules; the DPU4E takes up the equivalent of two maxPAC I/O module positions. IOP381 Four-pack assembly to accommodate four maxPAC or Model 564 I/O modules.
1-2

The rack assemblies contain an I/O backplane featuring edge connectors for I/O modules and connectors for 24V system supply and 24V and 48V loop power supplies. Input/Output modules connect to the I/O bus through four to eight connectors on the backplane, depending on chassis style. The backplane also contains ribbon cable connectors to interconnect chassis assemblies and extend the I/O bus to the maximum number of modules supported by the DPU.
System 24V
I/O Bus Connector Field 48V Field 24V
I/O Bus Connectors
Figure 1-2. Eight-Pack Rack
Figure 1-3. Six Wide Rack with DPU4E
1-3
Model Number IOP381 IOP382 IOP383 IOP015 IOP011,012
Description 4-wide frame assembly 8-wide rack assembly 6-wide rack assembly maxPAC Chassis used with IOP381 Model 564 Chassis used with IOP381
DPU Mounting
DPU4E mounts in the right most position of the six-pack chassis assembly. It occupies the equivalent of two I/O modules. Refer to Publication 278590 for DPU4E information. DPU4F mounts in the left most position of the eightpack chassis assembly. It occupies the equivalent of one I/O module. Refer to Publication 278705 for DPU4F information.
I/O Modules
The I/O modules are rugged enclosed printed circuit board assemblies. The edge connection at the rear of each module provides the interface to the backplane and the I/O bus. System power and field power, when applicable, is also available through this connection. While I/O modules vary by type, they may include one or more of the following: A color bar on the module faceplate identifies the module type. Each module type has a unique color. Euro-style terminal connector blocks for field wiring; each block contains 16 connectors; Rotary address switch; Light Emitting Diodes (LED) for module status indication; All the modules that require field power include a front mounted fuse disconnect and a LED fuse status indication; All discrete modules include front mounted LEDs for input/output logic state; The TC module includes front-end connectors with thermistors to measure the junction temperature for cold junction compensation. The I/O modules may be inserted and withdrawn safely with 24 Vdc and field power applied.
1-4
Figure 1-4. Typical I/O Module Front Panel
I/O Module Types

Because of the variety of input and output ranges needed in distributed control applications, the Model IOP I/O offers many types of easily configurable discrete and analog I/O modules. For a list of modules, along with their ranges and number of points per module, refer to the following tables. Digital Input (AC/DC)*
Part Number IOP330 IOP334 IOP331 IOP332 IOP333 IOP350 IOP351 IOP335 Description 24 Vdc common input; 16 channels 24 Vdc isolated input; 16 channels 48 Vdc common input; 16 channels 120 Vac/dc isolated input; 16 channels 240 Vac/Vdc isolated input; 16 channels Form C relay; 10 channels Form A/B relay; 16 channels Pulse I/O , 8 channels
*ac Voltages/currents are RMS
1-5

Analog Input
Part Number IOP301 IOP302 IOP303 IOP304 IOP305 IOP306 Description Isolated analog input; 16 channels 4-20mA common input; 16 channels 3-wire RTD input; 8 channels Thermocouple/emf input; 16 channels Voltage common input; 16 channels Kit with sixteen 100 Ohm resistors
Analog Output
Part Number IOP320 Description 4-20 mA common output, 8 channels
Other
Part Number IOP371 IOP336 IOP341 IOP345 Description Optical bus extender QuadPAT, 4 channels Turbine Valve Positioner Turbine Overspeed
Power Supply
The maxDNA Input/Output System uses the Model APS Power Supply Assembly, which provides 24V dc power for Distributed Processing Units and I/O. This Power Supply Assembly consists of a 19-inch rack mount or flush mount chassis accommodating up to six independent 10 amp power supply modules. Metso Automation typically installs the power supply modules in an N + 1 redundancy configuration. Because each module is individually isolated, the chassis can be split to provide both system power and loop power. Power supply features consists of the following: Redundant AC power inputs 250 Watt power supply modules Hot replaceable Current Sharing Power factor correction Front panel indicators on each module AC input Output voltage status Output current level External status signals
1-6
Field Termination Options

A maxPAC system uses three field cable termination approaches: Local Terminations Remote Terminations Field cables terminate directly on the I/O module. Field cables terminate on terminal blocks remotely to the I/O module with an interconnecting cable back to the I/O module. The QuadPAT, Turbine Valve and Overspeed modules require a DIN rail mounted termination assembly. Field cables terminate on this assembly with an interconnecting cable back to the I/O module.
Termination Assemblies
Local Terminations (standard)

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

Many remote field cable termination options are possible. Listed below are a few examples: I/O in front of cabinet, terminations in the rear of cabinet. Termination cabinet mounted adjacent to I/O cabinet. Termination cabinet located remotely from I/O cabinet. The types of terminal blocks installed in the termination facility are too numerous to list; typically these terminations are DIN rail style. The cabling back to the I/O module is typically made using two multi-conductor cables, one to each of the Euro-Style plugs supplied with the individual I/O module.
Termination Assemblies
Part Number IOP337 IOP342 IOP346 CTO301 CTO302 CTO303 Description QuadPAT Termination Assembly Turbine Valve Termination Assembly Turbine Overspeed QuadPAT Module to Termination Assembly Cable Turbine Valve Module to Termination Assembly Cable Turbine Overspeed Module to Termination Assembly Cable
1-7
Installing Model IOP I/O Equipment

This section covers the physical mounting and installation of the Model IOP I/O equipment. See "Module Mounting Considerations," before mounting any equipment. The following tools and hardware are required: Screwdriver Hex Key Wrench, Metso Part No. 064598 Mounting Screws, Metso Part No. 030162 (8 per unit supplied) Nut Retainers, Metso Part No. 003530 (8 per unit supplied) Crimp Tool for field connectors, Weidmuller Part No. 906480 Crimp Contact Removal Tool, Weidmuller Part No. 906481 Before mounting any hardware, see "Cabling, Power, and Ground Wiring."
Sequence of Mounting Operations

Mounting the parts of the Model IOP I/O in proper order can save time and duplication of effort. Follow this sequence as closely as possible for best results: 1. Refer to field wiring instructions that can influence mounting locations for chassis assemblies and chassis assembly/module replacement. 2. Mount the chassis assemblies; see "Mounting I/O Chassis Assemblies." 3. Perform all steps as outlined in "Cabling, Power, and Ground Wiring." 5. Complete field wiring. 6. Refer to "Module Addressing" for switch settings and jumper selections. 7. Install I/O modules. If your field wiring enters through the bottom of the cabinet, mount the Model IOP I/O units from top to bottom. This will make wiring of future units easier, since you will not have to pull wires from the bottom of the cabinet past existing Model IOP I/O units. This same reasoning applies to field wiring entering the top of the cabinet. Here you mount the Model IOP units from bottom to top.
1-8
Mounting I/O Chassis Assemblies

The Model IOP I/O chassis assembly attaches to the rear mounting rails in standard 19-inch maxDNA I/O cabinets. Three chassis styles are available. See Chassis Assembly. Up to seven chassis assemblies may be installed in a standard cabinets. Usually, the Model IOP I/O units are supplied already mounted in cabinets, but if you are mounting them yourself, follow this procedure. Note: before you mount an I/O chassis, it should contain the I/O backplane. To attach the chassis assembly: 1. At the desired chassis assembly mounting location in the cabinet, place eight 10-32 nut retainers (Metso Part No. 003530) in the rear mounting rail holes that correspond to the eight screw slots on the Model IOP chassis assembly. 2. The holes in the maxDNA cabinet rear mounting rails are arranged in a repeating pattern of two holes close together separated by a single hole. To make sure all chassis assembly mounting screw cutouts line up to corresponding mounting rail holes, you must align the top mounting screw cutouts (left and right) of the chassis assembly with the top holes (left and right) of two hole pair. 3. Position the chassis assembly (two ribbon connectors to the right) so that the screw slots align with the nut retainers. Insert eight 10-32 mounting screws (Metso Part No. 030162) and tighten securely. Cabling, power wiring, and chassis assembly to cabinet frame grounding should be completed before mounting the I/O modules. See next section.
Cabling, Power, and Ground Wiring

This section describes power wiring, Model IOP I/O connection, and connection to other Model IOP I/O units. The connections covered in this section should be done after the chassis assemblies are in place and before the I/O modules are mounted. Some cabling can be done when the I/O modules are mounted, but the job is easier when they are removed. (See also Interconnecting I/O Racks). Cables used in the maxDNA Distributed Control Systems are labeled at both ends with the device and connector number. Interconnecting ribbon cables are designed for specific orientation, however, the connectors still prohibit wrong electrical connection. Refer to Publication 278561, System Power and Grounding, for a discussion of cabinet grounding.
1-9

Supplying 24V Power to the I/O Modules
The I/O system requires a 24 Vdc 4.0 Vdc power supply. Normally, this is a maxDNA power supply mounted in the cabinet holding the DPU; to ensure reliability, Metso Automation recommends using a maxDNA power supply exclusively. If another 24 Vdc power supply is used, it must meet the same specification requirements as the maxDNA supply. All modules are individually fused. The CMOS technology in the Model IOP I/O design results in low module power consumption. Whether the power source is the standard maxDNA supply or another supply, the +24 Volts connector plugs into the 24V connector on the right side of the I/O backplane. Caution: The +24 Vdc power supply used to power any maxDNA hardware should never be used for external relay contact wetting or to power any other field equipment. Use a separate supply for contact wetting to provide noise and interference protection for the maxDNA hardware.
Interconnecting I/O Racks

Use a ribbon cable to interconnect, in a daisy chain manner, two or more adjacent I/O chassis assemblies in the same maxDNA I/O cabinet group. The cables should be installed in a manner that minimizes the total I/O bus length. This is done by utilizing the I/O bus connectors on both ends of the racks so that the bus flows through the racks. For example, consider the two-cabinet system shown in Figure 1-5a. A maxDPU4F pair is installed in the leftmost slots of the top two racks in cabinet 1. The bus begins at the DPU and flows through the rack to the connectors on the right side of the rack (P9 & P10). A ribbon cable connects the right side of rack 1 to the right side of rack 2. The bus flows through rack 2 to connector P11. Another ribbon cable connects the left side of rack 2 to the left side of rack 3. The bus flows through rack 3 to connectors P9 and P10. This same pattern is repeated until the last rack has been reached. Notice that the bottom rack of cabinet #1 is connected to the bottom rack of cabinet #2 by a cable that runs from P11 to P9. This is because that results in a shorter cable length than it would be had it run from P11 to P11. It is also a much shorter cable length than if it had been run from the bottom of cabinet 1 to the top rack in cabinet 2. To reiterate, when cabling the I/O racks together, the goal is to keep the I/O bus length as short as possible. Connecting the cables on alternate sides of the racks so that the I/O bus flows through from one rack to the next does this. Note that the ribbon cable connectors are keyed. The color stripe on the ribbon cable should match pin 1 on the backpanel connector. Connector pin 1 is indicated by a white triangle symbol on the backpanel adjacent to the connector.
1-10

A bus terminator (CPO402) must be installed at the end of the I/O bus farthest from the DPU. The bus terminator is a small PC card assembly that is designed to plug in to the I/O bus connector. When installing a terminator, be sure to match its pin 1 indication to the pin 1 indication on the backpanel. In Figure 1-5a, the terminator is shown inserted into connector P9 of the top rack in cabinet 2. That is the point on the bus that is farthest from the DPU. If you add I/O racks to your system at a later date, remember to move the terminator from its old location to the new end of the bus. I/O Bus Terminators are not used to provide impedance matching. They are simply pull-up resistors that are used to improve the rise time of the open collector I/O bus signals. For that reason, in some instances (e.g., a system with both maxPAC and 564-style I/O connected with long cable runs), an additional terminator at the DPU end might be required. Monitor the I/O Bus Errors and, if your system seems to have an excessive amount, try adding the additional terminator. Refer to the Bus Extender Module chapter in this manual for information on how to install terminators when BEMs are present in the system.
Cabinet #2 Terminator P9 P11 P10 D P P11 U Cabinet #1 P9 P10
P9 P11 P10 P11
D P U
P9 P10
P9 P11 P10
P9 P11 P10
P9 P11 P10 P11
P9 P10
Figure 1-5a. Interconnecting maxPAC I/O Racks (Shared I/O)
1-11

Terminating systems with Redundant or Mixed (Shared + Redundant) I/O is a little more complicated than a system with only Shared I/O. Refer to the following figures for examples. Additional information on Shared, Redundant and Mixed I/O is contained in the Backup Configuration Options section of this manual.
P11 DPU
Redundant I/O Primary
P9
P10
P11 DPU
Redundant I/O Secondary
P9
P10
I/O Bus Cable

Terminator
P11
Redundant I/O Primary
P9
P10
Terminator
P11
Redundant I/O Secondary
P9
P10
I/O Backup Cable (047472)
Figure 1-5b. Terminating & Cabling Redundant I/O
1-12
P11 DPU
Redundant I/O - Primary
P9
P10
P11 DPU
Redundant P9 I/O - Secondary P10
I/O Bus Cable

Terminator
P11
Redundant I/O - Primary
P9
P10
Pri Com
Terminator
P11
Redundant I/O - Secondary
P9
Sec
Y-Cable
P10
Terminator
P11
Shared I/O
P9
P10
Notes: 1. Keep the redundant I/O racks close to the DPUs that drive them. 2. Place the Y-Cable close to the I/O bus connectors (P10) on the redundant racks.
Figure 1-5c. Terminating & Cabling Mixed I/O
1-13

Summary of Cabling Rules for maxPAC I/O
Keep the total I/O bus length (cables + backpanels) as short as possible. The following techniques will do this. Use flow through cabling. When connecting columns of racks together, connect the bottom rack of column 1 to the bottom rack in column 2 or the top rack of column 1 to the top rack of column 2. In other words, do not cable a top rack to a bottom rack.
Put the DPU at one end of the I/O bus. Never put the DPU in the middle. Terminate the far end of the I/O bus (the end farthest from the DPU). In a system with Common (shared) I/O, the terminator should be placed at the far end of the common I/O bus. In a system with Redundant I/O, install a terminator at the far end of both redundant I/O bus segments. In a system with mixed (common + redundant) I/O, terminate all segments.
The maximum number of maxPAC modules supported by the maxDPU4E or maxDPU4F within a cabinet or adjacent cabinet pair is 60. This number of modules is reduced when the electrical I/O bus is extended to other cabinets. The limit of 60 modules per bus segment is based upon the electrical characteristics of the bus drivers. Other considerations such as the types of modules used, the use of BEMs and the availability of DPU resources may change the number and types of modules permitted. Thus, it is very important that the user verify the correctness of the proposed configuration by running the I/O Configuration Tool. Refer to Publication 278609 for more information on the tool.
maxPAC I/O Bus Cables

