Harmony IO - Bailey Net 90 and Infi 90

Harmony IO - Bailey Net 90 and Infi 90
Instruction
Harmony Series
Harmony Input/Output System
I/O and Auxiliary Blocks
Preface
The Harmony Input/Output (I/O) System sets new standards
for user convenience in industrial I/O. A wide variety of I/O
building blocks can be combined to form an optimum solution
for a specific application. The Harmony I/O system is part of
the Symphony Enterprise Management and Control System. It
is, however, fully compatible with the INFI 90® OPEN Strategic
Enterprise Management System.
This instruction overviews the Harmony I/O system; describes
the analog, digital, and control I/O blocks and auxiliary blocks
used for field I/O interface; and provides I/O and auxiliary
block installation and connection procedures.
WBPEEUI240751C0
List of Effective Pages
Total number of pages in this instruction is 368, consisting of the following:
Page No.
Preface
List of Effective Pages
iii through xviii
1-1 through 1-18
2-1 through 2-19
3-1 through 3-26
4-1 through 4-15
5-1 through 5-8
6-1 through 6-16
7-1 through 7-10
8-1 through 8-15
9-1 through 9-2
10-1 through 10-3
11-1 through 11-7
A-1 through A-4
PR1-1 through PR1-3
PR2-1 through PR2-2
PR3-1 through PR3-2
PR4-1 through PR4-2
PR5-1 through PR5-3
PR6-1 through PR6-6
PR7-1 through PR7-2
PR8-1 through PR8-6
PR9-1 through PR9-2
PR10-1 through PR10-2
PR11-1 through PR11-10
PR12-1 through PR12-8
PR13-1 through PR13-2
PR14-1 through PR14-5
PR15-1 through PR15-2
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
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Original
Original
PR16-1
PR17-1
PR18-1
PR19-1
PR20-1
PR21-1
PR22-1
PR23-1
PR24-1
PR25-1
PR26-1
PR27-1
PR28-1
PR29-1
PR30-1
PR31-1
PR32-1
PR33-1
PR34-1
WS1-1
WS2-1
WS3-1
WS4-1
WS5-1
WS6-1
WS7-1
WS8-1
WS9-1
Index-1
Page No.
through PR16-3
through PR17-4
through PR18-2
through PR19-14
through PR20-13
through PR21-14
through PR22-3
through PR23-6
through PR24-5
through PR25-2
through PR26-2
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
PR28-2
PR29-2
PR30-2
PR31-2
PR32-3
PR33-3
PR34-3
WS1-7
WS2-7
WS3-9
WS4-9
WS5-5
WS6-5
WS7-9
WS8-4
WS9-4
Index-5
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
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Original
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
WBPEEUI240751C0
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Purpose ................................................................................................................... 1-1
Harmony I/O System Documentation....................................................................... 1-1
System Overview ...................................................................................................... 1-2
Input/Output .......................................................................................................... 1-4
Harmony Controllers................................................................................................ 1-5
Harmony Bridge Controller................................................................................... 1-5
Harmony Area Controller...................................................................................... 1-7
Function Codes........................................................................................................ 1-8
Compatibility ........................................................................................................... 1-8
Features .................................................................................................................. 1-8
Intended User .......................................................................................................... 1-9
Instruction Content................................................................................................ 1-10
How to Use this Instruction .................................................................................... 1-11
Document Conventions .......................................................................................... 1-12
Glossary of Terms and Abbreviations...................................................................... 1-12
Reference Documents............................................................................................. 1-13
Abbreviated Harmony I/O Nomenclature ................................................................ 1-13
Related Nomenclature ............................................................................................ 1-14
Design Standards................................................................................................... 1-14
Specifications......................................................................................................... 1-16
Section 2 Input/Output Blocks ....................................................................................2-1
Introduction............................................................................................................. 2-1
AIN-120 ................................................................................................................... 2-1
AIN-200 ................................................................................................................... 2-2
AIN-220 ................................................................................................................... 2-4
AIN-300 ................................................................................................................... 2-5
AOT-150 .................................................................................................................. 2-6
BLK-100 .................................................................................................................. 2-7
CIO-100 ................................................................................................................... 2-8
CIO-110 ................................................................................................................. 2-12
DIO-400................................................................................................................. 2-13
DOT-100................................................................................................................ 2-15
DOT-120................................................................................................................ 2-16
RLY-100................................................................................................................. 2-17
RLY-200................................................................................................................. 2-18
Section 3 Description and Operation .........................................................................3-1
Introduction............................................................................................................. 3-1
Inputs and Outputs ................................................................................................. 3-1
WBPEEUI240751C0
iii
Table of Contents (continued)
Section 3 Description and Operation (continued)
Analog Input .........................................................................................................3-1
Data Conversion ...............................................................................................3-2
Calibrations ......................................................................................................3-3
Analog Output ......................................................................................................3-3
Data Conversion ...............................................................................................3-3
Calibrations ......................................................................................................3-3
Readback ..........................................................................................................3-4
Digital Input .........................................................................................................3-4
Digital Output ......................................................................................................3-5
I/O Block .................................................................................................................3-6
I/O Module ...........................................................................................................3-7
Block Power ......................................................................................................3-8
Central Processing Unit...................................................................................3-10
Memory ..........................................................................................................3-11
Hnet Interface .................................................................................................3-11
Machine Fault Timer .......................................................................................3-12
Serial Link Interface ........................................................................................3-12
LED Drivers and Status LEDs .........................................................................3-14
I/O Channel Interface .....................................................................................3-14
