vi TAC I/NET Seven Installation Guide Process Control Unit 5 for TAC I/NET Building Automation Systems TCON. 0/0
We at Schneider Electric have tried to make the information contained in this manual as accurate and reliable as possible. Nevertheless, Schneider Electric disclaims any warranty of any kind, whether express or implied, as to any matter whatsoever relating to this manual, including without limitation the merchantability or fitness for any particular purpose. Information in this document is based on specifications determined at the time of publication. As we introduce design enhancements, we reserve the right to make changes in specifications and models without obligation to notify the purchaser. In no event shall Schneider Electric be liable for any indirect, special, incidental, or consequential damages arising out of purchase or use of this manual or the information contained herein. The software described in this document is furnished under a license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement. It is against the law to copy Schneider Electric s TAC I/NET System software onto magnetic tape, disk, or any other medium for any purpose other than the purchaser's personal use. Printed in the United States of America. Document Number: Copyright 00 Schneider Electric. All rights reserved. On October st, 00, TAC became the Buildings business of its parent company Schneider Electric. This document reflects the visual identity of Schneider Electric; however, there remains references to TAC as a corporate brand in the body copy. As each document is updated, the body copy will be changed to reflect appropriate corporate brand changes.
Contents FCC Warning........................................... vi Overview............................................ Input/Output........................................... Communication.......................................... Reset................................................ Physical Description.................................... PCBs and Baseplates........................................ Power Supply........................................... Input/Output Terminals...................................... Input Terminations................................................ Output Terminations............................................... 5 Communication Ports.............................................. Serial Communication Port......................................... LAN Communication Port......................................... Memory.............................................. Static RAM.................................................... Memory Exhaustion Warning.......................................... Battery Backup.......................................... Universal Enclosure........................................ 8 RS Serial Expansion Module................................. 8 Installation Procedures.................................. 0 Initial Installation Procedures................................... 0 Grounding Requirements............................................ Earth Ground................................................ Baseplate Ground.............................................. LAN Ground................................................. Setting the 5 PCU Address.......................................... Setting the Tap Emulation............................................ Setting the Tap Baud Rate............................................ Setting the Controller LAN Baud Rate...................................... Setting the Power Line Frequency........................................ 00 Schneider Electric. All rights reserved. iii
Contents 5 Installation Guide Setting the Maximum Pulse Input Rate..................................... Installing the Input Field Connections.............................. 0 0 V Sensor Connection........................................... 0 5 V Sensor Connection............................................ 0 0 Milliampere Sensor Connection..................................... 5 Connecting Discrete Input Points....................................... 5 Installing Supervised Field Inputs....................................... Connecting Thermistor Inputs......................................... Connecting Lini-Temp Inputs......................................... Variable Voltage Selection............................................ 8 Resistor Installation............................................... 8 Installing the Output Field Connections............................. Form-C Relay (Universal) Output Connection................................. Analog Output Connection........................................... Voltage-Sourcing Triac Output Connection.................................. Connecting the HHC....................................... Connecting the LAN....................................... Connecting an External PC.................................... Connecting the Modem...................................... 5 Installing the Optional RS Serial Interface Board...................... 5 Connecting the Power Supply.................................. 5 Field Hardware Checkout and Addressing............................ Connecting the HHC.............................................. Cold Starting the 5 PCU.......................................... Check Signal Voltages.............................................. 8 Check Analog Inputs.............................................. 8 Checkout Discrete Inputs............................................ 8 Checkout Discrete Outputs........................................... Set Up and Operation.................................. 0 Hardware Inputs......................................... Lookup Tables.................................................. Selecting Input Type.............................................. Control Outputs......................................... Upper Motherboard Outputs.......................................... Lower I/O Board Outputs............................................ Analog Output Points........................................... Triac Output Points............................................. iv 00 Schneider Electric. All rights reserved.
5 Installation Guide Contents Manual Override................................................. Communication Ports....................................... LEDs....................................................... RS Port.................................................... 8 HHC Port..................................................... 8 RS85 LAN Port................................................. 8 Protocol................................................... LAN Node Address............................................. Data Rate................................................... Serial Expansion Module..................................... RS Serial Expansion Module Function................................. 0 Tap Emulation and Modem Setup................................ 0 80 Emulation and Beeper Calls........................................ 80 Tap Emulation and Pager Operation................................... Modem Switch Settings............................................. Auto Dial/Auto Answer........................................... Integrated Dial................................................ Point Address Summary................................. 5 Outputs.............................................. 5 Inputs............................................... 5 HOA Switch Status..................................... Resistor Configurations................................. 8 Troubleshooting....................................... Pinout Chart......................................... 50 Upper Motherboard............................................... 50 Lower I/O Board................................................. 50 RS Expansion Module............................................ 5 Internal RS.................................................. 5 Specifications......................................... 5 Index............................................... 55 00 Schneider Electric. All rights reserved. v
FCC Warning 5 Installation Guide FCC Warning FCC Warning The Federal Communications Commission (FCC) requirements prescribe certification of personal computers and any interconnected peripherals in the FCC rules and regulations. This device complies with Part 5 of the FCC rules. Operation is subject to the following two conditions: this device may not cause harmful interference, and this device must accept any interference received, including interference that may cause undesired operation. This equipment generates and uses radio frequency (rf) energy for its operation and, if not installed and used in accordance with the installation and operation manual, may cause interference to radio and television reception. It has been found to comply with the limits for a Class A computing device pursuant to the aforementioned regulations. These are designed to provide reasonable protection against such interference when operated in a residential area. Only peripherals (computer input/output devices) certified to comply with the Class A limits may be connected to this device. Operation with noncertified computer peripherals is likely to result in interference with radio and television reception. If this equipment does cause interference to radio or television reception, the user is encouraged to correct the situation by one or more of the following measures. Relocate the receiver with respect to the computer. Move the computer away from the receiver. Plug the equipment into a different outlet, so that the computing device and receiver are on different branch circuits. Disconnect and remove any unused cables that may be acting as a transmission source. Make certain that the computing device is plugged into a grounded outlet receptacle. If necessary, contact Schneider Electric for additional suggestions. vi 00 Schneider Electric. All rights reserved.