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

Part Number Description CPO301 CPO303 10 inches - 0 rack units between racks 12 inches - 1 rack unit between racks
1-14

CPO304 CPO305 14 inches - 2 rack units between racks 26 inches - 10 rack units between racks
Cables for maxPAC Connections to P11

Part Number Description CPO323 CPO324 CPO325 12 inches 0 or 1 rack units between racks 14 inches 2 rack units between racks 28 inches 10 rack units between racks
Long Cables for maxPAC Connections to P9, P10 or P11

For I/O bus connections to a cabinet outside the cabinet group, use the following cables: Part Number Description CPO307 CPO315 CPO400-LL 7-foot cable 15-foot cable Custom length cable (about 20 feet maximum)
Cables for Connections between maxPAC and 564 Racks

For applications that require I/O bus connections between maxPAC racks and Model 564 I/O racks, the following cables are available. Note that Model 564 I/O racks do not support flow through cabling so they will connect to the I/O bus as stubs. Part Number Description CPO504 CPO507 CPO515 CPO500-LL 13 inches - 2 rack units between racks (use P9 or P10) 7-foot cable 15-foot cable Custom length cable (about 20 feet maximum)
1-15
Module Mounting Considerations

I/O Modules As you determine how modules are positioned in a cabinet, give some thought to the signal levels that are to be wired to the modules. High and low signal levels and AC and DC wiring should be kept separate. In general, wherever possible, modules receiving the same type and level of signals should be grouped together, with similar signal types arranged in vertical columns.
DPU Modules
The DPU4E requires the use of the six-wide chassis and is mounted in the right most position. DPU4F is mounted in the left most position of the 8wide chassis to take advantage of the airflow. Likewise, when using a second DPU for backup, it is mounted on a second chassis beneath the primary DPU. Before mounting I/O modules, you should complete power and grounding and field wiring and any I/O module preparation and adjustment. See appropriate chapters in this publication to check correct addressing and jumper selection on the modules. Before installing an I/O module in the right-most position of a chassis assembly, make sure the +24Vdc is connected to the chassis assembly as well as the I/O bus cable. Additionally, connect the cabinet frame ground to the Model IOP I/O chassis assembly before installing an I/O module in the extreme left position of a chassis assembly. Refer to "Cabling, Power, and Ground Wiring." Before installing any modules, complete all field wiring. Model IOP I/O is designed to allow module installation and removal with the +24Vdc power supply ON. To mount modules: 1. With chassis assembly in place and all wiring completed, position module into top and bottom card guides of the chassis. Gently slide module forward, verifying that the connector pins on the side of the module board engage the corresponding contact guides on the chassis assembly. 2. When the contacts are engaged and resistance is felt, firmly press on the front panel of the module front plate to make the simultaneous connections at the front and rear. Apply pressure to the left of the LEDs to place the force directly in line with the printed circuit card of the module. 3. Secure module to chassis assembly with the top and bottom lock-down screws on the front of the module.
1-16
Module Addressing
You must set addresses for each I/O module using rotary switches mounted in the lower or upper right corner of the printed circuit board of the module, depending on module type. These hexadecimal switches permit 255 logical addresses (hexadecimal FF is not available). The lower switch is the low order address and the upper switch is the high order address. maxPAC modules use one, two, four or eight addresses. The address set on the module is its base address. For the eight-address module the base address is the address of channel 1. The module will automatically occupy an address for each of its channels, starting with its base address. To convert the hexadecimal address to the equivalent logical (decimal) address: 1. Multiply the low order switch setting by 1 to get the decimal equivalent, where switch positions A to F correspond to 10 to 15, respectively. 2. Multiply the high order switch setting by 16 to get the decimal equivalent, where switch positions A to F correspond to 10 to 15, respectively. 3. Add the two decimal equivalents for logical (decimal) module address. For example, a 2 setting of S2 (2 x 16 = 32) and an A setting of S1 (10) gives a module a logical (decimal) address of 42, the decimal equivalent of the hexadecimal word 2A formed by the switch setting. Module addressing is completely independent of module physical locations. Each module address must be different from all other module addresses in the system. Digital input modules must have an address less than 32 decimal. Addresses are determined by the system designer during system planning.
Backup Configuration Options

Three input/output configuration options are available: shared, redundant, and mixed.
Shared Configuration
1-17

A shared I/O configuration uses a primary DPU, a secondary DPU, and one set of Model IOP parallel modules. See Figure 1-6. Both DPUs share the I/O bus but only the active DPU (primary or secondary) receives data from, and sends data to, the set of common I/O modules.
Redundant network
D P U
D P U
I/O Bus
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
Figure 1-6. Shared Configuration
Redundant Configuration
A redundant I/O configuration uses a primary DPU, a secondary DPU, and two identical sets of Model IOP parallel modules. See Figure 1-7. The primary and secondary DPUs receive data from, and send data to, their set of I/O modules. Outputs from the inactive string of modules are inhibited until they become active. It is necessary to install a Part No. CPO309 cable between the two I/O strings as shown; this cable inverts the output-enable signal so that outputs of the inactive I/O string are disabled.
1-18
R ed u nd ant netw ork
D P U
D P U
I/O B us
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
C P O 3 09
Figure 1-7. Redundant Configuration
Mixed Configuration
A mixed configuration uses a primary DPU, a secondary DPU, a Y adapter, two identical sets of redundant Model IOP parallel modules, and various other common Model IOP modules. See Figure 1-8. The primary and secondary DPUs receive data from, and send data to, the redundant modules. The active DPU (primary or secondary) also receives data from, and sends data to, the common set of I/O modules. The output-enable signal to the modules is handled internally by the mixed backup adapter; Part No. CPO401. In redundant or mixed configurations, the inactive DPU polls its redundant modules for hardware failures when it is not performing control actions. No transfer of control will occur if a failure is detected by the inactive DPU. The inactive DPU also continuously updates its analog output modules with current values so that bumpless transfer occurs when the inactive DPU becomes active.
1-19
Redundant network
D P U
D P U
I/O Bus
I/O Bus
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
Backup Adapter Common I/O Bus
I O
I O
I O
I O
I O
Figure 1-8. Mixed Configuration
Remote I/O
A Bus Expander Module (BEM) permits the I/O bus to be extended up to 2,000 meters using highly reliable and noise immune fiber optic cables. BEMs, configured in pairs, support both locally and remotely mounted I/O cards. In a typical configuration using redundant Distributed Processing Units (DPUs), an I/O cabinet installed locally in a control room contains I/O modules, a DPU pair, and a BEM pair. This is connected via I/O optical cable to a ruggedized remote cabinet containing I/O modules, and a second BEM pair. The optical link is established between the local and remote expander modules. Any DPU or redundant pair of DPUs, can communicate with I/O that are locally and/or remotely mounted. Figure 1-9 shows a typical configuration with both redundant and common local I/O and
1-20

common remote I/O. The Y adapter would also be required at the remote end to support both common and redundant remote I/O.
redundant network
D P U B E M
backplane
Y ADAPTER
D P U B E M
backplane
Control Room
I O
I O
I O
I O
Optical Cable
I O
I O
I O
I O
B E M I O I O I O
B E M I O I O
Remote location
I O
I O
I O
I O
I O
I O
I O
I O
I O
Figure 1-9. Typical Bus Expander Module Configuration
1-21
Specifications
Environment
The Model IOP I/O operates in the temperature range of 0C to 60C at a relative humidity range of 0 to 90%, noncondensing.
I/O Bus
The Model IOP I/O uses an 8-bit parallel asynchronous I/O bus, capable of 10 microsecond transfers. The I/O bus interface uses LSI circuitry for better reliability. Parity checks are performed on all inputs and outputs, with additional security provided for outputs using a check-before-execute control strategy. To further enhance reliability, I/O incorporates module address verification and multiple module detection checks. Bus fault detection is also performed by automatic confirmation of input data on every module.
Inputs/Outputs
All modules, both analog and digital types, withstand the normal or common mode connection (IEEE-472, ANSI c37.90) and still maintain correct operation. Common mode transients are bypassed to chassis metal work. All points are optically isolated from the maxDNA I/O bus. Channel to channel isolation allows series or parallel connection between channels or external relay systems. All digital modules have logic state indication on the front panel, one indication per point. In addition to logic state indication, digital output modules contain fused outputs and a front-panel blown fuse indicator. Each output also has a deadman timer (approximately 1 second) that can be optionally used to freeze or drop out all outputs if the module is not updated by the DPU.
1-22
Chapter 2
Analog Input Modules Isolated Input Module IOP301
Overview
This module, featuring 16 isolated input channels, can be configured for any mix of voltage or current inputs. The current loop can be powered from a field supply or from a system loop supply provided via the backplane edge connector. For current inputs, this module is pin and function compatible with the IOP302 input module.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers, located near the address switches. Refer to the following table for jumper setting information.
Jumper W1 W6
Installed
50 Hz
Model 564
Not Installed 60Hz maxPAC
In addition, five jumpers per channel determine the type of input connected to the channel.
Input Type 4-20 mA powered by Metso Automation 4-20 mA powered by user Voltage input A IN IN OUT B IN IN OUT C IN OUT OUT D IN OUT OUT E OUT IN IN
Program Resistors
Jacks are provides at the front of the module for the installation of a pair of resistors per channel. These resistors can be used to scale a voltage input to the 2.4V span of the A/D measurement. These resistors are identified as follows:
Channel Series R Shunt R 1 1 3 2 7 10 3 26 29 4 32 35 5 51 53 6 57 60 7 78 80 8 85 88 9 113 115 10 120 123 11 142 144 12 148 151 13 175 177 14 193 196 15 211 215 16 233 234
The input circuit configuration for each type of input is shown in the following sketch. An electronic fuse protects the 24-volt loop power to the transmitter. A 200-Ohm thermistor in series with the 4-20 mA input provides current limiting for voltages up to 100 Volts. The 24-volt loop supply is
2-2

available to the module from the backplane. For current inputs with external shunt the channel is configured for voltage input and Rs = 0.
24V(+) 1A 1B 24V(-)
From backplane
200 2 Rs
100
A/D
Xmitter
1 24V
Rp 1D 1E 1C
4-20 ma powered by system
200 2 + Rs
1A
1B
100 Rp
A/D
Voltage
1
1D 1E 1C
Voltage input
200 2 + Rs
1A
1B
+
Rp 100 1D 1E 1C
A/D
Xmitter
1
4-20 ma powered externally, internal shunt
Module Operation
This microprocessor-based module supports up to 16 isolated high level inputs. A sigma delta A/D and precision reference is provided for each pair of inputs. The A/D reads the voltage generated by the selected input and converts the differential measurement to a 15-bit plus sign binary value
2-3

representing the voltage input, which is read by the microcontroller. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. Prior to starting each conversion, the microcontroller selects one of the two input channels by means of two solid-state, optically coupled relays. The two inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open input and over range conditions are checked. A separate DC/DC converter provides isolated power to each A/D converter measuring circuit. Communication between the microcontroller and each A/D is serial at 100kHz. A separate group of optical isolators provide the isolation between each A/D and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.
2-4

5V - logic DC/DC REF Channel 1
Multiplexer
Regulator
24V
FLASH
OPTO A/D 1
Channel 2
uC
Optical isolation between each pair of channels
FPGA I/O Bus
DC/DC REF Channel 15

Multiplexer
OPTO A/D 8 Channel 16
optical isolation field to logic
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on)
Code 0x12 0x13 0x14 0x15 0x16 0x22
2-5

CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) 0x23 0x24 0x25 0x26 0x32
Module specifications
Resolution Scan Rate Temperature Sensitivity Accuracy Source Impedance Effect Conversion method Span Calibration Input Impedance - 4-20 mA input - voltage input Normal Mode Voltage Normal Mode Rejection Common Mode Voltage Common Mode Rejection Isolation Input Power (from 24V system supply) 15 bits plus sign 100 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of full scale at 25oC 10 Mohm operational, 20K Ohms on loss of power Sigma Delta oversampling. Single A/D per channel 4 to 20 mA, 0-2.4V Self-calibration on power up. Periodically on line to compensate for temperature effects 300 Ohms 1 Mohm 50 Volts 60db @ 50/60 Hz 500 Volts dc or peak ac 120db @ 50/60 Hz, 100 Ohm imbalance 1500 Vac (field to logic) 500 Vac (channel to channel) 400 mA
2-6
Field Wiring
P2
1 1
P3 24V,In(-)
2
24V,In(-)
2
Channel 1
Channel 9
In(+)
3
In(+)
3
24V,In(-)
4
24V,In(-) Channel 2 In(+)

5 5 4
Channel 10
In(+) 24V,In(-)
6

7 7 6
Channel 11
In(+) 24V,In(-)
8

9 9 8
Channel 12
In(+) 24V,In(-)
10
Channel 5
24V,In(-)
10
Channel 13
In(+)
11
In(+)
11
24V,In(-)
12

13 13 12
Channel 14
In(+) 24V,In(-)
14

15 15 14
Channel 15
In(+) 24V,In(-)
16

16
Channel 16
In(+)
2-7
Field Wiring for Redundant Modules with Common Transmitter

The following figure shows the recommended wiring for two redundant IOP301 analog input modules that share a common two-wire or four-wire transmitter. Redundant inputs must be configured as voltage inputs with an external 100Ohm shunt resistor. The recommended maximum distance between the shunt and the I/O module is 10 meters. The +24V connection should be independently fused to each transmitter. The connection to the (-) terminal of the 24v supply must be made at the (-) side of the shunt resistor. The voltage that is developed across each 100-Ohm shunt by the 4-20 mA signal from the transmitter is wired to the AI module using twisted pair cables. A PTC thermistor is recommended between the transmitter output and the 100-Ohm shunt. This protects the 100-Ohm shunt against over voltage and provides additional resistance to increase the transmitter load to 250 Ohms. Kit IOP306 supplies 16 pairs of 100-Ohm shunts and thermistors to support two IOP301 analog input modules.
Twisted pair (-) 4 wire Transmitter thermistor 100 (+) Primary IOP301 AI Module
(-)
(+) Secondary IOP301 AI Module
Four Wire Transmitter
2-8