I/O Section .....................................................................................................3-14
Special Operations Switch (SW2) .....................................................................3-15
Base ...................................................................................................................3-15
Screw and Clamp Termination Bases ..............................................................3-15
Cable Connection............................................................................................3-18
Shield Terminations (Chassis Ground) ............................................................3-19
I/O Module Mounting .....................................................................................3-19
Hardware Keying ................................................................................................3-20
I/O Redundancy .................................................................................................3-20
Failure Mode (Outputs) .......................................................................................3-20
Short Circuit Protection ......................................................................................3-22
Auxiliary Block .......................................................................................................3-24
I/O System Configuration.......................................................................................3-24
I/O Block Hardware............................................................................................3-25
I/O Block Function Codes...................................................................................3-25
Section 4 Redundancy .................................................................................................4-1
Introduction .............................................................................................................4-1
Description...............................................................................................................4-1
Redundancy Arbitration........................................................................................4-2
Failover ................................................................................................................4-2
Analog Input.............................................................................................................4-3
iv
WBPEEUI240751C0
Table of Contents (continued)
Section 4 Redundancy (continued)
Analog Output ......................................................................................................... 4-4
Digital Input ............................................................................................................ 4-7
Digital Output.......................................................................................................... 4-9
Section 5 Installation ....................................................................................................5-1
Introduction............................................................................................................. 5-1
Special Handling ...................................................................................................... 5-1
Unpacking and Inspection........................................................................................ 5-2
Installation Procedures ............................................................................................ 5-2
Installation and Connection Sequence...................................................................... 5-3
Section 6 Configuration ...............................................................................................6-1
Introduction............................................................................................................. 6-1
Configuration Tools.................................................................................................. 6-1
Harmony Controller ................................................................................................. 6-1
Download............................................................................................................. 6-1
Verification........................................................................................................... 6-2
Changes............................................................................................................... 6-2
Time Synchronization........................................................................................... 6-3
Firmware Download ............................................................................................. 6-3
Labels ...................................................................................................................... 6-3
Device Label ......................................................................................................... 6-4
Electronic ID .................................................................................................... 6-4
Establishing a Device Label .............................................................................. 6-4
Predefining a Device Label ................................................................................ 6-5
Online Configuration ........................................................................................ 6-5
Channel Label ...................................................................................................... 6-6
Duplicate Labels................................................................................................... 6-6
Function Codes........................................................................................................ 6-7
I/O Device Definition (FC 221) .............................................................................. 6-8
I/O Channel (FC 222, 223, 224, 225).................................................................... 6-9
I/O Channel Data........................................................................................... 6-11
Suspect Condition .......................................................................................... 6-11
Exception Reporting ....................................................................................... 6-13
Engineering Units (EU) ................................................................................... 6-13
I/O Source ..................................................................................................... 6-14
Hnet Stall Mode (Default State) ....................................................................... 6-15
Status Reporting ............................................................................................ 6-15
Alarming ........................................................................................................ 6-15
Shaping Algorithms ........................................................................................ 6-16
WBPEEUI240751C0
v
Table of Contents (continued)
Section 6 Configuration (continued)
Test Status (FC 226) ...........................................................................................6-16
Section 7 Operating Procedures .................................................................................7-1
Introduction .............................................................................................................7-1
I/O Block .................................................................................................................7-1
I/O Module Front Panel ........................................................................................7-1
Block Type and Model .......................................................................................7-1
Operating Mode - Normal and Fault ..................................................................7-2
Status...............................................................................................................7-2
Block Power ......................................................................................................7-3
Field Power .......................................................................................................7-4
Digital Channels ...............................................................................................7-4
ID Labels ..........................................................................................................7-5
I/O Module Rear Panel..........................................................................................7-5
Termination Base Color Coding and Markings .......................................................7-6
Operation .............................................................................................................7-7
Startup .............................................................................................................7-7
Stop/Reset Button ............................................................................................7-7
Initialization......................................................................................................7-8
Auxiliary Block .........................................................................................................7-9
Section 8 Troubleshooting ..........................................................................................8-1