5 5 Installation Guide Overview Overview Input/Output The Model 5 Process Control Unit (PCU) from TAC is a combination of a highspeed, fully distributed microprocessor-based motherboard and a high-resolution I/O board which together provide full adaptive Direct Digital Control (DDC), energy management, and process control of up to 5 addressable I/O points. The 5 PCU is designed to connect directly to a controller LAN and works in conjunction with all other controllers and workstations on the TAC I/NET system. Processing, memory management, communication, and field input/output functions are provided on two printed circuit boards mounted in a double-layer stack. The upper motherboard provides the processing, memory, and communication support for the unit as well as a collection of I/O points. The lower I/O board provides an additional 0 I/O connections, conditioning, and analog signal processing with microprocessor management provided from the upper motherboard. The controller features all quick-disconnect terminals, downloadable firmware, onboard modem drivers, and a direct-connect RS port. The controller is further enhanced with extensive transient protection and automatic self-test features. The 5 PCU comes with the capability of supervising and controlling up to 5 addressable external points and internal points. The I/O configuration flexibility provided by the controller allows it to be interfaced with a variety of industry standard I/O devices. The 5 PCU supports the hardware I/Os listed in Table. Table. 5 PCU Hardware I/Os Upper Motherboard Lower I/O Board 8 universal inputs 8 universal relay outputs universal inputs 8 universal triac outputs 8 analog outputs Universal inputs can be defined as: analog inputs discrete inputs pulse inputs 00 Schneider Electric. All rights reserved.
Overview 5 Installation Guide Communication The 5 PCU provides up to four communication ports on the upper motherboard. A standard synchronous RS85 controller LAN port. Two asynchronous serial ports. These ports provide access to external PCs, external modems, and the Model HC0 hand-held console (HHC). The first asynchronous port provides an RS port for direct connection to a PC, or external Direct Distance Dial (Hayes compatible) modem. The RS port s baud rate is set using a TAC HC0. When connected directly to a PC, the 5 performs the functions of a TAC 80 Tap without consuming a second LAN address. When connected to a Hayes-compatible modem, the Integrated Dial function (i.e. one-way dial from the host PC to the controller LAN) is provided. The second asynchronous port provides a modular TTL-level interface to an HC0 and operates at 00 BPS. An optional plug-on board providing an RS serial port that can be used to connect an external synchronous or asynchronous modem or one of several communication multiplexing devices. (Refer to RS Serial Expansion Module on page 8.) Reset Upon power loss/restoration, the 5 PCU executes an automatic reset memory test of RAM and EPROM. The test uses a Checksum check, and, if the check is successful, control and execution is passed to programmed memory. A manual reset that is started by pressing the reset button executes the same tests. 00 Schneider Electric. All rights reserved.
5 Installation Guide Physical Description Physical Description PCBs and Baseplates The 5 PCU is comprised of two printed circuit boards mounted on a double-layer metal baseplate. The I/O board is mounted on the lower layer, while the motherboard is mounted on the top layer. The top layer is hinged such that easy access is provided to the lower interface. The baseplate provides keyhole mounting for easy installation within a TAC universal enclosure. All I/O connections to the 5 PCU are accomplished via plug-on terminal blocks. Power Supply The upper motherboard (see Figure ) measures approximately 8.5" W " H (.. cm); the baseplate measures approximately 8." W " H (.8. cm). A hinge allows the upper baseplate to swing downward, thus providing access to the lower I/O board. The lower I/O board (see Figure ) measures approximately 8.5" W 0" H (. 5. cm); the baseplate measures approximately." W " H (.. cm). The lower baseplate provides keyholes required for mounting the 5 unit within a TAC universal enclosure. Sensor input wiring to the upper interface board can be bundled and routed along the edge of the hinged upper baseplate to allow access to the lower I/O board without disconnecting the upper motherboard terminations. A cutout in the hinged upper baseplate provides user access to the HOA override switches on the lower I/O board. The lower I/O board connects to the upper motherboard through a 0-conductor ribbon cable. Electrical input power connections for the 5 PCU are provided along the lower left side of the lower I/O board. The 5 PCU is powered from a dual VAC source (external transformer). The AC input provides power to five on-board supplies. A switching power supply circuit is used to generate the +5 VDC logic power. Four linear power supplies are used to generate +5 VDC internal, +5 VDC External, 5 VDC and + VDC. The supply voltages are used for analog signal processing and RS communication. The separate +5 VDC (external) regulator is provided for supplying current loop excitation power to avoid loss of communication due to a field sensor wiring problem. Power line frequency selection (50/0 Hz) is available through an HHC connected directly to the 5. 00 Schneider Electric. All rights reserved.