(-) 24V Supply (+) thermistor 100 (+) Primary IOP301 AI Module Twisted pair (-)
2 wire Transmitter (-)
(+) Secondary IOP301 AI Module
Two Wire Transmitter
2-9
Chapter 3
Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305
Overview
The IOP302 module features sixteen 4-20 mA common input channels. The IOP305 module features 16 voltage input (not current input) channels. Transmitter loop power is available to the module via the backplane, providing individually fused 24V transmitter power for each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the

DPU. This LED blinks on and off at a constant rate when the module is not being scanned by the DPU.
Bus Address
The module contains two jumpers. Refer to the following table for jumper setting information.
Jumper W1 W6 Installed 50 Hz Model 564 Not Installed 60Hz maxPAC
Module Operation
This microprocessor-based module supports up to 16 4-20 mA inputs, all powered from a local 24V loop supply. A sigma delta A/D and reference are provided for each input. Each A/D constantly reads the voltage generated by the input and converts the differential measurement to a 15-bit plus sign binary value, which is read by the microcontroller. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. Immediately following each measurement, open input and over range conditions are checked. A DC/DC converter provides isolated power to the A/D measuring circuit. Communication between the microcontroller and the A/D is serial at 100kHz. Optical isolators provide the isolation between the A/D and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.
3-2
Analog Input Modules 4-20 mA Input Module IOP 302 Voltage Input Module IOP 305
5V - field DC/DC 5V - logic Regulator 24V
REF Signal Conditioning
FLASH
Channel 1
A/D
OPTO
uC
FPGA I/O Bus
REF Signal Conditioning
Channel 16
A/D
The input circuit for each channel of the 4-20 mA input module is shown in the following sketch. An electronic fuse protects the 24V loop power to the transmitter. A 200-Ohm thermistor in series with the input provides current limiting for overvoltage conditions up to 100 Volts. The 24-volt supply is available to the module from the backplane.
Current Limit 200 100 A/D
24V(-) From backplane 24V(+) Fuse
The following sketch shows the input circuit for the voltage-input module.
3-3
A/D
Voltage Input Module
Diagnostics
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on) Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Module Specifications
Resolution Scan Rate Temperature Sensitivity Accuracy Source Impedance Effect Conversion method Span Calibration Input Impedance Normal Mode Voltage Normal Mode Rejection Common Mode Voltage Common Mode Rejection Isolation Input Power (from 24V system supply) 15 bits plus sign 20 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of full scale at 25oC 10 Mohm operational, 20K Ohms on loss of power Sigma Delta oversampling. Single A/D per channel 4 to 20 mA, 0-2.4V. Self-calibration on power up. Periodically on line to compensate for temperature effects IOP302, 300 Ohms; IOP305, 1mOhm IOP302, 50 Volts; IOP305, 24 Volts 60db @ 50/60 Hz 100 volts dc or peak ac for the group 120db @ 50/60 Hz, 100 Ohm imbalance 1,500 Vac field to logic 125 mA
3-4
Field Wiring for IOP302

P2 1 24V
Transmitter
P3 1
Channel 1
24V
Transmitter
Channel 9
2 Iin 3 24V
2 Iin 3 24V
Transmitter
4 Iin 5 24V
Channel 2
Transmitter
4 Iin 5 24V
Channel 10
Transmitter
6 Iin 7 24V
Channel 3
Transmitter
6 Iin 7 24V
Channel 11
Channel 4
Channel 12
Transmitter
8 Iin 9 24V
Transmitter
8 Iin 9 24V
Transmitter
10 Iin 11 24V
Channel 5
Transmitter
10 Iin 11 24V
Channel 13
Transmitter
12 Iin 13 24V
Channel 6
Transmitter
12 Iin 13 24V
Channel 14
Transmitter
14 Iin 15 24V
Channel 7
Transmitter
14 Iin 15 24V
Channel 15
Transmitter
16 Iin
Channel 8
Transmitter
16 Iin
Channel 16
3-5
Field Wiring IOP 305 Analog Input Module
P2 1 (-)
0-2.4V
P3 1 (-)
Channel 1
2 (+) 3 (-)
0-2.4V
Channel 9
2 (+) 3 (-)
0-2.4V
4 (+) 5 (-)
Channel 2
0-2.4V
4 (+) 5 (-)
Channel 10
0-2.4V
6 (+) 7 (-)
Channel 3
0-2.4V
6 (+) 7
Channel 11
0-2.4V
Channel 4
(-)
0-2.4V
Channel 12
8 (+) 9 (-)
8 (+) 9 (-)
0-2.4V
10 (+) 11 (-)
Channel 5
0-2.4V
10 (+) 11 (-)
Channel 13
0-2.4V
12 (+) 13 (-)
Channel 6
0-2.4V
12 (+) 13 (-)
Channel 14
0-2.4V
14 (+) 15 (-)
Channel 7
0-2.4V
14 (+) 15 (-)
Channel 15
0-2.4V
16 (+)
Channel 8
0-2.4V
16 (+)
Channel 16
3-6
Field Wiring For Redundant Modules with Common Transmitter

The following figure shows the recommended wiring for two redundant IOP305 analog input channels that share a common transmitter. The recommended maximum distance between the shunt resistor and the I/O module is 10 meters. The +24V connection is independently fused to each transmitter. The voltage that is developed across each 100-Ohm shunt by the 4-20 mA signal from the transmitter is wired to the AI module using twisted pair cables. The (-) terminal of the loop supply is connected to the (-) side of the shunt resistors so that the 4-20 mA current does not flow through the twisted pairs wires. A PTC thermistor is recommended between the transmitter output and the 100-Ohm shunt. This protects the 100-Ohm shunt against over voltage and provides additional resistance to increase the transmitter load to 250 Ohms. Kit IOP306 supplies 16 pairs of 100-Ohm shunts and thermistors to support two IOP305 analog input modules.
(+) DCS 24V Loop Supply (-)

Twisted pair (-) 100 Transmitter 2-wire (+) thermistor Primary IOP305 AI Module
(-)
(+) Secondary IOP 305 AI Module
3-7
Chapter 4
Analog Input Modules 3 Wire RTD Module IOP303
Overview
This module features 8 isolated 3-wire RTD input channels.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU. It is also used to display errors detected by diagnostics.
Bus Address
The module contains three jumpers. Refer to the following table for jumper setting information.
Jumper Installed Not Installed W2 Common I/O Redundant I/O W3 50 Hz 60 Hz W4 Not used W6 Model 564** maxPAC ** For version B or earlier, W7 must be installed for model 564 operation
Module Operation
This microprocessor-based module supports up to 8 RTD inputs, which can be independently configured. A reference excitation current is provided for each input. A sigma delta A/D reads the voltage generated by one of the eight inputs and converts the differential measurement to a 15-bit plus sign binary value representing the millivolt input, which is read by the microcontroller. Multiple readings are done for each channel to compensate for the error introduced by the field wiring in 3-wire RTDs. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. The A/D also provides a variable gain amplifier function. Prior to starting each conversion, the microcontroller sets the gain required in the A/D and selects the RTD excitation current based on the configuration for that input. It also selects the input channel by means of four solid-state optically coupled relays. The inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open RTD and over range conditions are checked. A DC/DC converter provides isolated power to the field side of the measuring circuit. Communication between the microcontroller and the A/D is serial at 100kHz.
4-2
Analog Input Modules 3 Wire RTD Module IOP 303

Optical isolators provide the isolation between the A/D and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.
5V - logic 5V - field Excitation Current DC/DC
Regulator
24V
FLASH
Channel 1
REF
Field Interface Circuits
A/D
OPTO
uC
I/O Bus
Channel 8
4-3
Diagnostics
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on) Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Resolution Scan Rate Input Type Input Range Temperature Sensitivity Accuracy Input Multiplexer Conversion method Linearization Calibration Maximum Lead Resistance Compensation Backup Conformity Error Normal Mode Rejection Common Mode Rejection Common Mode Voltage Input Power (from 24V system supply) 15 bits plus sign 8 points converted in 1.6 seconds 10 ohm Cu, 10 ohm Pt, 25 ohm Pt, 100 ohm Cu, 100 ohm Pt, 100 ohm Ni, 1000 ohm Pt 0 1000 ohms 0.004% of reading/oC 1.5uv/oC RTI 0.15% of reading 0.5oC Solid-state FET, optical isolation Sigma Delta oversampling Digital in DPU. RTD ranges may be randomly mixed. Self-calibration on power up. Periodically on line to compensate for temperature effects. 5 Ohms each lead Conversions disabled if common RTD is connected to redundant modules. 0.3oC, 0.5oF 60db @ 50/60 Hz 120db @ 50/60Hz, 100 Ohm imbalance 240V rms, 350V dc peak 125 mA
4-4
Analog Input Modules 3 Wire RTD Module IOP 303
Field Wiring
P2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 16 Channel 4 15 11 16 Channel 3 Channel 2 Channel 1 1 2 3 4 5 6 7 8 9 10 11 Channel 7 12 13 14 Channel 8 Channel 6 Channel5 P3
Note: Field wires must be of equal length
4-5
Field Wiring For Redundant Modules with Common RTD
Twisted pair,
same length
(+)
(-) Primary IOP303 RTD Module Ret W2 not installed
(+)
(-)
Secondary IOP 303 RTD Module
Ret W2 - not installed
4-6
Chapter 5
Analog Input Modules TC Module IOP304
Overview
This module features 16 isolated thermocouple of emf input channels
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off at a constant rate when the module is not being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34, 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
The module contains three jumpers. These jumpers are located at the rear of the module above the edge connector. Refer to the following table for jumper setting information.
Jumper W3 W2 W6 Installed 50 Hz Common I/O Model 564 Not Installed 60Hz Redundant I/O maxPAC
Cold Junction Compensation

If this module is configured by the DPU to perform cold junction compensation, a thermistor (Metso Part No. 074566) must be installed in connectors P4 and P5 at the front of the module, above and below the input connectors.
Module Operation
This microprocessor-based module supports up to 16 TC or emf inputs, which may be independently configured. A sigma delta A/D reads the voltage generated by one of the 16 TC or emf inputs and converts the differential measurement into a 15 bit plus sign binary value representing the millivolt input, which is read by the microcontroller. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. The A/D also provides a variable gain amplifier function. Prior to starting each conversion, the microcontroller sets the gain required in the A/D for each configured input measurement, and selects the input channel by means of two solid state, optically coupled relays.
5-2

The inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open TC and over range conditions are checked. A DC/DC converter circuit provides isolated power to the field side of the measuring circuit. Communication between the microcontroller and the A/D is serial at 100kHz. Optical isolators provide the isolation between the field side and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects. When thermocouples are measured, the module monitors the TC cold junction temperature and the input value read is compensated for the cold junction temperature. Thermistors, installed at the terminal blocks provided above and below the field connectors, are used to measure the TC cold junction temperature. When remote terminations are used, these thermistors must be removed from the module and moved to the wiring connections at the remote terminations. The microcontroller schedules periodic measurements of the thermistors and uses these measurements to calculate a cold junction temperature for each channel.
5V - logic 5V - field DC/DC
Regulator
24V
FLASH
Channel 1
REF
A/D
OPTO
uC
FPGA I/O Bus
OPEN
TC
Channel 16
Diagnostics
5-3
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Resolution Scan Rate Input Type Input Range Temperature Sensitivity Accuracy Input Multiplexer Conversion method Linearization Calibration RJ Compensation Open TC Detection Backup Conformity Error Reference Junction Error Normal Mode Rejection Common Mode Rejection Common Mode Voltage Input Power (from 24V system supply) 15 bits plus sign 16 points converted in 1 seconds Types B, D, E, G, J, K, N, R, S, T, Platinell II +/-10mv, +/-25mv, +/-60mv, +/-100mv, +/-250mv, +600/-250mv 0.004% of reading/oC 1.5uv/oC RTI 0.15% of reading 0.5oC Solid-state FET, optical isolation Sigma Delta oversampling Digital in DPU. RTD ranges may be randomly mixed. Self-calibration on power up. Periodically on line to compensate for temperature effects Digital in module Performed each reading (1,000 0hm threshold) Conversions disabled if common TC is connected to redundant modules 0.3oC, 0.5oF 0.25oC 60db @ 50/60 Hz 120db @ 50/60 Hz, 100 Ohm imbalance 240V rms, 350V dc peak 125 mA
5-4
Field Wiring
P2 1 + 2 3 + 4 5 + 6 7 + 8 9 + 10 11 + 12 13 + 14 15 + 11 16 Channel 8 11 16 Channel 7 14 15 + Channel 16 Channel 6 12 13 + Channel 15 Channel 5 10 11 + Channel 14 Channel 4 8 9 + Channel 13 Channel 3 6 7 + Channel 12 Channel 2 4 5 + Channel 11 Channel 1 2 3 + Channel 10 1 + Channel 9 P3
5-5
Field Wiring For Redundant Modules with Common TC
(+)
(-) Primary IOP304 TC Module
TC extension wire
W2 not installed
(+)
(-) Secondary IOP 304 TC Module W2- not installed
Note: Thermistors must be installed in both modules.
5-6
Chapter 6
Analog Output Modules 4-20 mA Output Module IOP320
This module, featuring eight 4-20 mA output channels, receives power from the 24V-system supply via the backplane edge connector. Loop power is also available to the module via the backplane and is individually fused 24V for each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU. A second green LED provides the status of the loop power fuse disconnect.
Bus Address
This module requires eight bus addresses and provides eight channels. Each module address must be on a 0 or eight boundary (i.e. 32, 40, 48, etc.) in the range of 32 to 240. Addresses 0 to 31 are reserved for digital input modules.
The module contains four jumpers. Refer to the following table for jumper setting information. Note: this is for the newer modules that have two rotary address switches.
Jumper W1 W2 W3 W4 W6 Installed Run Mode Hold Output Secondary Common I/O 8 addresses Not Installed Calibrate Mode Reset Output Primary Redundant I/O N/A
6-2
Analog Output Modules 4-20mA Output Module IOP320
Module Operation
This microprocessor-based module supports up to eight 4-20 mA output channels. Communication between the microcontroller and each output is serial. The output request received from the I/O bus is translated by the microcontroller into a pulse width modulated signal, which is transmitted to each output circuit via a high-speed optical isolator. This optical isolator provides the isolation between the logic and the field. The duty cycle of the serialized output is proportional to the output level. The output circuit converts this signal into 4-20 mA. Open load is detected and reported to the DPU. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. A watchdog timer function is included to monitor communications on the I/O bus. The watchdog timers will timeout if there is no communications on the I/O bus for longer than 0.7 seconds. When this occurs, the outputs will either reset or remain in their last state depending on the position of the onboard program jumper. Module calibration is done automatically at power up following startup diagnostics. The 24-Volt loop supply is available to the module from the backplane. All the outputs are connected to the loop supply.
6-3
AO Module 5V - logic Regulator 24V
FLASH 4-20 ma out
Channel 1
D/A 1
OPTO
uC
Powered from field 24V supply
FPGA I/O Bus
Channel 8
4-20 ma out
D/A 8
OPTO
Diagnostics
6-4