Introduction .............................................................................................................8-1
Troubleshooting Procedures......................................................................................8-1
Operating Mode - Normal and Fault LEDs.................................................................8-1
Power LEDs ..............................................................................................................8-2
Status Code LEDs ....................................................................................................8-2
I/O Block Problem Reports .......................................................................................8-6
Station Problem Reports ...........................................................................................8-9
I/O Block Status ....................................................................................................8-11
Diagnostics ............................................................................................................8-12
Online ................................................................................................................8-12
Offline ................................................................................................................8-12
I/O Block Connectors .............................................................................................8-13
I/O Module (P1, P4, P5).......................................................................................8-13
CIO-100 (P7, P8) .................................................................................................8-14
DIO (P17) ............................................................................................................8-15
vi
WBPEEUI240751C0
Table of Contents (continued)
Section 9 Maintenance .................................................................................................9-1
Introduction............................................................................................................. 9-1
Preventive Maintenance Schedule............................................................................. 9-1
Section 10 Repair and Replacement .........................................................................10-1
Introduction........................................................................................................... 10-1
Repair.................................................................................................................... 10-1
Replacement .......................................................................................................... 10-1
Section 11 Replacement and Spare Parts ................................................................11-1
Introduction........................................................................................................... 11-1
I/O and Auxiliary Block Nomenclature ................................................................... 11-1
Cable Nomenclature............................................................................................... 11-4
Miscellaneous Parts ............................................................................................... 11-6
Appendix A Hardware Drawings ................................................................................ A-1
Introduction............................................................................................................. A-1
I/O Block................................................................................................................. A-1
Auxiliary Block......................................................................................................... A-4
List of Procedures
No.
PR1
PR2
PR3
PR4
PR5
PR6
PR7
PR8
PR9
PR10
PR11
PR12
PR13
PR14
WBPEEUI240751C0
Title
Installation Preparation
I/O Block Base Installation
I/O Module Installation
Auxiliary Block Installation
BLK-100 Installation
AIN-120 Setup
AIN-200 Setup
AIN-220 Setup
AIN-300 Setup
AOT-150 Setup
CIO-100 Setup
DIO-400 Setup
DOT-100 Setup
DOT-120 Setup
vii
List of Procedures (continued)
No.
PR15
PR16
PR17
PR18
PR19
PR20
PR21
PR22
PR23
PR24
PR25
PR26
PR27
PR28
PR29
PR30
PR31
PR32
PR33
PR34
Title
CIO-110 Setup
RLY-200 Setup
CIO-100/110 Cable Connection
RLY-100/200 Cable Connection
Field Wiring (S Type Base)
Field Wiring (C Type Base)
Field Wiring (Cable Connection)
CIO-110 Wiring
RLY-100/200 Wiring
Offline Diagnostics
Device Label Definition
I/O System Configuration
Connections Check
I/O Module Removal
I/O Block Base Removal
Auxiliary Block Removal
Wiring and Cabling Disconnection
DOT-100/120 Relay Replacement
RLY-100 Relay Replacement
RLY-200 Relay Replacement
List of Worksheets
No.
WS1
WS2
WS3
WS4
WS5
WS6
WS7
WS8
WS9
viii
Title
AIN-120
AIN-200
AIN-220
AIN-300
AOT-150
CIO-100
DIO-400
DOT-100
DOT-120
WBPEEUI240751C0
List of Figures
No.
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
7-1.
7-2.
WBPEEUI240751C0
Title
Page
Harmony Area Controller with Harmony I/O Blocks .................................. 1-2
Harmony Bridge Controller with Harmony I/O Blocks ............................... 1-3
Harmony I/O System ................................................................................ 1-4
Controller I/O Communication.................................................................. 1-7
Analog Control Station Interface................................................................ 2-9
Station Connection ................................................................................... 2-9
Analog Input ............................................................................................. 3-2
Analog Output .......................................................................................... 3-3
Digital Input ............................................................................................. 3-4
Digital Output........................................................................................... 3-5
I/O Block.................................................................................................. 3-7
Configuration Jumper Access.................................................................... 3-8
Block Diagram - I/O Module ..................................................................... 3-9
Block Power ............................................................................................ 3-10
Hnet Interface ......................................................................................... 3-11
Serial Link Interface................................................................................ 3-13
Screw Terminal Base (S Type).................................................................. 3-16
Clamp Terminal Base (C Type) ................................................................ 3-17
Terminal Markings (Door Removed) ......................................................... 3-18
C Type Base for Cable Connection ........................................................... 3-19
Redundant I/O Block .............................................................................. 3-21
Auxiliary Block........................................................................................ 3-24
Example I/O Connection, Setup, and Configuration ................................ 3-25
AIN-120 Block - Voltage Mode (Differential or Single -Ended) ..................... 4-4
AIN-120 Block - Current Mode (IFP or LFP Powered) .................................. 4-5
AIN-120 Block - Current Mode (RFP Powered)............................................ 4-6
AIN-200/220 Block - Voltage and Thermocouple Mode .............................. 4-7
AIN-220 Block - Current Mode (IFP or LFP Powered) .................................. 4-8
AIN-220 Block - Current Mode (RFP Powered)............................................ 4-9
AIN-300 Block......................................................................................... 4-10
AOT-150 Block ....................................................................................... 4-11
DIO-400 Block (IFP or LFP Powered) ........................................................ 4-12
DIO-400 Block (RFP Powered) ................................................................. 4-13
DOT-100 Block ....................................................................................... 4-14
DOT-120 Block ....................................................................................... 4-15
I/O and Auxiliary Block Installation and Connection Flowchart ................. 5-4
AIN Block Flowchart.................................................................................. 5-4
AOT Block Flowchart................................................................................. 5-5
CIO Block Flowchart ................................................................................. 5-6
DIO and RLY Blocks Flowchart.................................................................. 5-7
DOT Block Flowchart ................................................................................ 5-8
I/O Block Front Panel ............................................................................... 7-2
I/O Module Rear Panel.............................................................................. 7-6
ix
List of Figures (continued)
No.