Physical Description 5 Installation Guide lower baseplate width." (. cm) 8.5" (. cm) TB TB " (. cm) " (.8cm) RS85 port signal inputs TB signal inputs TB resistors resistors U U P U U LEDs reset button manual override switches TB signal outputs P RJ hand held console port TB power input serial option port I/O expansion port RS port modem or external PC P P 8." (.8 cm) Input/Output Terminals Figure. Upper Motherboard and Baseplate The 5 PCU s input and output terminals are located in different areas of both the upper motherboard and the lower I/O board. The inputs and outputs do not use the same number of terminals to make up a terminal set. See Figure for the upper motherboard terminal locations. See Figure for the lower I/O board terminal locations. Input Terminations Both the upper motherboard and lower I/O board provide universal inputs for the 5 PCU. The upper motherboard provides 8 universal inputs. The lower I/O board provides additional universal inputs. All universal inputs are user-configurable for 0 5 VDC, 0 0 VDC, 0 0 ma, or discrete/pulse contact input. Additionally, the lower I/O board universal inputs can be configured for fast scan of pulse input (0 Hz) points. 00 Schneider Electric. All rights reserved.
5 Installation Guide Physical Description.0" (.0 cm).00" (.8 cm) TBB TBA TB U U U5 U TBB TBA.00" (. cm).00" (.8 cm) TBB TBA Analog Type Selection Resistors TB 0" (5. cm) 0-Pin Ribbon Cable Connector TB P TB5A TB5B HOA Switches 8.50" (.0 cm) Figure. Lower I/O Board and Baseplate Signal inputs to the upper motherboard are provided along the upper left side of the board in two groups of four inputs (TB and TB). Three screw terminations are provided for each input (Signal, Ground and +5/ V). The inputs (analog, discrete, or pulse) use point addresses 0000 000. Jumper settings on the upper motherboard allow selection of variable voltages for contact excitation and input pull-up levels. Signal inputs to the lower I/O board are provided along the left side of the board in three groups of eight inputs. Each group provides two tiers of terminal blocks: TBA through TBA on the lower tiers, TBB through TBB on the upper tiers. The inputs (analog, discrete, or pulse) use point address 000 00 (TBA/B), 000 00 (TBA/B), and 000 00 (TBA/B). Output Terminations Output terminations for the 5 PCU are provided along the right side of both the upper motherboard and the lower I/O board. Discrete (Form-C relay) outputs are provided on the upper motherboard. The lower I/O board provides two output types: analog and discrete voltage-sourcing triac. Universal output terminations along the upper right side of the upper motherboard are arranged in two groups of four outputs, with a single -pin plug-on terminal block for each group (TB and TB). Each output consists of a Form-C relay contact capable of 00 Schneider Electric. All rights reserved. 5
Physical Description 5 Installation Guide Communication Ports Serial Communication Port handling 0.5 amp (derated from amps) at volts AC/DC. Each output provides discrete control of a field contact or a proportional control via pulse-width-modulation of the output contact. The outputs use point addresses 0000 000. Output terminations for the lower I/O board are arranged in two groups: analog outputs along the upper right side (TB) and triac outputs below the analog outputs (TB). A single -pin plug-on terminal block is provided for each group. The analog output terminal block (TB) provides 8 high-resolution, -bit analog output points. Each output provides a 0 0 volt span and is capable of handling up to 5 ma. The eight analog outputs use point addresses 00 0. The triac output terminal block (TB) provides 8 voltage-sourcing triac outputs which are user-configured as discrete latching, momentary contacts, or pulse-width-modulated (PWM) proportional outputs. Each output is capable of switching up to 0.5 amps at VAC. A manual override switch (HOA switch) is provided for each triac output as well as discrete input feedback of the switch status. Each HOA switch allows the individual output to be placed in Manual-On, Manual-Off, or Automatic mode. An LED indicator is provided adjacent to each HOA switch and will illuminate when the individual triac output is energized. The eight voltage-sourcing triac outputs use point addresses 000 00. There are three communication ports on the upper motherboard and an optional communication board that can be added as a plug-on daughterboard. All connections to the LAN, modems, external PCs and the HHC are made using these ports. See Figure for port locations. The two asynchronous serial ports (on the upper motherboard) provide access to external PCs, external modems, and the HC0. Modem and PC Connection HHC Connection LAN Communication Port The first asynchronous port (P) provides an RS port for direct connection to a PC or external direct dial (Hayes) modem. The RS port s baud rate is set using the HHC. The second asynchronous port (P) provides a modular interface to the standard HC0 HHC and operates at 00 BPS. An RJ modular jack is provided along the lower left side of the upper motherboard for connection of the HHC. The LAN communication port (TB) is located along the lower left side of the upper motherboard. A terminal block provides connection of the RS85 shielded, twisted pair on the standard controller LAN. The normal speed of communication on the controller LAN is,00 baud. The controller LAN speed can be lowered to 00 baud using the HHC in order to accommodate lower grade cable installations. 00 Schneider Electric. All rights reserved.