Error Condition RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) Calibration Error (channel 1 to 8) Code 0x22 0x23 0x24 0x25 0x26 0x32 0x41 0x48
Resolution Rise Time Temperature Sensitivity Accuracy Span Calibration Load Impedance Input Power (from 24V system supply) 12 bits 750 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of reading .05% of span at 25oC 4 to 20 mA. Self-calibration on power up with calibration jumper set 0 800 Ohms 175 mA
6-5
Field Wiring
P2 1 Iout
Load
Channel 1
2 Return 3 Iout
Load
4 5 Iout
Channel 2
Return
Load
6 7 Iout
Channel 3 Return Channel 4
Load
8 Return 9 Iout
Load
10 11 Iout
Channel 5
Return
Load
12 Return 13 Iout
Channel 6
Load
14 Return 15 Iout
Channel 7
Load
16
Channel 8 Return
6-6
Field wiring for redundant modules with common end element
Current Loop Controlled Device
(+)
(-) Primary IOP320 AO Module W2 not installed W3 not installed W4 - not installed
(+)
(-) Secondary IOP 320 AO Module W2 not installed W3 installed W4 not installed
6-7
Chapter 7
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331
Overview
These modules feature 16 digital common inputs.
LED Indication
Individual red front-panel LEDs provide the input status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being

scanned by the DPU. A second green LED provides the status of the loop power fuse disconnect.
Bus Address
This module requires one bus address. The address range for digital input modules is 0 to 31 (0 1F). The address range for digital input modules configured as slow DIs is 32 to 254.
Module Operation
The following is a simplified sketch of the circuit for one channel. The signal-conditioning block provides filtering, current limiting circuit, and an input threshold. It also includes the input status LED. The optical isolator provides isolation between the field circuits and the logic circuits. The input status is buffered and latched in the I/O bus interface circuit. The data is presented to the I/O bus as a 16-bit word when the module is scanned by the DPU. A watchdog timer in the I/O bus interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds. The 24V/48V(+) and 24V/48V(-) loop power signals are connected to all the channels. They are routed to the module from the backplane via a fuse disconnect which is accessible from the front of the module.
24V/48V(-)
24V/48V(+)
Fuse disconnect
Signal Conditioning Circuit
I/O BUS Interface Circuit
To other channels
7-2
Rated Input Voltage Input current per point On-State Voltage Isolation User input to logic Indicators IOP 330 24V IOP331 48V 24Vdc nominal, 40 Vdc 48Vdc nominal, 60V dc maximum maximum 5 mA @ 24 Volts 5 mA @ 48 Volts 8.5 Volts 22 Volts 250 VAC continuous, 1,500 VAC for 1 minute 1 LED per point provides status indication. LED provides power and communication indication. LED provides loop power disconnect status One address 50 mA
I/O Bus Address Input Power (from 24V system supply)
7-3
Field Wiring
P2 1 2 3 4 5 6 7 8 9 10 11 12 Channel 6 13 14 15 11 16 Channel 8 Channel 7 Channel 5 Channel 4 8 9 10 11 12 Channel 14 13 14 15 11 16 Channel 16 Channel 15 Channel 13 Channel 3 Channel 2 Channel 1 2 3 4 5 6 7 Channel 12 Channel 11 Channel 10 1 Channel 9 P3
7-4
Field Wiring For Redundant Modules with Common DI
(+)
(-) Primary IOP30,331 DI Module
(+)
(-) Secondary IOP 330,331 DI Module
7-5
Chapter 8
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333
Overview
These modules provide16 isolated digital inputs
LED Indication
Individual red front-panel LEDs provide the input status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating

with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module requires one bus address. The address range for digital input modules is 0 to 31 (0 1F). The address range for digital input modules configured as slow DIs is 32 to 254.
For IOP332 and IOP333, jumpers (W1W16) must be installed for AC inputs. Note: IOP334 does not include jumpers.
Module Operation
The following is a simplified sketch of the circuit for one channel. The signal-conditioning block provides filtering, current limiting circuit, and an input threshold. It also includes the LED. The optical isolator provides isolation between the field circuits and the logic circuits. The input status is buffered and latched in the I/O bus interface circuit. The data is presented to the I/O bus as a 16-bit word when the module is scanned by the DPU. A watchdog timer in the interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds.
Input Voltage
Signal Conditioning Circuit
I/O BUS Interface Circuit
8-2
IOP 332 120V 120 Volts ac/dc nom. Rated Input Voltage 180 Volts max Input current per 5 mA @ 120 Volts point On-State Voltage 48 Volts dc Isolation User input to logic Isolation Channel to channel Indicators IOP333 240V 240 Volts ac/dc nom. 280 Volts max 5 mA @ 240 Volts IOP334 24V 24V dc nominal, 40V dc max 5 mA @ 24Volts
70 Volts dc 8.5 Volts dc 100 Volts ac 60 VAC; 250 VAC continuous, 125 VAC; 1500 VAC for 1 minute
350 VAC continuous
1 LED per point provides status indication LED provides power and communication indication One address 50 mA
I/O Bus Address Input Power (from 24V system supply)
8-3
Field Wiring
P2 1 AC/DC 2 3 AC/DC 4 5 AC/DC 6 7 AC/DC 8 9 AC/DC 10 Channel 5 11 AC/DC 12 Channel 6 13 AC/DC 14 15 AC/DC 11 16 Channel 8 AC/DC Channel 7 AC/DC AC/DC AC/DC Channel 4 AC/DC Channel 3 AC/DC Channel 2 AC/DC Channel 1 AC/DC 1 2 3 4 5 6 7 8 9 10 Channel 13 11 12 Channel 14 13 14 15 11 16 Channel 16 Channel 15 Channel 12 Channel 11 Channel 10 Channel 9 P3
8-4
Field Wiring For Redundant Modules with Isolated DI

(+)
(-)
AC/DC
Primary DI Module
(+)
(-) Secondary DI Module
8-5
Chapter 9
Digital Input Modules Counter Timer Module IOP335
This module provides eight isolated digital input channels. Each channel provides a pair of digital inputs, which can be individually programmed to support 24, or 48 Volt inputs.
Features Software stored in FLASH Low Power Dissipatioin Configuration per channel
LED Indication
A red status LED is provided for each input. A green LED, labeled Active on the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module only requires two bus addresses and provides 8 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules. This module is compatible with DPU4E and DPU4F only.
A two-position jumper is used to select the input voltage for each input. The input number identifies the jumpers. The two positions are A and B as follows:
Jumper W1A - 16A Installed 24 V Not Installed 48V
This microprocessor-based module supports up to eight pulse input channels. Each channel can be independently configured for both function type and debounce time. The functions supported are: Mode 1 Frequency Input Frequency in counts per second in input1. Input 2 is not used. The Pulse I/O Buffer in DPU4E supports the following timebase mode selections for frequency measurement: 20 msecs, 50 msecs, 100 msecs, 250 msecs, 500 msecs, and 1 second. For the selected timebase, the Pulse I/O module measures frequency for the specified duration and normalizes each measurement to cycles per second. The measurement is updated at the end of each interval and the counts read by the DPU when the module is scanned represent the average of the last four measurements in cycles/second. The scan rate of the DPU is asynchronous from the scan rate by the module. The accuracy of the frequency measurement is +/-1 count for the one-second timebase. The accuracy for the other timebases is approximately the normalizing multiplier divided by 4. Thus for the shortest timebase (20 msecs), the accuracy is reduced to approximately +/-12 counts. In applications requiring fast frequecy measurements, a period measurement (mode 7) can also be used to measure frequency. Since each count in the period measurement corresponds to 0.5 microseconds, the inverse of the period will yield a fast frequency measurement with an accuracy of 0.1% for a 2000Hz input and 0.25% for a 5000Hz. Mode 2 Simple Event Counter (default configuration)
9-2

32 bit accumulation of OFF-to-ON transitions in input1. Input2 provides an external accumulator reset. Mode 3 Up/Down Event Counter Net counts of OFF to ON transitions in input1 and input2. Input1 counts up and input2 counts down. Mode 4 On-Time Timer The timebase frequency (0.5 usec/count) is counted while input1 = ON. Input 2 provides an external reset. Mode 5 Up/Down Pulse Timer Counts corresponding to the on-time difference in input1 and input2. The timebase frequency (0.5 usec/count) is counted up while input1 = ON and counted down while input2 is ON. Mode 6 Pulse Width ON time of last detected pulse in input1, based on the timebase frequency (0.5 usec/count). Input2 is not used. The measurement is updated at the end of each detected pulse (ON to OFF transition). Counts read by DPU represent the average of the last four measurements. Mode 7 Period Time duration between the last onset of input1and the previous onset of input1. The timebase frequency (0.5 usec/count) is counted during this time. Input2 is not used. The measurement is updated at the end of each detected period. Counts read by DPU represent the average of the last four measurements.
Module Operation
This microprocessor based module supports up to 16 digital inputs. As shown in the functional block diagram, the field circuits are used to detect and optically isolate the digital inputs. High-speed optical isolators support higher frequency inputs. The processor circuits implement the configured timing functions and provide the interface to the I/O bus FPGA. The Time Processor Unit (TPU) included in the 68332 processor is used to process the timing functions. The TPU operates from microcode masked in 68332 ROM. The 16 DI inputs are debounced in an FPGA and are available individually to the processor TPU inputs.
9-3
Diagnostics
The module executes diagnostics on power up. To indicate any errors detected during power-up or on-line operation the LED labeled active blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation this LED stays on or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on) Code 0x22 0x23 0x24 0x25 0x26 0x32
Input voltage Input thresholds Debounce Accuracy Maximum frequency Minimum Pulse Width Common Mode Voltage Input Power (from 24V system supply) 24V, 48V jumper selectable 24V 10 Volts 48V 20 Volts 0-255 msec dynamically configured per channel 1 cycle or 0.15%, whichever is greater 32KHz 10 usecs 240Vac rms, 350V dc peak 150 mA
9-4
Field Wiring
P2 1 + 2 Channel 1 + 5 + 6 Channel 2 + 9 + 10 Input 5 Channel 3 + 13 + 14 Channel 4 + 15 11 16 Input8 Input 7 Channel 8 + 11 16 Input 16 15 + 14 Input 15 11 12 Input 6 13 Channel 7 + 11 12 Input 14 + 10 Input 13 7 8 Input 4 Input 3 Channel 6 + 9 + 6 7 8 Input 12 Input 11 3 4 Input 2 5 Input 1 + 2 Channel 5 + 3 4 Input 10 1 Input 9 P3
9-5
Chapter 10
Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350
Overview
These modules provide 16 Form A relays or 10 form C relays. The form A outputs can be converted to form B via on-board jumpers.
LED Indication
Individual red front-panel LEDs provide the output status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module requires one I/O one bus address. This module requires one bus address. The address range for digital output modules is 32 to 254. Addresses 0 to 31 are reserved for digital input modules.
Jumper W1 configures all the outputs to either reset or fail in place when there is no communications in the I/O Bus for more than 0.7 seconds. Configuration is as follows:
Jumper W1 Position 2-3 Reset Output Position 1-2 Hold Output
For the IOP351 module, each channel can be strapped in the printed circuit assembly for form A or form B operation per the following table. The default configuration is form A for all channels.
Channel Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Form A R100 R103 R106 R108 R111 R114 R116 R119 R122 R124 R127 R130 R132 R135 R138 R140 Form B R101 R104 R107 R109 R112 R115 R117 R120 R123 R125 R128 R131 R133 R136 R139 R141
Module Operation
The following is a simplified sketch of the circuit for one channel. The relay drivers energize the relay coils and control the operation of the output LEDs to correspond to the data in the I/O bus interface circuit. A watchdog timer in the interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds. It also controls the state of the outputs on loss of communications.
10-2
Digital Output Modules Form A/B of Relay Module IOP351 Form C Relay Module IOP350
5V Reg 24V
Channel 1
BUFFER
I/O Bus Interface Circuit
I/O Bus
Channel 16 PROM
Maximum Switching Capacity Number of Channels Expected Relay Life Maximum Operating Speed Operating Time Release Time LED Indication I/O Bus Address Input Power (from 24V system supply) IOP 350 Form C IOP351 Form A/B 5 amps @ 250 VAC 3 amps @ 30 VDC 0.3 amps @ 110 VDC 10 16 Mechanical @ 180cpm - 5X10^6 Electrical @ 20cpm (resistive load) 10^5 20cpm 15 msec. Maximum (excluding bounce) 5 msec. Maximum (excluding bounce) 1 LED per point provides output status indication active LED provides power and communication indication One address 400 mA
10-3
5V
Reg
24V
Channel 1
BUFFER
I/O Bus Interface Circuit
I/O Bus
Channel 16 PROM
10-4
Field Wiring IOP 351

P2 1 Channel 1 2 3 Channel 2 4 5 Channel 3 6 7 Channel 4 8 9 Channel 5 10 11 Channel 6 12 13 Channel 7 14 15 Channel 8 11 16 Channel 16 Channel 15 Channel 14 Channel 13 Channel 12 Channel 11 Channel 10 Channel 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 16 P3
10-5
Wiring IOP350
P2 1 Channel 1 2 Channel 6 3 4 5 Channel 2 6 7 8 Channel 3 9 10 11 Channel 4 12 13 14 Channel 5 15 11 16 Channel 10 15 11 16 Channel 9 12 13 14 Channel 8 9 10 11 Channel 7 6 7 8 3 4 5 1 2 P3
10-6
Field Wiring For Redundant Modules with Common End Element
Power Source Switched Device
(+)
(-) Primary Relay Module
W1 installed
(+)
(-) Secondary Relay Module
W1 installed
10-7
Chapter 11
Bus Extender Unit Module IOP371
Overview
The Bus Extender Unit (BEM) provides a flexible way to distribute the system throughout the plant, resulting in reduced cabling costs and installation time. Placing I/O in remote cabinets closer to a given process typically reduces tray loading and the number of required junction boxes since remote I/O cabinets are substituted. It also shortens wiring distances to field devices, such as thermocouples and RTDs.