7-3.
10-1.
10-2.
10-3.
10-4.
A-1.
A-2.
A-3.
A-4.
PR2-1.
PR3-1.
PR4-1.
PR5-1.
PR5-2.
PR6-1.
PR6-2.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR11-7.
PR11-8.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR14-3.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
x
Title
Page
Auxiliary Block Front Panel .....................................................................7-10
Replacement Flowchart (1 of 4) ................................................................10-2
I/O Module Replacement Flowchart (2 of 4)..............................................10-2
I/O Block and Auxiliary Block Replacement Flowchart (3 of 4) .................10-3
Relay Replacement Flowchart (4 of 4) .......................................................10-3
I/O Module............................................................................................... A-1
Nonredundant Base.................................................................................. A-2
Redundant Base ....................................................................................... A-3
Auxiliary Block ......................................................................................... A-4
Base Attachment .................................................................................. PR2-2
I/O Module Attachment ........................................................................ PR3-2
Auxiliary Block Installation................................................................... PR4-2
Base Attachment .................................................................................. PR5-2
Blank Module Attachment .................................................................... PR5-3
User-Configurable Jumpers - Base ....................................................... PR6-4
Analog Input Field Power Selection (J17/J18) ....................................... PR6-5
Analog Input (Simplified) ...................................................................... PR7-2
User-Configurable Jumpers - Base ....................................................... PR8-4
Analog Input Field Power Selection (J17/J18) ....................................... PR8-5
Analog Input (Simplified) ...................................................................... PR8-6
Analog Input (Simplified) ...................................................................... PR9-2
Analog Output (Simplified) .................................................................. PR10-2
User-Configurable Jumpers - Base ..................................................... PR11-5
Analog Input Field Power Selection (J15/J16) ..................................... PR11-6
Configuration Jumper Access ............................................................. PR11-6
User-Configurable Jumpers - I/O Board ............................................. PR11-7
Analog Input (Simplified) .................................................................... PR11-8
Analog Output (Simplified) .................................................................. PR11-9
Digital Input (Simplified) ..................................................................... PR11-9
Digital Output (Simplified) .................................................................PR11-10
Configuration Jumper Access ............................................................. PR12-5
User-Configurable Jumpers - I/O Board ............................................. PR12-6
Digital Input (Simplified) ..................................................................... PR12-7
Digital Output (Simplified) .................................................................. PR12-7
DIO with RLY - Digital Output (Simplified) .......................................... PR12-8
Digital Output (Simplified) .................................................................. PR13-2
Configuration Jumper Access ............................................................. PR14-3
User-Configurable Jumpers - I/O Board ............................................. PR14-4
Digital Output (Simplified) .................................................................. PR14-5
I/O Board Layout ............................................................................... PR15-2
I/O Board Layout (Shown Without Relays) .......................................... PR16-3
CIO Connection .................................................................................. PR17-1
Current Mode Bypass Cable Connection ............................................. PR17-3
WBPEEUI240751C0
List of Figures (continued)
No.
PR17-3.
PR18-1.
PR18-2.
PR19-1.
PR19-2.
PR19-3.
PR19-4.
PR19-5.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR22-1.
PR23-1.
PR23-2.
PR24-1.
PR28-1.
PR29-1.
PR30-1.
PR32-1.
PR32-2.
PR33-1.
PR34-1.