5 Installation Guide Physical Description Memory The 5 PCU upper motherboard provides support for several types of memory with variable amounts of each. The memory is currently organized as follows: Table. 5 Memory Socket Amount Memory Type U KB EPROM (Stores boot firmware) U, U and U KB Static RAM The upper motherboard also provides 5 bytes of serial nonvolatile RAM (NOVRAM) memory storage. This memory is used to hold all parameters necessary to establish basic communication with the controller after a long-term power outage (i.e., loss of RAM memory). The software can be downloaded while the 5 is on-line with TAC I/NET. The software design and memory organization supports the complete download of all software, including revised LAN drivers that are invoked after completion of the download. The downloaded software is held in RAM. When the 5 is emulating a 80 Tap, it can store telephone numbers as a standard 80 Tap would. At least eight 5-digit telephone numbers can be stored in memory. Static RAM The 5 PCU provides a minimum of KB of battery-backed static RAM for software data storage and embedded 80, 805 and 80 Tap functions such as message queue, dial telephone numbers, and async/sync communication buffers. Memory Exhaustion Warning Battery Backup The PCU editors provide a warning message when the user adds a point or function that could exceed the available PCU memory. The 5 provides battery-backup of static RAM contents and of the clock/calendar. The onboard NiCad rechargeable battery provides backup for up to 0 days during a power failure. Note: The backup battery must be fully charged in order to provide the full span of backup power. Due to normal discharge during product storage and shipment, the battery may not be fully charged immediately following installation and power-up. You must allow the controller to operate continuously for a minimum of seven days (8 hours) before depending on battery backup. 00 Schneider Electric. All rights reserved.
Physical Description 5 Installation Guide Universal Enclosure TAC s universal enclosures provide a protected environment in locations in which dirt, dust, or other contaminants may exist. TAC universal enclosures are available in several sizes and capacities designed to house various combinations of TAC control units and interfaces. The model used for the 5 PCU is the ENCL8, measuring.5" W 8.5" H." D (.. 0. cm). The universal enclosure allows back panel mounting, providing additional space for optional equipment such as transformers and electrical junction boxes. The enclosure includes a door key lock. The 5 PCU boards are shipped already mounted on a double-layer baseplate. That baseplate/pcb assembly is then mounted into the universal enclosure. If the perforated backplane is used to mount the baseplate, then the size of the baseplate and the enclosure are the limiting factors for enclosure mounting. Baseplates vary in dimension depending upon the type of controller. All controllers or interface units are attached to a baseplate for mounting in a universal enclosure. Table. Universal Enclosure Dimensions Model Panel Dimensions Standard Door Mounting Baseplate Qty Perforated Panel Backplane Dimension W H D W H Panel Backplane w/studs Door Key Lock ENCL8 with Knockouts and Gasketed Door.5" (. cm) 8.5" (. cm)." (0. cm) None.5" (.5 cm).5" (. cm) (#8 hardware Optional Panel mounting Mount one (max.) TAC baseplate unit Options: Transformer Junction box Yes RS Serial Expansion Module The RS Serial Expansion Module provides a fourth serial interface. It provides a full complement of modem control, data, and clock signals on an RS port. It provides two-way dial or dedicated line communication as currently supplied by TAC s 80 or 805 Tap. This interface supports user-selected data rates up to,00 baud. This optional interface can be connected to: External auto-dial/auto-answer (AD/AA) modem When connected to a Hayescompatible AD/AA modem, the 5 will provide the functionality of the 80 Tap. The following types of modems are supported: Synchronous Use a synchronous modem when the controller is loaded with a TAC I/NET version.x or earlier binary file. The controller must also have TAC I/NET version.x boot firmware (EPROM). Asynchronous Use an asynchronous modem when the controller is loaded with a TAC I/NET 000 or later binary file. The controller must also have TAC I/NET 000 or later boot firmware (EPROM). 8 00 Schneider Electric. All rights reserved.
5 Installation Guide Physical Description Note: Ensure that all AD/AA Taps within your TAC I/NET system are configured to use the same communication protocol either synchronous, or asynchronous. Mixing AD/AA protocols will cause communication errors. TAC I/NET 000 is compatible with TAC I/NET version.x Tap and controller binary loads. Therefore, when synchronous AD/AA communication is required on a TAC I/NET 000 system (for example, when using a 800, 8050, or 800 Tap), you must continue to use TAC I/NET version.x Tap and controller binary loads. External synchronous dedicated line modem When connected to an external Hayes-compatible dedicated line modem, the 5 provides the functionality of a TAC 805 Tap. Refer to TCON0, TAC I/NET Tap and Repeater Installation Guide, for a complete description the 805 Tap function. Another RS data communication device. 