BEM Front Panel
The BEM front panel contains a pair of optical connectors (optical transceivers), LEDs to report the status of the two optical links, a push button for link testing, and an output contact, used to detect and report the failure of either optical cable when redundant cables are provided (optional).
LED Indication
Individual green front-panel LEDs provide status indication for each channel. The lower LED, labeled Active at the bottom of the module front panel, is on when the BEM and its associated DPU are active. The LEDs labeled link1 and link2 indicate which optical link is operational.
Link Test
A link test pushbutton is provided to switch operation between the two optical links. This can be used to verify that the two links are operational.
Bus Address
This module does not require a bus address.
The module contains two jumpers located in the bottom right corner of the board. Refer to the following table for jumper setting information.
Jumper W1 W3
Installed Remote Redundant
Not Installed Local Common
Bus Extender Modules, configured in pairs, support both locally and remotely mounted I/O cards. The local BEM installed with the DPU plugs into the I/O backplane to access the DPU's parallel I/O bus. Locally mounted I/O can share the I/O bus with the BEM. The remote BEM receives the bus data over the optical link and establishes the I/O bus at the remote location. A single DPU, or redundant pair of DPUs, can communicate with I/O modules that are locally and/or remotely mounted. In a typical configuration using redundant Distributed Processing Units (DPUs), an I/O cabinet
11-2

installed locally in a control room contains I/O modules, a DPU pair, and a BEM pair. This is connected via I/O optical cables to a ruggedized remote cabinet containing I/O modules and a second BEM pair. The optical link is established between the local and remote Extender modules as shown in figure 11-1.
D P U D P U
Local I/O Bus

Y Cable B E M I / O I / O Optical Links I / O Optical Links I / O B E M
B E M
B E M
Remote I/O Bus
I / O
I / O
Figure 11-1. Optical Link between Local and Remote Extender Modules
Multiple BEMs can be connected to the I/O bus to allow multiple remote locations for I/O. When multiple BEM modules are connected to different parts of the system, all BEMs connected to a DPU must share the same I/O bus as the DPU, as shown in figure 11-2. See also, "Redundant Configuration Approaches."
11-3
Local Model IOP I/O Bus - Up to 60 BEMs and/or I/O Modules I / O I / O D P U
B E M
B E M
B E M
Redundant Optical Links
Remote I/O Bus Area 1 Up to 45 Modules
Figure 11-2. The DPU Supports up to 60 Modules Locally and Up to 45 per Remote Location.
In addition to the configuration described in Figure 11-1, BEMs may be nonredundant, and configured with redundant or non-redundant DPUs. All options are possible. See " Redundant Configuration Approaches."
DPU Compatibility
The Extender is compatible with 4A, 4B and 4E DPUs, but is not compatible with the earlier DPU3, DPU4 or controller file models. To use a bus Extender with DPU 4A and 4B, firmware EPLD may need to be updated. Contact Metso Automation Customer Care for assistance.
I/O Bus Loading

BEMs may also be used to expand the number of I/O modules that may be configured locally. The local BEM represents the same bus loading as one I/O module, regardless of the number of I/O modules attached to the remote I/O bus. Without the use of BEMs, a single DPU supports up to 60 modules. When BEMs are used, a DPU could support up to 60 modules locally and up to 45 modules (including a remote BEM) at each remote location. The DPU supports a maximum of 255 I/O addresses (local + remote modules). Important: Remember other factors limit the number of modules you may configure, such as I/O mix, DPU loading, application requirements, etc. Such
11-4

sizing factors need to be considered when planning I/O configurations. See also "BEM Configuration Considerations."
BEM Operation
Each Extender module is packaged in a Model IOP I/O style printed circuit board. Each board contains a chipset that includes a transmitter, receiver and an optical transceiver. The transmitter converts the parallel data into serial data, appends encoded error checking bits and sends the data serially over a very fast fiber optic link (160 MBaud). The receiver decodes the serial data, does error checking and converts the data back to the original parallel form. The Extender also includes the buffers/darlingtons associated with the Model IOP bus, bosfet switches to disconnect the backup DPU Extender from the bus, and a CPLD to provide some small additional logic required to support the operation of the chip set. The MACK condition (multiple modules on the bus) is detected by the remote Extender transmitted over the link and simulated locally for interpretation by the DPU. Figure 11-3 shows a functional block diagram of the Bus Extender Module. Operation is as follows: I/O Bus Interface Buffers to duplicate both the DPU and I/O module bus interface. The ACK signal from the module is detected at the remote end transmitted by the link and simulated at the DPU end. CPLD provides all the logic resources required by the link. This includes latching and synchronizing the bus data to the frame clock, error detection and link failover. Transmitter (Serializer) Converts a snapshot of the parallel bus data into 160Mb TTL level serial stream. Receiver (Serializer) Converts the received TTL level serial stream into parallel data. Frame Clock 8 MHz clock initiates the serial conversion of the I/O bus data. Thus a snapshot of the Model IOP bus is sent every 125 nsecs. This corresponds to a serial speed of 160Mb of the optical transceivers.
11-5
Local Area
Primary DPU
OUT/IN LO/HI ADDR DATA LATCH INT
Remote area
Local Bus Expanders

Transmitter
Fiber
Remote Bus Expanders

Receiver
B u f f e r s
M A C K
CPLD
Redundant Fiber Optic Transceiver
DATA[8..0]
CPLD
M A C K Transmitter
Fiber
Receiver
ACK XACK
B u f f e r s
Remote 564 Bus
OUT/IN LO/HI ADDR DATA
ALT_IN LATCH
Status Secondary DPU
INT
DATA[8..0] OUT/IN LO/HI Receiver ADDR DATA LATCH INT
Fiber
B u f f e r s
M A C K
Transmitter
B u f f e r s
ACK XACK ALT_IN
CPLD
CPLD
M A C K
DATA[8..0]
Fiber
Transmitter
Receiver
ACK XACK ALT_IN
Status
Figure 11-3. BEM Functional Block Diagram
Optical Transceivers Convert the TTL level transmit serial data into an optical signal and the received optical signal into a TTL level serial data. A second transceiver supports redundant links for single DPU applications. The transmitter/receiver chip pair detects the operational state of the active link. On power-up transceiver 1 is selected. If a failure is detected, the circuit will switch the link to transceiver 2, a digital output will be set and an LED will
11-6

identify which link is operational. If the link cannot be established using transceiver 2 the circuit will go back to transceiver 1 and the sequence will repeat indefinitely until the link is established. Power on reset The power on reset circuit includes a watchdog timer to monitor the operation of the CPLD.
Optical Cabling
The two front-accessible optical transceivers, designated Link 1 (top link) and Link 2 (bottom link), each have two ST type connectors, one to transmit (Tx) and the other to receive (Rx). The fiber optic cable connects the transmit output of one BEM to the receive input of the other BEM. Multimode 62.5-micron cable is used to connect the local and remote Extender modules. Cable is run between the redundant optical transceivers to support redundant optical cable pairs. If redundant cables are provided, one cable pair is always active while the second pair serves as a hot standby link. See "Ensuring Link Availability.
Model 564 and maxPAC I/O Compatibility

Because the Extender module has the same form factor as the Model IOP I/O modules, it can be used in either Model 564 or maxPAC applications. The module installs in an IOP015 4-pack I/O Chassis or any of the maxPAC chassis described in chapter 1.
Termination Requirements
Two terminations are required on each electrical I/O bus segment; one at each end of the bus. This rule applies to the local I/O bus (the bus segment that contains the DPU) as well as to all remote I/O busses (bus segments that contain only the BEM and I/O modules). The DPU itself acts as a terminator so one Terminator card (CPO402) is required on the other end of the DPU local bus segment. The Local BEM does not require any more termination than this. The Remote BEM I/O bus segment does not contain a DPU. Thus, two terminator cards (CPO402) are required one plugged in to each end of the Remote BEMs electrical bus. See the figure titled Termination of Local and Remote BEM Busses.
11-7
D P P11 U
P9 P10 P11
Terminator
P9 P10
P11
D P U
P9 P10 P11
B E M
P9 P10
P11
B E M
P9 P10
Fiber Optic Cables
Terminator
P11
P9 P10
Figure 114. Termination of Local and Remote BEM Busses
Redundant Configuration Approaches

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

Redundant DPUs and redundant BEMs may be employed in any of the following configuration schemes: 1. 2. 3. 4. Remote I/O only (redundant, common or mixed). Remote I/O and local redundant I/O. Remote I/O and local common I/O. Remote I/O and mixed local I/O consisting of common and redundant configurations.
Configuring Remote I/O only

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

In a redundant DPU configuration using local common I/O (configuration scheme No. 3), the I/O bus active control signal from each DPU must be
11-8

connected to its associated BEM only. A special cable (Part No. 047374) must be used to connect the local I/O bus between the racks housing each DPU. When this cable is used, jumpers in the following module types must be set up for common I/O as follows: Analog Output W4 installed Thermocouple W2 installed RTD W2 installed
Configuring Mixed Common and Redundant I/O

Configurations with mixed redundant and common I/O can be used at either the local or remote end. The I/O bus from each DPU at the local end or each BEM at the remote end is connected separately to the redundant modules. A mixed backup adapter, (Part No. 080441) is used to combine the redundant I/O buses into a common I/O bus. See Figure 11-4. At the remote location, the I/O bus connections to the BEMs end must be isolated only for redundant I/O applications. For common I/O applications the two remote BEM modules, connected to primary and secondary DPUs, are connected to the same Parallel I/O backplane or daisy chained Parallel I/O backplanes.
11-9
D P U B E M
backplane
Y CABLE
D P U B E M
backplane
Control Room
I O
I O
I O
I O
Optical Cable
I O
I O
I O
I O
B E M I O I O I O
B E M I O I O
Remote location
I O
I O
I O
I O
I O
I O
I O
I O
I O
Figure 11-5. Redundant DPUs with local common and remote common I/O configuration using Y cable.
Single DPU Configurations

For configurations using a single DPU, setup schemes as described in "Four Configuration Approaches" still apply. However, the special cabling used in redundant configurations is of course not needed. This applies to Part No. 04374 and the mix cable adapter. Additionally, special jumper considerations as listed in "Configuring Local Common I/O" do not apply. See Figure 11-5.
11-10
backplane
D P U B E M I O I O Control Room B E M
To other Locations
Optical Cable
I O
I O
I O
I O
Optical Redundant Cable
B E M
I O
I O
I O
Remote location
I O
I O
I O
I O
Figure 11-6. Single DPU with common and remote I/O configuration. The redundant optical cables shown in this illustration are optional but recommended.
11-11
BEM Configuration Considerations

Communication between the DPU and the remote I/O occurs in real time using the existing Model IOP protocol. The remote I/O modules communicate with the DPU, as if they were local I/O. Extenders are transparent to the bus. Although the BEM extends the Model IOP I/O bus up to 2000 meters, a time delay factor reduces the maximum number of I/O modules that may be installed beyond 400 meters. The time delay in the Extender circuit is minimal; however there is a delay in the optical cable, introduced by the speed of light, which is proportional to distance (approximately 1 x 10-9 sec/ft). In configurations using a cable link no more than 400 meters in length, I/O module reduction is minimal. See "Calculating Link Capacities."
Calculating Link Capacities

While as noted, a DPU supports up to 45 modules per remote location, a link delay that is proportional to distance is introduced by the speed of light. The Extender circuits themselves introduce very little delay. The distance factor primarily limits the number of Digital Input modules set for SOE operation since they must be scanned every 1 msec. An IO Bus Configuration Limits utility is provided to calculate the effect of link distance on the number of modules and scan rate supported by the DPU. Refer to Publication 278609 (System Resources Guide) for a description of this program. Links can be connected in series or in parallel, the preferred configuration approach. In a parallel link, a star approach, each remote location's BEM is connected to a BEM located on the electrical bus with the DPU. In a series link, the links can be configured such that one BEM and DPU connects to a remote's BEM and its rack. This rack then contains another BEM, which is then connected to a second remote's rack with its BEM. This configuration approach introduces time delays, which will limit the number of supported modules. Consult the factory if more than two links are on one DPU.
11-12
Ensuring Link Availability

To ensure link availability, installations may include multiple levels of redundancy. In configurations using only a single DPU, redundant cables ensure availability. The loss of either cable pair will automatically route the signal to the alternate cable pair. Only a momentary loss of the remote I/O, (milliseconds), will occur while the Extender switches over to the inactive cable. To ensure optimal availability, each cable pair should be routed separately to minimize the probability of damage to both cables. With separate cables, in the event a cable should break or fail, a second cable is still available. In configurations using redundant DPUs, each DPU can have its own bus Extender to the remote location. Any single failure of the Extender or cable will not result in loss of operation, and the replacement of the failed component can occur without loss of service. A failure in the remote location will only affect the remote I/O modules associated with the remote Extender. Refer to the front-panel LEDs and digital output to identify fault conditions detected by the link, specifically loss of lock and receive error.
Detecting Failover Conditions