Title
Page
Electric Drive/Pulse Positioner Bypass Cable Connection .................... PR17-4
DIO to RLY Connection ....................................................................... PR18-1
DIO Block to RLY Block Cable Connection........................................... PR18-2
Screw Terminal Base........................................................................... PR19-2
Analog Input ....................................................................................... PR19-5
Analog Output .................................................................................... PR19-6
Digital Input ....................................................................................... PR19-6
Digital Output..................................................................................... PR19-7
Clamp Terminal Base.......................................................................... PR20-2
Analog Input ....................................................................................... PR20-5
Analog Output .................................................................................... PR20-5
Digital Input ....................................................................................... PR20-6
Digital Output..................................................................................... PR20-6
C Type Base for Cable Connection ....................................................... PR21-2
Shield Wire Faston Adapter ................................................................. PR21-4
Analog Input ....................................................................................... PR21-6
Analog Output .................................................................................... PR21-6
Digital Input ....................................................................................... PR21-7
Digital Output..................................................................................... PR21-7
Wiring Terminals and Assignments ..................................................... PR22-2
Wiring Terminals and Assignments (RLY-100) ..................................... PR23-3
Wiring Terminals and Assignments (RLY-200) ..................................... PR23-4
Diagnostics Status LED Indications..................................................... PR24-1
I/O Module Removal ........................................................................... PR28-2
Base Removal ..................................................................................... PR29-2
Auxiliary Block Removal...................................................................... PR30-2
Configuration Jumper Access.............................................................. PR32-2
I/O Board Layout (Shown Without Relays)........................................... PR32-3
RLY-100 Board Layout (Shown Without Relays)................................... PR33-3
RLY-200 Board Layout (Shown Without Relays)................................... PR34-3
List of Tables
No.
1-1.
1-2.
1-3.
1-4.
1-5.
WBPEEUI240751C0
Title
Page
Available I/O and Auxiliary Blocks ............................................................ 1-5
I/O Block Capabilities............................................................................... 1-6
Glossary of Terms and Abbreviations....................................................... 1-12
Reference Documents.............................................................................. 1-13
Abbreviated Harmony I/O System Nomenclature..................................... 1-14
xi
List of Tables (continued)
No.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
5-1.
6-1.
6-2.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
9-1.
11-1.
11-2.
11-3.
xii
Title
Page
Related Nomenclature..............................................................................1-14
Design Standards ....................................................................................1-15
General I/O Block Specifications .............................................................1-16
General Auxiliary Block Specifications .....................................................1-17
Environmental Specifications...................................................................1-18
AIN-120 Specifications...............................................................................2-1
AIN-200 Specifications...............................................................................2-3
AIN-220 Specifications...............................................................................2-4
AIN-300 Specifications...............................................................................2-5
AOT-150 Specifications..............................................................................2-6
BLK-100 Specifications..............................................................................2-8
CIO-100 Specifications ............................................................................2-10
CIO-110 Specifications ............................................................................2-13
DIO-400 Specifications ............................................................................2-13
DOT-100 Specifications ...........................................................................2-15
DOT-120 Specifications ...........................................................................2-16
RLY-100 Specifications (Electromechanical Relays) ..................................2-17
RLY-200 Specifications (Solid State Relays) ..............................................2-19
I/O Block Failure Mode Output Conditions ..............................................3-22
Channel Fault Currents (Nominal) Under Short Conditions ......................3-23
Installation Procedures ..............................................................................5-2
I/O Channel Function Code Summary .......................................................6-9
I/O Channel Specifications Summary ........................................................6-9
Operating Mode - Normal and Fault LEDs..................................................7-3
Normal Operating Mode Status Codes........................................................7-3
Digital Channel Status ..............................................................................7-4
Special Operations Switch (SW2) Settings ..................................................7-6
Terminal Strip Markings and Color Coding ................................................7-6
Startup Sequence ......................................................................................7-8
Operating Mode - Normal and Fault LEDs..................................................8-2
Block and Field Power LEDs ......................................................................8-3
Status Codes .............................................................................................8-4
I/O Block Problem Reports ........................................................................8-7
Station Problem Reports ..........................................................................8-10
P1 Power Pins..........................................................................................8-13
P4 Redundancy Link Pins ........................................................................8-13
P5 Communication Pins ..........................................................................8-14
CIO-100 P7 and P8 Connector Pins..........................................................8-14
DIO P17 Connector Pins ..........................................................................8-15
Preventive Maintenance Schedule ..............................................................9-2
Analog Input Nomenclature .....................................................................11-1
Analog Output Nomenclature...................................................................11-2
Control Input/Output Nomenclature .......................................................11-2
WBPEEUI240751C0
List of Tables (continued)
No.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
PR1-1.
PR1-2.
PR6-1.
PR6-2.
PR6-3.
PR6-4.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
PR19-1.
PR19-2.
PR19-3.