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide Installation Procedures This section provides instructions for installing the 5 PCU. Field checkout procedures using an HHC are also included in this section. Note: Operational errors may occur if equipment is inadequately grounded. Symptoms may include, but are not limited to: intermittent LAN communication, improper control actions, or loss of NOVRAM contents. Refer to Grounding Requirements on page during equipment installation. Initial Installation Procedures Use the following steps to install the 5 controller. This procedure allows you to set up the 5 with the proper DCU address, perform a field checkout on the hardware, and set Tap emulation, baud rate and controller LAN baud rate.. Disconnect power to the 5 PCU.. Disconnect power to all devices that will be connected to the 5 PCU. Warning: Failure to disconnect power from all interconnected equipment when performing electrical installation may result in electrical shock or burns.. Mount universal enclosure on a wall.. Bring conduit into box (conduit contains power, sensor cables, etc.). 5. Attach the double-layer metal baseplate (and its attached PCBs) into the universal enclosure box (keyhole mount).. If using the optional RS serial expansion module, install the module on the 5 upper motherboard at port P.. Terminate wires at PCBs. Refer to Installing the Input Field Connections on page and Installing the Output Field Connections on page. 8. Connect the modem or external PC.. Connect the power supply to the 5. Remember to set the power line frequency (50/0 Hz) using Setting the Power Line Frequency on page. 0. Reconnect power to devices that are connected to the 5 PCU.. Perform field checkout. (Refer to Field Hardware Checkout and Addressing on page.) 0 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures Grounding Requirements Earth Ground To ensure proper operation of the controller, it is imperative that the unit be correctly grounded. Depending on the mounting location and mounting method used to install the unit, the controller chassis may not necessarily provide adequate ground for the input power circuit and interconnected sensors/devices: therefore, use the following grounding requirements during unit installation. Note: You must establish a proper earth ground connection point prior to connecting ground wires to electrical equipment. Baseplate Ground Electrical Service Earth Ground must be securely connected to the equipment chassis. The Electrical Service Earth Ground must then be connected to the ground terminal on the controller power input terminal block (TB5A pin ). Note: Baseplate grounding requirements apply to all controllers having a baseplate. Good contact must exist between the baseplate and chassis. Ensure that all mounting screws are tight. Attach a -AWG (. mm ) ground wire from the Electrical Service Earth Ground to the baseplate. Attach the ground wire to the baseplate grounding post in the lower right corner. LAN Ground Note: This procedure applies to all LAN controller connections. Shield drain wire continuity must be maintained as the LAN cable passes through each controller. Shield drain wires from each controller LAN cable must be bonded together, insulated, and tied back such that wires do not come in contact with ground or any conductive surface within a controller. Connect the shield drain wire directly to Electrical Service Earth Ground at only one end of the cable. Setting the 5 PCU Address. Connect the Model HC0 HHC and set the 5 s LAN address. Press [DCU ADDR]. The current 5 address displays in the two right-most digits of the HHC display.. Enter the desired address using the numeric keys. The address displays as it is entered.. Press [Enter]. The 5 NOVRAM is updated with the new address. 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide Setting the Tap Emulation. Press [Code].. Press 0 and then press [Enter]. The emulated device type model number displays in the read out.. Press [Inc] or [Dec] to select 80, 805 or 80 Tap emulation. Refer to Table for Tap emulation as it appears on the HHC. Table. HC0 Tap Emulation Selection Tap Model HC0 Display No Tap Emulation 500 80 50 805 50 80 50. Press [Enter] to accept your choice. Setting the Tap Baud Rate. Press [Code]. Setting the Controller LAN Baud Rate Setting the Power Line Frequency. Enter and then press [Enter] to set the Tap baud rate.. Press [Inc] or [Dec] to cycle through the available PC port baud rates, typically 00.. Press [Enter] to accept your choice.. Press [Code].. Enter and then press [Enter] to set the controller LAN baud rate.. Press [Inc] or [Dec] to toggle between 00 baud and.k baud rates.. Press [Enter] to accept your choice.. Press [Code].. Enter and then press [Enter] to select the AC line frequency.. Press [Inc] or [Dec] to switch between 50 and 0 Hz.. Press [Enter] to accept your choice. 5. Connect the 5 to the LAN.. Program the PCU from the host PC. Refer to the TAC I/NET Operator Guide for instructions. 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures Setting the Maximum Pulse Input Rate Installing the Input Field Connections. Press [Code].. Enter 0, press [Enter] to display the current rate, and press [Enter].. Enter 0 to set for a pulse rate of per second.. Enter to set for a pulse rate of 0 per second. 5. Press [Enter] to accept your selection. The 5 supports several types of inputs, each using different field connections. Use the procedures shown below to connect the sensors you use to the 5. The illustrations and procedures describe connection to the upper motherboard and to the lower I/O board. Warning: Caution: Note: Ensure that no power is connected to the 5 and all interconnected equipment when performing the following procedures. Failure to disconnect power from the 5 and all interconnected equipment when performing electrical installation may result in damage to the components and electrical shock or burns. The input, output and power wiring must be routed along the side of the controller. The wiring is not to lay across the controller. When field wiring the upper motherboard, wires should be bundled and routed up along the edge of the upper baseplate, and a service loop in the wiring should be provided in the area of the upper baseplate hinge. Proper wire routing will permit access to the lower I/O board without disconnection of the upper motherboard termination blocks. 