A Form C relay is provided to indicate a link failure. When a BEM experiences a failover between the redundant links, a momentary relay closure occurs. Attach the DI Contact on module front panel to a Digital Input Module to monitor this logic output. The module produces a logic output to indicate and report the occurrence of an optical link failover or link failure. Use a front panel pushbutton to test the redundant links. The pushbutton initiates a failover between the two links.
Cabling Recommendations
To augment cable reliability, Metso Automation recommends the following cabling practices: For configurations using either single or redundant pairs of BEMs, use two separate, four-fiber optical cables (Part No. CON064-LLLL). Attach one cable to Link 1 and the other cable to Link 2. As noted, route cables separately to minimize the possibility of damage to both cables. For each link connect two of the four available connector ends to the optical transceiver connectors. The two extra, unused fibers in each cable serve as spares in the event that the active fibers are cut or damaged.
11-13
Specifications
Model: IOP371 Bus Extender Module (Part No. 181500) Distance: Up to 2000 meters Speed: Maintain Model IOP I/O bus communications I/O addresses: Up to 255 unique I/O addresses per DPU Link bus loading: One module Number of I/O Modules Per Location: On the DPU Local Bus: 60 maximum including local BEM(s) On Each Remote BEM Bus: 45 maximum including remote BEM Approval Bodies and Standards The product meets SAMA PMC33.1 EMI/RFI specs at three different frequencies, and is designed to meet IEC 801-2 static specification (8,000 Volts). Power Requirements 24 Volts @0.5 amps Environment The module operates in the temperature range of 0oC to 60oC at a relative humidity range of 0 to 90%, noncondensing. Optical cable 62.5/125 m multimode fiber optic cable CON062-LLLL Two- fiber optical cable CON064-LLLL Four-fiber optical cable Operating wavelength 1300 nm.
11-14
Chapter 12
QuadPAT Module IOP336 QuadPAT Termination Module IOP337
Overview
The maxPAC Quad Position Adjusting (QuadPAT) module in combination with the maxPAC Quad PAT termination assembly produces PAT increase and decrease outputs (120V or open collector) for single phase AC drive units or three-phase power switches. The module accommodates 1000-ohm slidewires or two-wire rotary position sensors. In addition, the maxPAC Quad PAT termination includes the DI circuits for sensing the drive unit limit switches.
Features Self-calibration on power up Software stored in FLASH Field to logic Isolation Channel-to-channel Isolation Fast scan time
Front Panel
The QuadPAT front panel contains bicolor LEDs to report the status of the increase and decrease outputs and limit switch for each channel and also LEDs for module status indication. It also includes the two I/O connectors. The top connector includes all the digital I/O and the analog signals are available at the bottom connector.
LED Indication
A pair of bi-color LEDs provides I/O state indication for each QuadPAT channel. The DO is the first LED of the pair and the DI is the second LED. For normally closed limit switches (open at a limit) the LED indication for each digital input and digital output pair is as follows:
LED Output Output Limit Limit Limit Limit Color Green Red Green Red Amber OFF Description Decrease Increase Decrease Limit Increase Limit No limit No Power
For normally open limit switches the LED indication is as follows:

LED Output Output Limit Limit Limit Limit Color Green Red Green Red OFF OFF Description Decrease Increase Increase Limit Decrease Limit No limit No Power
In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
Refer to the following table for the jumper setting information that is applicable to this module. Bold indicates the default position of the jumper.
12-2
QuadPAT Module IOP336 QuadPAT Termination IOP337

Jumper W1 W2 W3 W4 W5 W6 Installed Backup Ignore Limit Common I/O QuadPAT Not Installed Not Used Primary Not Used Stop on Limit Redundant Other
Channel 1
Jumper W11 W12 W13 W14 W15 W16 W17 Slidewire A C A Installed A Installed Not Installed Rotary sensor B A,B B Not Installed Not Installed Not Installed Installed
Channel 2
Jumper W21 W22 W23 W24 W25 W26 W29 Slidewire A C A Installed Installed Not Installed A Rotary sensor B A,B B Not Installed Not Installed Installed Not Installed
Channel 3
Jumper W31 W32 W33 W34 W35 W36 W37 Slidewire A C A Installed A Installed Not Installed Rotary sensor B A,B B Not Installed Not Installed Not Installed Installed
Channel 4
Jumper W41 W42 W43 W44 W45 W46 W49 Slidewire A C A Installed Installed Not Installed Installed Rotary sensor B A,B B Not Installed Not Installed Installed Not Installed
12-3
Bus Address
This module requires four bus addresses and provides four channels. Each module address must be a multiple of 4 (i.e. 32, 36, 40, 44, 56, etc.) in the range of 32 to 248. Addresses 0 to 31 are reserved for digital input modules. The two address rotary switches can be found at the upper right hand corner of the module above the edge connector as follows:
Most Significant Less Significant
DPU Compatibility
This module is only compatible with DPU4E and DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes eight analog inputs, four analog outputs, 8 digital inputs and eight digital outputs. Successive approximation 14-bit A/D converters digitize the input signals in microseconds. Sixteen-bit digital to analog output conversion also provides fast analog outputs. Both the analog inputs and analog outputs self-calibrate on power up. Optical isolation is provided between the field circuits and the logic. DC/DC converters provide isolated power to the A/D converters and analog output circuits. The microprocessor communicates serially with the field circuits via optical isolators. The analog outputs provide the reference for the slidewires. The analog inputs measure each slidewire feedback and reference. The digital outputs provide increase and decrease signals to the triac circuits, while the digital inputs monitor the state of the limit switches. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. A FPGA includes the I/O bus control logic and provides support logic for the other circuits.
12-4

+/-15V 24V
DC/DC
24V
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
D/A 2 channels Optical Isolation A/D 4 channels
5V
DC/DC
24V +/-15V
DC/DC RAM 64K Parity
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
FLASH 2Mbit
5V
DC/DC
68332G Processor 25MHz
CLOCK
DI1 DI8 Open Collector Drivers
FPGA I/O Bus Interface
I/O Bus
DO1 DOI8
Output Virtual Power
QuadPAT Termination
The IOP346 QuadPAT Termination interfaces with the QuadPAT module via cable CTO301. It is a DIN rail mounted assembly with two 16-point Eurostyle plugs providing the interface for the field connections. The QUADPAT module provides 24-volt power for the Termination circuits. The termination assembly provides the following functions: It provides four optically isolated TRIAC circuits. Each circuit includes a pair of TRIACs for the increase and decrease signals as well as the output suppression circuits
12-5

Each channel also includes digital input circuits to monitor the two limit switches associated with each channel. The state of the limit switches is provided to the DPU buffer.
Feedback Options
Slidewire: The bottom of the slidewire is connected to ground through a 100-ohm resistor to allow detection of an open slidewire. A reference current of 2 ma produces an approximate voltage range of 0.5 to 2 volts for the slidewire. Open wipers are detected through a pulldown resistor on the slidewire input. If a high or low signal reading is detected when the module is scanned by the DPU, outputs to the module from the DPU will be suspended. Rotary Sensor: Power to the sensor is supplied from the field 24V. The sensor 4-20ma signal results in a 0.4 to 2V signal across the internal 100 ohm sensing resistor. Overvoltage protection is provided for the 100 shunt. If a shorted sensor or an open circuit is detected by the DPU, outputs to the module are suspended.
Output Options
Single-Phase and Three-Phase Drive Units TRIAC outputs require the use of the termination assembly. DC Power Switch Open collector outputs are wired directly from the module, and the termination assembly is not required. A commoning strip is required for the ground connections to the individual power switches. No IEEE surge suppression is available for the open collector outputs.
Limit Switch Detection

The module detects the state of the drive unit limit switches via the termination assembly. For Normally Closed switches, the module inhibits drive unit motion when it detects an open limit switch in the direction of travel. The module will ignore the limit switches if jumper SW4 is
12-6

installed. If Normally Open contacts are used, jumper SW4 must be installed and any interlock while the limit is exceeded must be done in the control logic or external hardware. Note: The QPAT buffer includes status attributes (Out0xLimitHi or Out0xLimitLo) that represent the state of the High and Low Limit inputs. These inputs are normally wired to the limit contacts of the drive unit. The contacts are most often Normally Closed contacts and open when the limit is reached. In this case, when the contact is open (the limit exceeded) the status will be equal to one. If Normally Open contacts are used, the status attributes will be one and go to zero when the limit is reached (contact closed). The jumper on the card to ignore the limit does not affect these status attributes
Redundant Configuration
Standby Mode Standby mode is activated when a QUAD PAT module is one of a redundant pair in a backup configuration and its DPU is inactive. All outputs from the module will be suspended while in the standby mode. The slidewire reference is also disabled in the standby mode.
12-7

Jumper Positions Jumpers must be re-positioned to remove the 100-ohm slidewire end resistor and the open slidewire detection resistor from the circuit. See jumper table. These resistors must be mounted externally. Jumper W2 is set to designate one module as primary and the other as backup. Jumper W5 is removed from both modules to defeat force INT. Terminal Connections When using the Quad PAT modules in a redundant configuration all terminals must be wired in parallel. Backup transfer Bump The specified backup transfer bump is 0.2%. On insertion or withdrawal of an inactive module, up to a 1% temporary bump can occur and the drive unit will return to its original position within a few seconds depending on the stroke time of the drive. This bump can be avoided by disabling the ac power to the inactive module termination, while inserting or withdrawing the inactive module.
Diagnostics
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Error FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x33 0x35 0x36 0x37 0x38 0x39
12-8
Module Field Connections

P2 1 DEC1 (DO01) 2 INC1 (DO02) 3 HI LIM1 (DI01) 4 LO LIM1 (DI02) 5 DEC2 (DO03) 6 INC2 (DO04) 7 HI LIM2 (DI03) 8 LO LIM2 (DI04) 9 DEC3 (DO05) 10 INC3 (DO06) 11 HI LIM3 (DI05) 12 LO LIM3 (DI06) 13 DEC4 (DO07) 14 INC4 (DO08) 15 HI LIM4 (DI07) 16 LO LIM4 (DI08) 17 24V 11 18 GND Field Ground Return/4-20ma In 16 Feedback/Field 24V 15 Reference Out 4 14 Field Ground 13 Return/4-20ma In 12 Feedback3/Field 24V 11 Field Ground 9 Reference Out 3 10 Return/4-20ma In 8 Feedback2/Field 24V 7 Reference Out 2 6 Field Ground 5 Return/AI In 4 Feedback1/Field 24V 3 Reference Out 1 2 1 P3
12-9
Termination Field Connections Channels 1-2

Field P2 1 CH1 120V ac 2 CH1 ac neutral 3 CH1 ac neutral 4 CH1 Decrease 5 CH1 Increase 6 Hi Limit1 7 Limit Com 8 Lo Limit1 9 CH2 120V ac 10 CH2 ac neutral 11 CH2 ac neutral 12 CH2 Decrease 13 CH2 Increase 14 Hi Limit2 15 Limit Com 16 Lo Limit2 17 18 24V Logic Ground 16 15 14 13 12 11 10 9 8 CH2 Lo Limit 7 CH2 Hi Limit 6 CH2 Increase 5 CH2 Decrease 4 CH1 LO LIMIT 3 CH1 HI Limit 2 CH1 Increase P1 1 CH1 Decrease module
12-10
Termination Field Connections Channels 3-4

Field P3 1 CH3 120V ac 2 CH3 ac neutral 3 CH3 ac neutral 4 CH3 Decrease 5 CH3 Increase 6 Hi Limit3 7 Limit Com 8 Lo Limit3 9 CH4 120V ac 10 CH4 ac neutral 11 CH4 ac neutral 12 CH4 Decrease 13 CH4 Increase 14 Hi Limit4 15 Limit Com 16 Lo Limit4 17 18 16 CH4 Lo Limit 24V Logic Ground 15 CH4 Hi Limit 14 CH4 Increase 13 CH4 Decrease 12 CH3 Lo Limit 11 CH3 Hi Limit 10 CH3 Increase 9 CH3 Decrease 8 7 6 5 4 3 2 P1 1 module
12-11
Group1 Analog I/O Configuration

Slidewire P3 P3 Rotary Sensor
AO01(4-20ma) 1 W15
A B
AO01(4-20ma) 1 W15
A B
AO01(+/-10V) W11
A
AO01(+/-10V) W11
A
AuxAI01
B
AuxAI01
B
F1
W16 24VF1
W17
W16
F1
W17
24VF1 2 AI01
A C
A C
W12
B 100K
W12 AI01
B 100K
A B
W13 W14 therm shunt

F1
A B
W13 W14 therm shunt

F1
F1
F1
W29
AO02(4-20ma) 5 W25 W26
W29
AO02(4-20ma)
W25
A
W26
W21
AuxAI02 W21 24VF1
AuxAI02 24VF1
F1
F1 A
AI02 W22 W23

C B
AI02 W22 C
B
100K
A B
W23 7
A B
100K therm W24

F1
therm
W24
F1
shunt
8
F1
shunt
F1
12-12

Slidewire P3 P3 Rotary Sensor
AO03(4-20ma) 9 W15
A B
AO03(4-20ma) 9 W35
A B
AO03(+/-10V) W11
A
AO03(+/-10V) W31
A
AuxAI03
B
AuxAI03
B
F2
W36 24VF2
W37
W36
F2
W37
24VF2 10 AI03
A C
10
A C
W12
B 100K
W32 AI01
B 100K
11
A B
W13 W14 therm shunt

F2
11
A B
W33 W34 therm shunt

F2
12
12
F2
F2
13
W49
AO02(4-20ma) 13 W45 W46
W49
AO04(4-20ma)
W45
A
W46
W41
AuxAI04 W41 24VF1
AuxAI04 24VF2
F2
F2 A
14
AI04 W42 W43

C B
14
AI04 W22 C
B
15
100K
A B
W43 15
A B
100K therm W44

F2
therm
W44
F2
16
shunt
16
F2
shunt
F2
12-13
Digital I/O Configuration Channels 1-2 Single-Phase and Three-Phase Motors

P2 120 AC H N
DEC1
Termination
P1
P2
Module
1 2 3
4 1 1 DO01 2 3 2 DO02 3 DI01
INC1
HI LIM 1
6 7 8 4 4
DI02
LO LIM 1 9 H 120 AC N 10 11
M DEC212
5
INC2
5 DO03
13 6 7 6 7
DO04 DI03
HI LIM 2 14 15 16 LO LIM 2 18 18 8 17 8 17
DI04 24V GND
12-14
Digital I/O Configuration Channels 3-4 Single-Phase and Three-Phase Motors
P3 120 AC H N
DEC3
Termination
P1
P2
Module
1 2 3
4 9 5 9 DO05 10 11 6 10 DO06 11 12 DI06 8 9 DI05
INC3
HI LIM 3 COM LO LIM 3 H 120 AC
12
N 10 11
DEC4
12 13 13 DO07 14 15 14 15 DO08 DI07 16 DI08 17 18 17 24V 18 GND
INC4
13
HI LIM 4 COM LO LIM 4
14 15 16
16
12-15
Digital I/O Configuration - DC Power Switches