WBPEEUI240751C0
Title
Page
Digital Input/Output Nomenclature ........................................................ 11-3
Digital Output Nomenclature .................................................................. 11-3
Auxiliary Relay Assembly Nomenclature .................................................. 11-4
Blank Block Nomenclature...................................................................... 11-4
DIO to RLY Cable Nomenclature .............................................................. 11-4
I/O Block to Remote Termination Cable Nomenclature ............................ 11-5
CIO Cable Nomenclature ......................................................................... 11-5
Fuses...................................................................................................... 11-6
Relays..................................................................................................... 11-6
Miscellaneous ......................................................................................... 11-7
Worksheets ........................................................................................... PR1-2
Worksheet Information.......................................................................... PR1-3
Field Power Select Jumpers (Module)..................................................... PR6-2
Analog Input Field Power Select Jumpers (Base) .................................... PR6-2
Input Channel Jumpers ........................................................................ PR6-2
Analog Input (Simplified) ....................................................................... PR6-6
Field Power Select Jumpers................................................................... PR7-1
Field Power Select Jumpers (Module)..................................................... PR8-2
Analog Input Field Power Select Jumpers (Base) .................................... PR8-2
Input Channel Jumpers ........................................................................ PR8-2
Field Power Select Jumpers................................................................... PR9-1
Field Power Select Jumpers................................................................. PR10-1
Field Power Select Jumpers................................................................. PR11-2
Analog Input Field Power Select Jumpers (Base) .................................. PR11-2
Analog Input Channel Jumpers........................................................... PR11-3
Analog Output Channel Jumpers ........................................................ PR11-3
Digital Input Channel Jumpers ........................................................... PR11-4
Digital Output Channel Jumpers ........................................................ PR11-4
Digital Output Field Power Select Jumpers.......................................... PR12-2
Digital Input Field Power Select Jumper .............................................. PR12-2
Digital Input Field Power Monitor Jumper ........................................... PR12-2
Digital Input Channel Jumpers ........................................................... PR12-3
Digital Output Channel Jumpers ........................................................ PR12-4
Field Power Select Jumpers................................................................. PR13-2
Field Power Select Jumpers................................................................. PR14-2
Readback/Fusing Select Jumpers ....................................................... PR14-2
M/A Power Select Jumpers ................................................................. PR15-1
Fuses.................................................................................................. PR16-2
CIO-100 to CIO-110 Connector Relationship ....................................... PR17-2
CIO-100 and IISAC01 Analog Input Relationship ................................. PR17-2
Terminal Strip Markings and Color Coding .......................................... PR19-3
Terminal Assignments Tables .............................................................. PR19-4
AIN-120 and AIN-220 .......................................................................... PR19-8
xiii
List of Tables (continued)
No.
PR19-4.
PR19-5.
PR19-6.
PR19-7.
PR19-8.
PR19-9.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR20-6.
PR20-7.
PR20-8.
PR20-9.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR21-7.
PR21-8.
PR21-9.
PR21-10.
PR22-1.
PR22-2.
PR23-1.
PR23-2.
PR23-3.
PR24-1.
PR24-2.
PR24-3.
PR24-4.
xiv
Title
Page
AIN-200.............................................................................................. PR19-9
AIN-300.............................................................................................PR19-10
AOT-150............................................................................................PR19-11
CIO-100 ............................................................................................PR19-12
DIO-400 ............................................................................................PR19-13
DOT-100 and DOT-120......................................................................PR19-14
Terminal Strip Markings and Color Coding ......................................... PR20-3
Terminal Assignments Tables ............................................................. PR20-3
AIN-120 and AIN-220 ......................................................................... PR20-7
AIN-200.............................................................................................. PR20-8
AIN-300.............................................................................................. PR20-9
AOT-150............................................................................................PR20-10
CIO-100 ............................................................................................PR20-11
DIO-400 ............................................................................................PR20-12
DOT-100 and DOT-120......................................................................PR20-13
HRM-RTS Cable Requirements ........................................................... PR21-3
Terminal Strip Markings and Color Coding ......................................... PR21-5
Connector Pin Assignments Tables ..................................................... PR21-5
AIN-120 and AIN-220 ......................................................................... PR21-8
AIN-200.............................................................................................. PR21-9
AIN-300.............................................................................................PR21-10
AOT-150............................................................................................PR21-11
CIO-100 ............................................................................................PR21-12
DIO-400 ............................................................................................PR21-13
DOT-100 and DOT-120......................................................................PR21-14
Station to Wiring Terminal Relationship.............................................. PR22-3
Terminal Assignments ........................................................................ PR22-3
Channel Label Makings ...................................................................... PR23-2
RLY-100 Terminal Assignments .......................................................... PR23-5
RLY-200 Terminal Assignments .......................................................... PR23-6
Offline Diagnostic Tests - Switch Settings ........................................... PR24-2
Group 1 Diagnostic Tests.................................................................... PR24-3
Group 2 Diagnostic Tests.................................................................... PR24-4
Group 3 Diagnostic Tests.................................................................... PR24-5
WBPEEUI240751C0
Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as described in the installation section.