0 0 V Sensor Connection Refer to Resistor Installation on page 8, to determine the correct resistor configuration for your inputs. A 0 0 V sensor uses three leads to connect to an input. The upper motherboard provides eight inputs with excitation voltages selectable between +5 volts DC and + volts DC. The lower I/O board provides support for an additional twenty-four 0 0 volt inputs with a fixed excitation voltage of + volts DC. Refer to Resistor Installation on page 8 for resistor configuration. Connection is identical for the upper motherboard and the lower I/O board.. Connect the out lead of the 0 0 V sensor to a signal (UI-x) terminal on TB or TB on the upper motherboard or on TBA/B, TBA/B or TBA/B on the lower I/O board.. Connect the negative lead of the sensor to the GND terminal.. Connect the +V lead of the sensor to the +V terminal (see Figure ). Note: Sensors requiring more than 0 ma should be wired to an external power supply. 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide 0 0V Sensor Signal Out GND +V In TB 5 8 0 C Sensor connected at TB-: 00K ohm, /8 W, % resistor in C (on upper board). Strap J to +5V or +V as required (on upper board). 0 5 V Sensor Connection Figure. 0 0 Volt Sensor Connections. If connecting to the upper motherboard, install a 00K Ohm, 8 W, % resistor in the corresponding resistor C position. If connecting to the lower I/O board, no resistor is required. 5. If connecting to the upper motherboard, ensure that the variable voltage selection is set on J of the upper motherboard to the appropriate voltage (refer to Variable Voltage Selection on page 8). A 0 5 V sensor uses three leads to connect to an expansion board input. The upper motherboard provides eight inputs with excitation voltages selectable between +5 volts DC and + volts DC. The lower I/O board provides support for an additional twentyfour 0 5 volt inputs with a fixed excitation voltage of + volts DC. Refer to Resistor Installation on page 8 for resistor configuration. Connection is identical for the upper motherboard and the lower I/O board.. Connect the out lead of the 0 5 V sensor to a signal (UI-x) terminal on TB or TB on the upper motherboard or on TBA/B, TBA/B or TBA/B on the lower I/O board.. Connect the negative lead of the sensor to the GND terminal.. Connect the +V lead of the sensor to the +V terminal (see Figure ). Note: Sensors requiring more than 0 ma should be wired to an external power supply. 0 5V Sensor Signal Out GND +V In TB 5 8 0 Sensor connected at TB-: Strap J to +5V or +V as required (on upper board). Figure. 0 5 Volt Sensor Connections. If connecting to the upper motherboard, ensure that the variable voltage selection is set on J of the upper motherboard to the appropriate voltage (refer to Variable Voltage Selection on page 8). 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures 0 0 Milliampere Sensor Connection 0 0 milliampere sensors can be connected as shown in Figure 5. The upper motherboard provides eight inputs with excitation voltages selectable between +5 volts DC and + volts DC. The lower I/O board provides additional inputs for up to twenty-four 0 ma loops with a fixed excitation voltage of + volts DC. Refer to Resistor Installation on page 8 for resistor configuration. See Figure on page 0 for resistor installation.. Connect the output lead from the sensor to a SIGNAL terminal on TB or TB on the upper motherboard or on TBA/B, TBA/B or TBA/B on the lower I/O board.. Connect the output lead of the sensor to the +V terminal of the input set. 0 0mA, 0mA Sensor In Out (+) ( ) 0 0mA, 0mA In Out Sensor (+) ( ) Input Power External Power Supply + Output TB/TB 5 8 0 A A Sensor connected at TB-: ohm, /8 W, 0.% resistor in A Sensor connected at TB-: ohm, /8 W, 0.% resistor in A Note: Use external power supply if more than eight (combined, upper and lower board) 0 0 or 0 ma sensors are used. Connecting Discrete Input Points Figure 5. 0 0 ma Sensor Connections. If connecting to the upper motherboard, ensure that the variable voltage selection is set on J of the upper motherboard to the appropriate voltage (refer to Variable Voltage Selection on page 8). For contact sensing on the upper motherboard or lower I/O board, either DI or PI, the excitation current for the field contact is achieved by placing a K ohm, W, 5% resistor in the appropriately numbered B position. The B position provides a pull-up on the input to 5 volts DC for dry contact excitation.. Connect one lead from the field contact to the signal (UI-x) terminal on TB or TB on the upper motherboard or on TBA/B, TBA/B or TBA/B on the lower I/O board.. Connect the other lead of the sensor to the GND terminal (see Figure ).. Install a K Ohm, W, 5% resistor in the corresponding resistor B position. Dry Contact For DI or PI Note: Contact closed = logical st or nd of state description pair. TB 5 8 0 B Dry Contact connected at TB-: K ohm, / W, 5% resistor in B Figure. Dry Contact Connections 00 Schneider Electric. All rights reserved. 5