P2 Dec Power Switch Inc 1 DIO1 2 3 4 Dec Commoning Strip Power Switch Inc 5 DIO3 6 7 8 9 Power Switch 10 11 12 13 Power Switch 14 15 16 17 18 GND DIO4 DIO2 Module
DIO5 DIO6
DIO3 DIO4
24V
12-16
Specifications
TRIAC Outputs 120VAC: Maximum Voltage: 200 VAC Continuous on-state current: 2A On-state voltage: 1.6 VAC Off-state current: 3.5 mA Hold Current: 50 mA Open Collector Outputs Maximum Current: 100mA Maximum Voltage: 28VDC Maximum on-resistance: 0.2 ohms Power 24Vdc system supply Temperature Humidity Surge (TRIAC Outputs only) 400 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
12-17
Chapter 13
Turbine Valve Positioner Module IOP341 Turbine Valve Termination Module IOP342
Overview
The Turbine Valve Positioner module implements the logic for real-time closed loop control of a single turbine valve. The module provides two independent and electrically isolated channels. Each channel includes a coil drive output and a position feedback input normally receiving inputs from position transducers. Each channel also includes auxiliary inputs for loopback measurement of the output signal. In addition, a turbine speed input is provided as a service with the intent of bringing back three speed signals, one on each of three Turbine Valve Positioner modules for triple redundancy of speed input. The product consists of a maxPAC Positioning Module and a Turbine Valve Termination card. The Termination card provides both current and voltage outputs for characterizing the output for different coil types. It also provides signal conditioning for the frequency input. The logic shown in the following sketch is programmed in the maxDPU4F Atom Compiler language and may be modified by a trained engineer via tools provided. It is one of up to nine personalities that can be downloaded to the module and stored in flash memory. A cable is provided for downloading the configuration. Personality selection, the configuration Tuning constants for the PI loop, I/O status, and other signals are accessible via the maxDPU4F.
Pos
Valve Pos Mode Governor or Throttle Valve Position Demand
>
Pos
4-20 ma
Servo Amp
K+
Pos Err Coil(s) Status
Servo Amp
+/- 10 volt or +/- 40 ma
Turbine Speed
Freq
Speed
Positioner Front Panel

The Turbine Valve Positioner front panel contains LEDs to report the status of the digital inputs and outputs, and LEDs for module status indication. It also includes the two I/O connectors and a connector for the configuration cable.
13-2
Turbine Valve Positioner IOP341 Turbine Valve Termination IOP342
Features Self-calibration on power-up Software stored in FLASH Field to logic isolation Channel-to-channel isolation Fast Scan Time Fast slew rate Full complement of I/O Frequency inputs On-line diagnostics Downloadable personality
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip output and frequency input. Two bicolor LEDS, Stat 1 and Stat 2 provide diagnostic indication In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
13-3
The Turbine Valve Positioner module uses a multi-purpose-positioning module with multiple jumper options as its base. The base module has four AI/AO and eight DI/DO. Not all the jumpers are used for this application. Jumpers W1-W4 at the rear of the module are for factory test only and must not be installed. Refer to the following table for the jumper setting information that is applicable to this module. Bold indicates the default position.
Channel 1
Jumper W11 W12 W13 W14 W15 W16 W17 Position 4-20ma +/-10V B A, B B Not Installed A B OUT IN OUT IN
Channel 2
Jumper W21 W22 W23 W24 W29 W25 W26 Position 4-20ma +/-10V A C B Not Installed Not Installed OUT IN OUT IN
Channel 3
Jumper W31 W32 W33 W34 W35 W36 W37 Position 4-20ma +/-10V B A, B B Not Installed A B OUT IN OUT IN
Channel 4
Jumper W41 W42 W43 W44 W49 W45 W46 Position 4-20ma +/-10V A C B Not Installed Not Installed OUT IN OUT IN
13-4

Refer to the following table for the Turbine Valve Termination jumpers. W11 and W12 select the resistance in series with the +/-10V or 4-20 ma output from the Positioner module. W13 and W14 select the +/-40 ma output or the output selected in the Positioner module (4-20 ma or +/-10V). When the +/-40 ma output is selected, the +/-10V output must be selected in the Positioner module. Bold indicates the default position:
Jumper W1 W2 W11 W12 W13 W14
function Wetting Voltage Frequency Voltage Channel 1 Series R Channel 2 Series R V/I Out V/I Out
Installed Local 0.2 10V
Not Installed Remote 24V 210 ohms 210 ohms
160 ohms and +/-10V 160 ohms
and +/-10V
+/- 40 ma +/- 40 ma
100 ohms or 4-20ma 100 ohms or 4-20ma +/-10 volts or 4-20ma +/-10 volts or 4-20ma
Bus Address
This module consumes two bus addresses. The two address rotary switches can be found at the upper right hand corner of the module above the edge connector as follows:
DPU Compatibility
This module is only compatible with maxDPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes four analog inputs, four analog inputs, 8 digital inputs and eight digital outputs. Four auxiliary analog inputs are also included for diagnostic use. Successive approximation 14-bit A/D converters digitize the input signals in microseconds.
13-5

Sixteen-bit digital to analog output conversion also provides fast analog output current or voltage. Both the analog inputs and analog outputs self-calibrate on power up.
+/-15V 24V
DC/DC
24V
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
5V
DC/DC
24V +/-15V
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
FLASH 2Mbit
5V
DC/DC
CLOCK
FPGA
RS232
I/O Bus
DO1 DOI8
I/O Bus Interface
The analog I/O is separated into two electrically isolated groups as shown in the functional sketch. There is also optical isolation between the field circuits and the logic. DC/DC converters provide isolated power to the A/D converters and analog output circuits. The microprocessor communicates serially with the field circuits via optical isolators. Each of the four analog output circuits provides 4-20 ma. Two of the circuits provide 10 to +10 volt outputs. The A/D in each group has four inputs. Two of the inputs are used as auxiliary inputs for diagnostic monitoring of the analog outputs.
13-6

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

The IOP342 Turbine Valve Termination interfaces with the Positioner module via cable CTO302. It is a DIN rail mounted assembly with an 18point Euro-style plug providing the interface for the field connections. The Positioner module provides 24-volt field power for the Termination circuits. The termination assembly provides the following functions: It coverts the +/-10V signals to 0-2 volts plus sign to be fed to the module for diagnostic loopback. A voltage-to-current converter converts the +/-10V signals to 40 to 40 ma. Either voltage or current output is available via jumper selection. A current sense circuit measures the output current and provides a 0-2v signal proportional to the current to the I/O module. It conditions and isolates the frequency input and provides a 5-volt TTL compatible signal to the module.
Configuration
The Turbine Valve Module provides a serial port for downloading the configuration programs that are generated and compiled with the maxPAC Positioning Module Compiler Tool. Up to nine programs (personalities) can reside in the module FLASH. The interpreter code running in the module executes any one of the nine personalities selected via the DPU. A module personality typically defines an exchange of variable data between the DPU POS Buffer and the module I/O and other parameters defined in the module shell; it also includes the logic sequence that implements the required application. See the maxPAC Positioning Module Programming Guide.
Calibration
The Turbine Valve Module can be configured via on-board jumper selection to provide either a current or voltage output. The module is factory calibrated for 4-20 ma current outputs and the calibration constants are stored in FLASH. Calibration is only required when the FLASH program is upgraded.
13-7

The Module Compiler provides functions that allow the user to either override or restore the factory calibration values. When voltage outputs are used, the factory calibration values for channels 1 and 3 must be changed to 0 and 65535. This can be accomplished by setting AOLo and AOHi for the two channels in the first pass of the application program, or by downloading a calibration program that overrides the values stored in FLASH.
Diagnostics
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x35 0x36 0x37 0x38 0x39
The turbine valve module can also execute on line diagnostics to verify the integrity of the loop. This test must be defined in the personality program. The module shell includes four AOs (AO01-AO04), four AIs (AI01-AI04), four Auxiliary AIs (AuxAI01- AuxAI04), eight DIs (DI01-DI08) and eight DOs (DO01 DO08). These shell variables are associated with I/O signals at the module I/O connector. The bipolar analog outputs generated by the module are converted at the termination assembly to a 0-2V plus sign signal. As shown in the Group1 Analog I/O configuration sketches at the end of the chapter, the analog output from the module is buffered by the termination and fed back to AuxAI02. The coil current is fed back to AI02, while the sign is available as status DI02 (1 is negative). The personality program must define the input types to be 0-2V. Also the analog value read at those inputs must be sign adjusted. For example, the configuration program includes the following code to define the input types and adjust the sign.
13-8

If FirstPass AIType01 AIType02 AuxAIType02 EnableOutputs EndIf
= = = =
1 3 3 1
;4-20ma AI ;0-2V AI
If DI02 = 0 Coil1ACurRaw Coil1V Else Coil1ACurRaw Coil1V EndIf
= AuxAI02 = AI02 = AuxAI02 * -1.0 = AI02 * -1.0
13-9

P2 P3
1 DO1 2 DO2 3 DI1 4 DI2 5 DO3 6 DO4 7 DI3 8 DI4 9 DO5 10 DO6 11 DI6 12 DI7 13 DO7 14 DO8 15 DI7 16 DI8 17 24V 11 18 GND Voltage Feedback Voltage Feedback Ch 3-4 field Ground 4-20 ma input Ch 3-4 Field Power 4-20 ma or +/-10V out Voltage Feedback Voltage Feedback Ch 1-2 Field Ground 4-20 ma input Ch 1-2 Field Power 4-20 ma or +/-10V out
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
13-10
Termination Field Connections

Field P2 1 Coil 1 (+) 2 Coil 2 (-) 3 Chassis Gnd 4 Field 24V_1 5 4-20ma input 6 Coil 1 (+) 7 Coil 2 (-) 8 Chassis Gnd 9 Field 24V_2 10 4-20ma input 11 12 24V frequency 13 14 0.2-10V frequency 15 16 NO COM 11 18 NC Logic Ground 17 24V 11 Coil_2 Current loopback 12 13 DI2 (+/-10V_1 sign) 14 DI3 (+/-10V_2 sign) 15 DI1 (frequency) 16 DO1 10 +/-10V_2 loopback 9 4-20 ma or +/-10V out 8 Field Ret_2 7 Field 24V_2 6 Ch 1-2 Field Ground 5 Coil_1 Current loopback 4 +/-10V_1 loopback 3 4-20 ma or +/-10V out 2 Field Ret_1 P1 1 Field 24V_1 module
13-11

Termination Module
P2
P1
P3
W13
+/- 40 ma AO01(4-20ma)
50 62 50
50
W15
A B
AO01(+/-10V)
Current Sense W11
W11
AuxAI01
B
2
F1
Sign 1
Buffer
F1
24VF1 3 24VF1 4 24VF1 4-20 ma 6 3

A B
A C
W12 AI01
B 100K
W13 W14 therm shunt

F1
4
F1
F1
4 Output voltage
W29
AO02(4-20ma)
W21
AuxAI02 24VF1
F1
Output current
AI02 W22 W23

B
100K
A B
therm
W24
F1
shunt
F1
13-12

Termination Module
P2
P1
P3
W14
+/- 40 ma AO03(4-20ma)
50 62 50
50
W35
A B
AO03(+/-10V)
Current Sense W12
W31
AuxAI03
B
7
F2
Sign 2
Buffer
F1
24VF3 8 24VF2 9 24VF2 4-20 ma 12 11

A B
10
A C
W32 AI03
B 100K
10
W33 W34 therm shunt

F2
12
F2
F2
10 Output voltage
13
W49
AO04(4-20ma)
W41
AuxAI04 24VF2
F2
Output current
11
14
AI04 W42 W43

B
15
100K
A B
therm
W44
F2
16
shunt
F2
13-13
Digital I/O Configuration

Termination Module
P2
W1
P1
P2
24VF2 12 13
W2
15
DIO1
Sign 1
13
7 DIO3
14 15 Conditioning Circuit Sign 2 14 8 DIO4
16 17 18 17 17 16 2 DO02
24V
18
18 GND
13-14
Specifications
Turbine valve Outputs Analog +/- 10 VDC at 40 ma. or +/- 40 ma at 200 ohms max 4-20 ma (isolated 24V supplied from the system) Accuracy: +/-10V, 4-20 ma: 0.25% of full scale +/- 40 ma: +/-1% of full scale Resolution: 16 bits Slew Time: 5 msecs Digital Form C Relay 5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC Turbine valve Inputs Analog: 4-20 ma (isolated 24V supplied from the system) Accuracy: 0.15% Resolution: 14 bits Scan Time: 5 msecs
Frequency:
Frequency: 0 -10KHz Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz 50Kz. Input voltage: 200 mv. to 10V or 24V. Isolation Galvanic isolation between two analog I/O groups. Common mode between groups: 350V dc or peak ac Galvanic isolation between field and logic: 500V
RS232 Port: 9600 baud Power 24Vdc system supply Temperature Humidity Surge 500 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
13-15
Chapter 14
Overspeed Trip Module IOP345 Overspeed Termination Module IOP346
Overview
The Overtrip module measures and processes turbine speed from three separate tachometers based speed inputs without intervention from the DPU. If the overspeed logic determines that two out of the three inputs exceed a defined threshold, Trip contacts are energized to protect the turbine from an overspeed condition.
Raw Speed3
F
Raw Speed2
F
Turbine Speed Pulses
Raw Speed1
F
DPU
Median
Field
Runback Status Runback %
>
Runback Output
Median Speed Trip % Trip Status
>
Trip Output
The product consists of a maxPAC Overspeed Positioning Module and an Overspeed Termination card. The Termination card provides signal conditioning and isolation for the frequency inputs and also two form C relays.
The logic shown in the sketch is programmed in the maxDPU4F Atom Compiler language and may be modified by a trained engineer via tools provided. It is one of up to nine personalities that can be downloaded to the module and stored in flash memory. A cable is provided for downloading the configuration. Personality selection, the configuration, I/O status, and other signals are accessible via the maxDPUF.
Features Software stored in FLASH Field to logic isolation Fast scan time Fast frequency measurements On-line diagnostics Downloadable personality
Overspeed Front Panel

The Overspeed module front panel contains LEDs to report the status of the digital inputs and outputs, and LEDs for module status indication. It also includes the two I/O connectors and a connector for the configuration cable.
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip outputs and frequency inputs. Two bicolor LEDS, Stat 1 and Stat 2 provide diagnostic indication In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the
14-2
Overspeed Trip Module IOP345 Overspeed Termination IOP 346

module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
The Overspeed module uses a multi-purpose-positioning module with multiple jumper options. Not all the jumpers are applicable for this application because the analog I/O is not used. Refer to the following table for the jumper setting information that is applicable to this module.
Jumper W11 W12 W13 W14 W15 W16 W17
Position B A Not Installed Installed Not Installed Installed Installed
Jumper W21 W22 W23 W24 W25 W26 W29
Position B Not Installed Not Installed Installed Installed Installed Not Installed
Jumper W31 W32 W33 W34 W35 W36 W37
Position B Not Installed Not Installed Installed Not Installed Installed Installed
Jumper W41 W42 W43 W44 W45 W46 W49
Position B Not Installed Not Installed Installed Not Installed Installed Installed
Refer to the following table for the Turbine Valve Termination jumpers.Bold indicated the default positions:
Jumper W1 W2 W3 W4 W5 W6
function Wetting 1 Voltage Frequency 1 Voltage Wetting 2 Voltage Wetting 2 Voltage Wetting 3 Voltage Wetting 3 Voltage
Installed Local 0.2 10V Local 0.2 10V Local 0.2 10V
Not Installed Remote 24V Remote 24V Remote 24V
14-3
Bus Address
This module consumes two bus addresses.
DPU Compatibility
This module is only compatible with DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes four analog inputs, eight analog inputs, 8 digital inputs and eight digital outputs. The turbine overspeed application utilizes only the digital I/O portion of the module. The unused analog portion is shown with dashed lines in the functional sketch. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. The Time Processor Unit (TPU) included in the 68332 processor is used to process the frequency measurements. A FPGA provides support logic including parity and the I/O bus control logic.
14-4