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous. (p. 3-7, PR3-1,
PR28-1)
Verify the main power, field power, and power entry panel circuit
breakers/switches are turned off before starting installation, retrofit,
upgrade, or wiring procedures. Failure to do so could result in
severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete. (p. PR19-1,
PR20-1, PR21-2, PR22-1, PR23-1, PR31-1)
Turn off all power before attempting the connections check maintenance procedure. Failure to do so could result in severe or fatal
shock, or equipment damage. (p. PR27-1)
Verify power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal shock. Do not
turn the power on until the replacement procedure is complete.
(p. PR33-1, PR34-1)
WBPEEUI240751C0
xv
Safety Summary (continued)
SPECIFIC
CAUTIONS
For analog input channels, if the fused AI IFP/LFP option is selected
to power a 4 to 20 milliampere input, removing the I/O module from
the base in nonredundant applications will result in a loss of power
to all input current loops. (p. PR6-1, PR8-1, PR11-1, PR28-1)
Insure the setting for the digital input field power monitor jumper
DIFP-J2 matches the actual field power voltage (IFP or LFP). Circuit
damage will occur if the LFP voltage is greater than the voltage setting of jumper DIFP-J2. (p. PR12-1)
Use only ABB Automation approved relays on the relay assembly.
Using unapproved relays could improperly route signals and damage equipment connected to the relay and the relay itself. CSA certification is voided when unapproved relays are used. (p. PR16-1,
PR32-1, PR33-1, PR34-1)
xvi
WBPEEUI240751C0
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and
scheduling.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI240751C0
xvii
Trademarks and Registrations
Registrations and trademarks used in this document include:
™ Composer
® INFI 90
® INFI-NET
xviii
Trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
WBPEEUI240751C0
Preface
The Harmony Input/Output (I/O) System sets new standards
for user convenience in industrial I/O. A wide variety of I/O
building blocks can be combined to form an optimum solution
for a specific application. The Harmony I/O system is part of
the Symphony Enterprise Management and Control System. It
is, however, fully compatible with the INFI 90® OPEN Strategic
Enterprise Management System.
This instruction overviews the Harmony I/O system; describes
the analog, digital, and control I/O blocks and auxiliary blocks
used for field I/O interface; and provides I/O and auxiliary
block installation and connection procedures.
WBPEEUI240751C0
List of Effective Pages
Total number of pages in this instruction is 368, consisting of the following:
Page No.
Preface
List of Effective Pages
iii through xviii
1-1 through 1-18
2-1 through 2-19
3-1 through 3-26
4-1 through 4-15
5-1 through 5-8
6-1 through 6-16
7-1 through 7-10
8-1 through 8-15
9-1 through 9-2
10-1 through 10-3
11-1 through 11-7
A-1 through A-4
PR1-1 through PR1-3
PR2-1 through PR2-2
PR3-1 through PR3-2
PR4-1 through PR4-2
PR5-1 through PR5-3
PR6-1 through PR6-6
PR7-1 through PR7-2
PR8-1 through PR8-6
PR9-1 through PR9-2
PR10-1 through PR10-2
PR11-1 through PR11-10
PR12-1 through PR12-8
PR13-1 through PR13-2
PR14-1 through PR14-5
PR15-1 through PR15-2
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
PR16-1
PR17-1
PR18-1
PR19-1
PR20-1
PR21-1
PR22-1
PR23-1
PR24-1
PR25-1
PR26-1
PR27-1
PR28-1
PR29-1
PR30-1
PR31-1
PR32-1
PR33-1
PR34-1
WS1-1
WS2-1
WS3-1
WS4-1
WS5-1
WS6-1
WS7-1
WS8-1
WS9-1
Index-1
Page No.