Installation Procedures 5 Installation Guide Installing Supervised Field Inputs Configure the field inputs for supervision in the resident I/O points editor of the host. You may supervise a single switch or contact in a normally-closed or normally-open configuration, or you may supervise multiple normally open switches or contacts connected in parallel. The contact/switch may be normally-open or normally-closed (see Figure and Figure 8). Single resistor supervision with a parallel resistor. Configuration is the same for normally closed switch/contact. Entire circuit is supervised for line cuts ( open wire) Double resistor supervision with a parallel and a series resistor. Entire circuit is supervised for line cuts ( open wire) K K K Parallel Resistor Parallel Resistor Series Resistor Normally Open Switch/Contact Figure. Supervised Single Switches/Contacts Portion of circuit is supervised for jumpers ( shorts in wiring) Normally Closed Switch/Contact Note: The components shown inside the dashed boxes should be in close physical proximity. Multiple switches or contacts connected to a supervised input (see Figure 8) must consist of normally-open switches or contacts wired in parallel. Single resistor supervision with a parallel resistor. Entire circuit is supervised for line cuts ( open wire) Double resistor supervision with a parallel and a series resistor. Entire circuit is supervised for line cuts ( open wire) Parallel Resistor Parallel Resistor Note: The components shown in the dashed box should be in close physical proximity. Figure 8. Supervised Multiple Switches/Contacts Series Resistor Portion of circuit is supervised for jumpers ( shorts in wiring) 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures Connecting Thermistor Inputs The inputs on the lower I/O board are shipped in a thermistor input configuration with a 0K ohm, 8 W, 0.% resistor in the B position for each input.. Connect one lead from the thermistor to the signal (UI-x) terminal on TBA/B, TBA/B or TBA/B on the lower I/O board.. Connect the other lead of the sensor to the GND terminal (see Figure ). 0K Ohm Thermistor TBA Signal Ground VDC TBB B 0K Ohm Thermister at TBA-: 0K ohm, /8 W, 0.% resistor in B. Figure. Thermistor Connections on Lower I/O Board Note: For units containing upper motherboard assembly 05-0 Revision F or later, the upper motherboard may also use the 0K ohm thermistor. The connection method is the same as that described above for the lower I/O board. Connecting Lini-Temp Inputs Note: The lower I/O board should not be used for Lini-Temp sensor inputs. Only the upper motherboard allows selection of the +5 volts DC excitation voltage required for Lini-Temp sensors. The lower I/O board provides a fixed + volts DC excitation voltage. Signal inputs are provided along the upper left side of the upper motherboard in two groups of four inputs. Three screw terminations are provided for each input (Signal, Ground and +5/V) as shown in Figure 0. The LTS80 temperature sensors can be connected in a -wire or -wire configuration as shown in Figure 0. Refer to Resistor Installation on page 8 for resistor configuration. The -wire configuration does not require any resistor configuration. See Figure on page 0 for resistor installation.. Connect the white lead to a signal (UI-x) terminal on TB or TB on the upper motherboard.. Connect the orange lead to one of the +5 V terminals of terminal blocks TB or TB on the upper motherboard.. For -wire sensors, connect the blue lead to the GND terminal (see Figure 0).. When using a -wire sensor configuration, place a 0K, 8 W, 0.% resistor in the corresponding resistor A position. 5. Ensure that the variable voltage selection is set on J of the upper motherboard to +5 V (refer to Variable Voltage Selection on page 8). 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide WHT LTS Sensor ORN Typical -wire Sensor connection LTS Sensor Typical -wire Sensor connection WHT BLU ORN Signal +5 V Signal Ground +5 V TB 5 8 0 A -Wire Connection: 0K ohm, /8 W, 0.% resistor in A. Strap J to 5V. -Wire Connection: No resistor required. Strap J to 5V. Variable Voltage Selection Figure 0. Lini-Temp Input Sensor Connections (Upper Motherboard) You may select either +5 or + volt DC power provided by the upper motherboard to a connected sensor by positioning a jumper on J (see Figure ). To achieve +5 volts, position the jumper on posts B and C. Position the jumper on posts A and B to achieve + volts. Refer to Table 5 for details. Table 5. Upper Motherboard Variable Voltage Selection Jumper Setting Result J B to C A to B +5 volts DC excitation on terminal blocks + volts DC excitation on terminal blocks Resistor Installation The eight inputs on the upper motherboard are shipped in a 0 0 ma configuration. The 0 0 ma configuration is achieved by placing ohm 0.% resistors in the appropriate plug-in position for each input. These positions are labeled A through A8, A corresponding to input UI- and A8 to UI-8. Table. Resistor Configurations Location Function Resistor Upper Motherboard ( bit A/D converter) 0 5 volts None 0 0 volts 00K ohm, 8 W, % in position C 0 0 ma ohm, 8 W, 0.% in position A, remove any resistor in position B Thermistor 0K ohm, 8 W, 0.% in position B Note: Thermistor may be used only on upper board assembly 05-0 Revision F or later. Discrete K ohm, 8 W, 5% in position B Low-speed pulse input (PI) K ohm, 8 W, 5% in position B Discrete Supervised Lini-Temp (-wire configuration only) K ohm, 8 W, 5% in position B and end-of-line resistor(s) (K ohm, W, %) 0K ohm, 8 W, 0.% in position A 8 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures Lower I/O Board ( bit A/D converter) Note: Table. Resistor Configurations (Continued) Location Function Resistor 0 5 volts None (see note) 0 0 volts None 0 0 ma 0 0 ma Thermistor Discrete Low-speed pulse input (PI) High-speed pulse input ohm, 8 W, 0.% in position A, remove any resistor in position B (see note) ohm, 8 W, 0.% in position A, remove any resistor in position B 0K ohm, 8 W, 0.% in position B K ohm, 8 W, 5% in position B K ohm, 8 W, 5% in position B K ohm, 8 W, 5% in positions B and D K ohm, 8 W, 5% in position B and end-of-line Discrete Supervised resistor(s) (K ohm, W, %) Using 0 5 VDC or 0 0 ma inputs on the lower I/O board of the 5 PCU only uses half of the available A/D counts (0, counts rather than 0 5,55 counts). Keep this in mind when calculating conversion coefficients. The inputs on the lower I/O board are shipped in a thermistor configuration. The thermistor configuration is achieved by placing 0K ohm 0.