Positioning Module
+/-15V 24V
DC/DC
24V
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
5V
DC/DC
24V +/-15V
4-20ma or +/-10V 4-20 ma 0-2.5V 4-20 ma 0-2.5V 4-20 ma
FLASH 2Mbit
5V
DC/DC
CLOCK
FPGA
RS232
I/O Bus
DO1 DOI8
I/O Bus Interface
Overspeed Trip Termination

The IOP346 Turbine Overspeed Termination interfaces with the Positioner module via cable CTO303. It is a DIN rail mounted assembly with an 18point Euro-style plug providing the interface for the field connections. The Positioner module provides 24-volt field power for the Termination circuits. The termination assembly provides the following functions: It provides signal conditioning and optical isolation for the three frequency inputs and provides 5-volt square waves to the module.
14-5

Two form C relay outputs are included.
Diagnostics
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x35 0x36 0x37 0x38 0x39
14-6

P2 1 DO01 2 DO02 3 DI01 4 DI02 5 DO03 6 DO04 7 DI03 8 DI04 9 DO05 10 DO06 11 DI06 12 DI07 13 DO07 14 DO08 15 DI07 16 DI08 17 24V 11 18 GND 16 15 14 13 12 11 10 9 8 7 6 Field Ground 5 4 24V Field Power 3 2 1 P3
14-7
Termination Field Connections

Field P2 1 24V frequency 2 3 0.2-10V frequency 4 5 24V frequency 6 7 0.2-10V frequency 8 9 24V frequency 10 11 0.2-10V frequency 12 13 NO 14 COM 15 NC 16 NO COM 11 18 NC Logic Ground 17 Logic Ground 16 24V 15 24V 14 DO02 P1 1 Field 24V 2 Field 24V 3 Field Ground 4 Field Ground 5 Frequency 1 6 7 Frequency 2 8 9 Frequency 3 10 11 12 13 DO01 module
14-8

Termination Module
P2
P1
P3
AO01(4-20ma) 1 W15
A B
AO01(+/-10V) W11
A
AuxAI01
B
F1
24VF1 2 24VF1 2
A C B 100K
W12 AI01
3 3
A B
W13 W14 therm shunt

F1
F1
F1
W29
AO02(4-20ma)
W21
AuxAI02 24VF1
F1
AI02 W22 W23

B
100K
A B
therm
W24
F1
shunt
F1
14-9

P2 Termination P1 P3 Module
AO03(4-20ma) 9 W35
A B
AO03(+/-10V) W31
A
AuxAI01
B
F2
24VF2 10
A C B 100K
W32 AI03
11
A B
W33 W34 therm shunt

F2
12
F2
13
W49
AO04(4-20ma)
W41
AuxAI04 24VF2
F2
14
AI04 W42 W43

B
15
100K
A B
therm
W44
F2
16
shunt
F2
14-10
Digital I/O Configuration

P2
W1
Termination 24VF2
P1
P2
Module
12 13
W2
3 DIO1
14 15 Conditioning Circuit
W3
24VF2 7 7 DIO3
12 13
W4
14 15 Conditioning Circuit
W5
12 13
W6
24VF2 9 11 DIO5
14 15 13 14 15 16 15 17 16 18 17 18 18 GND 17 24V Conditioning Circuit 13 2 DO02
14
6 DO04
14-11
Specifications
Frequency Input: Frequency: 0 -10KHz Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz 10KHz. Input voltage: 200 mv to 10V or 24V. Digital Output Form C Relay 5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC RS232 Port: 9600 baud Power 24Vdc system supply Temperature Humidity Surge 500 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
14-12
Chapter 15
HART Input Module IOP307 HART Output Module IOP322 HART Transceiver Module IOP364
Overview
The set of HART maxPAC I/O modules provide eight isolated HART channels with an independent HART modem/UART per channel. The analog input and output modules support standard 4-20 ma signals in addition to the digital HART data. The HART Transceiver card provides the same HART interface without analog input or output capability; it is intended for adding HART capability to other analog input or analog output modules.
H A R T
Features Fully isolated channels Hart modem per channel 16 bit A/D and D/A Performance Standard variables available in maxDPUF for use in control Custom interface for special purpose control Asset Management through Metso FieldCare Product line
Hart Module
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip outputs and frequency inputs. Two bicolor LEDS, Stat 1 and Stat 2 provide diagnostic indication In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
The following are the jumper settings for the various HART modules. Analog Output Module
Jumper W1 W2 W3 W4 W5 Installed MaxPAC-8 address * Hold Output Secondary Not used Common I/O Not Installed HART 2 address Reset Output Primary Not used Redundant I/O
* This is a compatibility mode jumper that configures the module to operate in 8-address mode like the non-HART maxPAC module. Analog Input and Transceiver Module
Jumper W1 W2 W3 W4 W5 Installed Not used Not used Not used Not used Common I/O Not Installed Not used Not used Not used Not used Redundant I/O
Bus Address
These modules normally consume two bus addresses. The HART Output module consumes eight addresses if set to be compatible with a standard maxPAC analog output module.
15-2
Hart Analog Input IOP307 Hart Analog Output IOP322 Hart Transceiver IOP364
DPU Compatibility
These modules are only compatible with DPU4F.
Module Operation
These microprocessor-based modules provide eight isolated channels of 4-20 ma inputs or outputs, including the HART interface for each channel. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. A FPGA provides support logic including parity and the I/O bus control logic. Optical isolators and a DC/DC converter per channel provide channel to channel and field to logic isolation as well as field power to each of the channels.
Eight UARTS provide the interface to the HART modems via the optical isolators. The transceiver module does not include the AI or AO circuits.
15-3
Hart Module DC/DC *** AI or AO Optical Isolation Hart Modem 24V
4-20 ma
UART (8)
I/O Bus Interface
I/O Bus
DC/DC *** AI or AO Optical Isolation Hart Modem 68332G Processor 25MHz *** Not included in Tranceiver Module
RS232 CLOCK
FPGA FLASH 2Mbit
4-20ma
RAM 64K Parity
Diagnostics
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault
Code 0x12 0x13
15-4
ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x35 0x36 0x37 0x38 0x39
15-5
HART Analog Input Field Connections

P1
1 24V 2 CH1 4-20 ma 3 4 GND 5 24V 6 CH2 4-20 ma 7 8 GND 9 24V 10 CH3 4-20 ma 11 12 GND 13 24V 14 CH4 4-20 ma 15 16 GND GND CH4 CH3 4-20 ma 11 12 GND 13 24V 14 4-20 ma 15 16 24V 10 GND 9 CH2 4-20 ma 7 8 GND 5 24V 6 CH1 4-20 ma 3 4 24V 2 1
P2
15-6
HART Analog Output Field Connections
P1
1 (+) CH1 4-20 ma in (-) 3 CH2 (+) 4-20 ma in (-) (+) CH3 4-20 ma in (-) 7 (+) CH4 4-20 ma in (-) 9 (+) CH5 4-20 ma in (-) 11 (+) CH6 4-20 ma in (-) 13 (+) CH7 4-20 ma in (-) 15 (+) CH8 4-20 ma in (-) 16 14 12 10 8 6 4 5 2
15-7
HART Transceiver Field Connections
P1
1 (+) CH1 (-) 3 (+) CH2 (-) 5 (+) CH3 (-) 7 (+) CH4 (-) 9 (+) CH5 (-) 11 (+) CH6 (-) 13 (+) CH7 (-) 15 (+) CH8 (-) 16 14 12 10 8 6 4 2
15-8
Transceiver to Analog Input Wiring Shared IO: Two-wire Transmitter
AI Module - IOP301
200 1A 1B
24V(+)
From Backplane
24V(-)
4-20 ma
2 Rs
+ Xmitter
1 1C Rp 100 1D 1E
A/D -
Transceiver Module - IOP361

1
HART MODEM
15-9
Transceiver to Analog Input Wiring Shared IO: Four-wire Transmitter
AI Module - IOP301
1A 1B
24V(+)
From 24V(-) backplane
200
4-20 ma
2 Rs
+ Xmitter
1 1C Rp 100 1D 1E
A/D -

1
HART MODEM
15-10
Transceiver to Analog Input Wiring Redundant IO: Two-wire Transmitter

(-) 24V (+) Supply AI Module - IOP301
24V(+) 24V(-)
From backplane
200 200 2 Rs
1A
1B
Xmitter
100 1 Rp 100 1D 1E 1C
+ A/D -
AI Module - IOP301
24V(+)
200 2 Rs
1A
1B
+
Rp 1 1C 100 1D 1E
A/D -

1
HART MODEM
2
15-11
Transceiver to Analog Input Wiring Redundant IO: Four-wire Transmitter

AI Module - IOP301
24V(+)
200 200 2 Rs
1A
1B
+ Xmitter
100 1 Rp 100 1D 1E 1C
A/D -
AI Module - IOP301
24V(+)
200 2 Rs
1A
1B
+
Rp 1 1C 100 1D 1E
A/D -

1
HART MODEM
2
15-12
Transceiver to Output Driver Wiring
Output Driver- IOP116 4-20 ma Output Device

17 16
D/A

1
HART MODEM
Transceiver to Analog Output Wiring

Analog Output IOP320 4-20 ma Output Device
2 1
D/A

1
HART MODEM
15-13
HART Analog Input Wiring

Two-WireTransmitter
4-20 ma 1 24V HART AI Module
TRANSMITTER 2
Disconnect for redundant module input

200 ohm
100 ohm shunt 4

To HART modem
TO A/D
Four-Wire Transmitter
1
NOT USED
24V
HART AI Module
Disconnect for redundant module input 4-20 ma Transmitter Power 2

200 ohm
TRANSMITTER 4
100 ohm shunt
TO A/D
To HART modem
15-14
HART Analog Input Wiring Redundant Modules: Two-Wire Transmitter

1
24V(+)
24V
HART AI Module
TRANSMITTER 2
Disconnect for redundant module input. On when DPU active 200 ohm
100ohm shunt 4 24V(-)

To HART modem
TO A/D
24V
HART AI Module
Disconnect for redundant module input. On when DPU active 2 200 ohm
4
To HART modem
100ohm shunt
TO A/D
15-15
HART Analog Input Wiring Redundant Modules: Four-Wire Transmitter

1
24V
HART AI Module
Disconnect for redundant module input. On when DPU active 2 Transmitter Power 200 ohm
TRANSMITTER 4
100ohm shunt
TO A/D
To HART modem
24V
HART AI Module
Disconnect for redundant module input. On when DPU active 2 200 ohm
4
To HART modem
100ohm shunt
TO A/D
15-16
HART Analog Output Wiring

HART AO Module Disconnect for redundant module input. Closed when DPU active 24V(+)
4-20 ma OUTPUT DEVICE
1 D/A
HART MODEM
2 24V(-)
Redundant Modules
Disconnect for redundant module input. Closed when DPU active HART AO Module 24V(+)
4-20 ma OUTPUT DEVICE
1 D/A
HART MODEM
2 24V(-)
HART AO Module 24V(+)
1 D/A
HART MODEM
2 24V(-)
15-17
Specifications
Channels per Module: 8 I/O Bus Address per Module: 2 Input Specifications Type: 4-20 ma Resolution: 16 bits, A/D per channel Scan time: 20 msecs. Accuracy: 0.15% of full scale. Normal Mode Voltage: 50 volts Normal Mode Rejection: 60 db @50/60 Hz Common Mode Voltage: 500 volts Common Mode Rejection: 120 db @50/60 Hz Isolation: Channel to channel and field to logic Output Specifications Type: 4-20 ma Accuracy: 0.25% of full scale. Resolution: 16 bits, D/A per channel Slew Time: 10 msecs Load: 250 600 ohms Common Mode Voltage: 150 volts Isolation: Channel to channel and field to logic HART Meets the HART Foundation physical layer requirements Power 24Vdc system supply Temperature Humidity Surge 500 ma 0-60 degrees C 0-90% non-condensing IEEE-472-1974
15-18

Max

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Max

Uploaded by

Copyright:

Available Formats

maxPAC Hardware Reference Guide

Metso Automation 278596

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

Metso Automation 278596

maxPAC Hardware Reference Guide

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

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

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

Metso Automation 278596

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

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

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

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

maxPAC Hardware Reference Guide

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

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

Metso Automation 278596

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

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

maxPAC Hardware Reference Guide

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

Metso Automation 278596

Metso Automation 278596

Model IOP I/O Subsystem

Metso Automation 278596

maxPAC Hardware Reference Guide

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

Metso Automation 278596

maxPAC Input/Output Subsystem

I/O Bus Connector Field 48V Field 24V

I/O Bus Connectors

Figure 1-2. Eight-Pack Rack

Figure 1-3. Six Wide Rack with DPU4E

Metso Automation 278596

maxPAC Hardware Reference Guide

Model Number IOP381 IOP382 IOP383 IOP015 IOP011,012

Metso Automation 278596

maxPAC Input/Output Subsystem

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

I/O Module Types

*ac Voltages/currents are RMS

Metso Automation 278596

maxPAC Hardware Reference Guide

Metso Automation 278596

maxPAC Input/Output Subsystem

Field Termination Options

Local Terminations (standard)

Remote Terminations (option)

Metso Automation 278596

maxPAC Hardware Reference Guide

Installing Model IOP I/O Equipment

Sequence of Mounting Operations

Metso Automation 278596

maxPAC Input/Output Subsystem

Mounting I/O Chassis Assemblies

Cabling, Power, and Ground Wiring

Metso Automation 278596

maxPAC Hardware Reference Guide

Interconnecting I/O Racks

Metso Automation 278596

maxPAC Input/Output Subsystem

P9 P11 P10 P11