% resistors in the appropriate plug-in position for each input. These positions are labeled B through B; B corresponding to input UI- and B corresponding to input UI-. The A positions provide a pull-down to DC ground on the input signal for analog input current sensing. The B positions provide a pull-up on the input to 5 volts DC. On the upper motherboard, the 5 volt source is suitable for the excitation of discrete contacts. On the lower I/O board, the 5 volt source is provided by a precision reference and is suitable for exciting thermistors as well as discrete contacts. The C positions allow you to configure the upper motherboard for 0- to 0-volt inputs. The lower I/O board accepts 0 0 V as a standard configuration (no resistor required). The D positions are used only on the lower I/O board to reduce input filtering to allow high-speed pulse input (up to 0 Hz) processing. Position D is not used on upper motherboard. In order to configure an input for 0 0 ma, insert a ohm 8 W, 0.% current sensing resistor in the corresponding resistor position (A through A8 or A through A). The position numbers (A A8) correspond to the inputs through 8 on the upper motherboard (see Figure ). The position numbers A A correspond to the inputs through on the lower I/O board (see Figure ). For -wire Lini-Temp, install a 0K Ohm 8 W, 0.% resistor in an A position. For 0 0 V on the upper motherboard, install a 00K Ohm, 8 W, % resistor in a C position. For 0 0 V on the lower I/O board, no resistor is required. Dry contact inputs (DI or PI) require a K Ohm, 8 W, 5% resistor in a B position. To configure an input for 0 0 ma, insert a ohm 8 W, 0.% current sensing resistor in the corresponding resistor A position. Remove any resistor in the corresponding B position for 0 0 ma or 0 0 ma inputs. Figure shows connection examples for -wire Lini-Temp, 0 0 V, 0 0 ma, and dry contact inputs. For high-speed processing of pulse inputs on the lower I/O board, install a K Ohm, 8 W, 5% resistor in a D position. See Figure for details of installation. 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide TB 5 8 0 TB 5 8 0 UI- GND +V UI- GND +V UI- GND +V UI- GND +V UI-5 GND +V UI- GND +V UI- GND +V UI-8 GND +V A A A A B B B B A5 A A A8 B5 B B B8 C C C C D D D D C5 C C C8 D5 D D D8 TBA UI- UI- 5 UI- 8 0 UI- UI- UI-0 UI- UI- UI- UI-8 UI- UI-0 TBA 5 8 0 TBA 5 8 0 TBB A B C D UI-5 5 UI- 8 UI- 0 UI-8 TBB A B C D UI- 5 UI- 8 UI-5 0 UI- TBB A B C D UI- 5 UI- 8 UI- 0 UI- 5 8 0 5 8 0 Upper Motherboard Lower I/O Board Figure. Input Configuration Resistors A A A A B B B B C C C C 0K, / 8W, 0.% For -Wire Lini-Temp, Part Number 00-00, W, 0.% For 0-0 ma Input, Part Number 80080-58 / 8 K, / W, 5% For Dry Contact Input (DI or PI) Part Number 8005-00K, /8 W, % For 0-0V Input on Upper Motherboard Part Number 00-00 Figure. Resistor Installation on Upper Motherboard 0 00 Schneider Electric. All rights reserved.
5 Installation Guide Installation Procedures A B C D 0 K, /8 W, 0.% For Thermistor on lower I/O board Part Number 00-00 5 8 5 8 5 5 8 For 0Hz (high speed) pulse input on lower I/O board Part Number 8005- K,/8 W, 5% Required for low or high speed pulse inputs on lower I/O board K, /8 W, 5% resistor Figure. Resistor Installation on Lower I/O Board Installing the Output Field Connections Form-C Relay (Universal) Output Connection Form-C relay (universal) output terminations are provided along the upper right side of the upper motherboard (see Figure ). Each output consists of a Form-C relay contact capable of handling 0.5 amp at volts AC/DC. Each output provides discrete control of a field contactor or a proportional control via pulse-width-modulation (PWM) of the output contact. Analog output terminations are provided along the upper right side of the lower I/O board (see Figure 5). The eight high-resolution, -bit analog output points provide a 0- to 0-volt span and can each drive up to 5 ma. Discrete triac output terminations are also provided along the right side of the lower I/O board (see Figure ). Each discrete output consists of a voltage-sourcing ( VAC) triac contact capable of handling 0.5 amperes at volts AC. Each output provides discrete control of a field contactor or a proportional control via PWM of the output contact. When connecting a device to the upper motherboard universal output, first determine whether the device is normally open (NO) or normally closed (NC). Connect one wire to the middle terminal of the set (numbered through 8) and one wire to the terminal designated NO or NC (see Figure ).. Connect one lead from the device to the desired NO or NC terminal.. Connect the other lead to the corresponding Common terminal on the upper motherboard. 00 Schneider Electric. All rights reserved.
Installation Procedures 5 Installation Guide TB 0 8 5 TB 0 8 5 NC 8 NO NC NO NC NO NC 5 NO NC NO NC NO NC NO NC NO Note: When possible, ground the common side of the VAC source. Normally Closed Common Normally Open VAC Source MOV VAC Relay Coil Analog Output Connection Figure. Output Terminal Locations on Upper Motherboard When connecting an analog device to the lower I/O board, connect one lead to the signal output (AO-x) terminal and the other lead to the GND terminal (see Figure 5).. Connect the positive control lead from the device to the desired AO-x voltage output terminal.. Connect the negative control lead to the GND terminal(s) on the expansion module. TB 0 8 5 Ground 0 0 V Control Actuator + Typical Voltage-Sourcing Triac Output Connection Figure 5. Analog Output Location on Lower I/O Board When connecting a discrete device to the lower I/O board triac output, connect one lead to the signal output (DO-x) terminal ( through 8) and the other lead to ground (see Figure ).. Connect one lead from the device to the desired DO-x terminal.. Repeat as required for additional connections. 00 Schneider Electric. All rights reserved.