through PR16-3
through PR17-4
through PR18-2
through PR19-14
through PR20-13
through PR21-14
through PR22-3
through PR23-6
through PR24-5
through PR25-2
through PR26-2
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
PR28-2
PR29-2
PR30-2
PR31-2
PR32-3
PR33-3
PR34-3
WS1-7
WS2-7
WS3-9
WS4-9
WS5-5
WS6-5
WS7-9
WS8-4
WS9-4
Index-5
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
WBPEEUI240751C0
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Purpose ................................................................................................................... 1-1
Harmony I/O System Documentation....................................................................... 1-1
System Overview ...................................................................................................... 1-2
Input/Output .......................................................................................................... 1-4
Harmony Controllers................................................................................................ 1-5
Harmony Bridge Controller................................................................................... 1-5
Harmony Area Controller...................................................................................... 1-7
Function Codes........................................................................................................ 1-8
Compatibility ........................................................................................................... 1-8
Features .................................................................................................................. 1-8
Intended User .......................................................................................................... 1-9
Instruction Content................................................................................................ 1-10
How to Use this Instruction .................................................................................... 1-11
Document Conventions .......................................................................................... 1-12
Glossary of Terms and Abbreviations...................................................................... 1-12
Reference Documents............................................................................................. 1-13
Abbreviated Harmony I/O Nomenclature ................................................................ 1-13
Related Nomenclature ............................................................................................ 1-14
Design Standards................................................................................................... 1-14
Specifications......................................................................................................... 1-16
Section 2 Input/Output Blocks ....................................................................................2-1
Introduction............................................................................................................. 2-1
AIN-120 ................................................................................................................... 2-1
AIN-200 ................................................................................................................... 2-2
AIN-220 ................................................................................................................... 2-4
AIN-300 ................................................................................................................... 2-5
AOT-150 .................................................................................................................. 2-6
BLK-100 .................................................................................................................. 2-7
CIO-100 ................................................................................................................... 2-8
CIO-110 ................................................................................................................. 2-12
DIO-400................................................................................................................. 2-13
DOT-100................................................................................................................ 2-15
DOT-120................................................................................................................ 2-16
RLY-100................................................................................................................. 2-17
RLY-200................................................................................................................. 2-18
Section 3 Description and Operation .........................................................................3-1
Introduction............................................................................................................. 3-1
Inputs and Outputs ................................................................................................. 3-1
WBPEEUI240751C0
iii
Table of Contents (continued)
Section 3 Description and Operation (continued)
Analog Input .........................................................................................................3-1
Data Conversion ...............................................................................................3-2
Calibrations ......................................................................................................3-3
Analog Output ......................................................................................................3-3
Data Conversion ...............................................................................................3-3
Calibrations ......................................................................................................3-3
Readback ..........................................................................................................3-4
Digital Input .........................................................................................................3-4
Digital Output ......................................................................................................3-5
I/O Block .................................................................................................................3-6
I/O Module ...........................................................................................................3-7
Block Power ......................................................................................................3-8
Central Processing Unit...................................................................................3-10
Memory ..........................................................................................................3-11
Hnet Interface .................................................................................................3-11
Machine Fault Timer .......................................................................................3-12
Serial Link Interface ........................................................................................3-12
LED Drivers and Status LEDs .........................................................................3-14
I/O Channel Interface .....................................................................................3-14
I/O Section .....................................................................................................3-14
Special Operations Switch (SW2) .....................................................................3-15
Base ...................................................................................................................3-15
Screw and Clamp Termination Bases ..............................................................3-15
Cable Connection............................................................................................3-18
Shield Terminations (Chassis Ground) ............................................................3-19
I/O Module Mounting .....................................................................................3-19
Hardware Keying ................................................................................................3-20
I/O Redundancy .................................................................................................3-20
Failure Mode (Outputs) .......................................................................................3-20
Short Circuit Protection ......................................................................................3-22
Auxiliary Block .......................................................................................................3-24
I/O System Configuration.......................................................................................3-24
I/O Block Hardware............................................................................................3-25
I/O Block Function Codes...................................................................................3-25
Section 4 Redundancy .................................................................................................4-1
Introduction .............................................................................................................4-1
Description...............................................................................................................4-1
Redundancy Arbitration........................................................................................4-2
Failover ................................................................................................................4-2
Analog Input.............................................................................................................4-3
iv
WBPEEUI240751C0
Table of Contents (continued)
Section 4 Redundancy (continued)
Analog Output ......................................................................................................... 4-4
Digital Input ............................................................................................................ 4-7
Digital Output.......................................................................................................... 4-9
Section 5 Installation ....................................................................................................5-1
Introduction............................................................................................................. 5-1
Special Handling ...................................................................................................... 5-1
Unpacking and Inspection........................................................................................ 5-2
Installation Procedures ............................................................................................ 5-2
Installation and Connection Sequence...................................................................... 5-3
Section 6 Configuration ...............................................................................................6-1
Introduction............................................................................................................. 6-1
Configuration Tools.................................................................................................. 6-1
Harmony Controller ................................................................................................. 6-1
Download............................................................................................................. 6-1
Verification........................................................................................................... 6-2
Changes............................................................................................................... 6-2
Time Synchronization........................................................................................... 6-3
Firmware Download ............................................................................................. 6-3
Labels ...................................................................................................................... 6-3
Device Label ......................................................................................................... 6-4
Electronic ID .................................................................................................... 6-4
Establishing a Device Label .............................................................................. 6-4
Predefining a Device Label ................................................................................ 6-5
Online Configuration ........................................................................................ 6-5
Channel Label ...................................................................................................... 6-6
Duplicate Labels................................................................................................... 6-6
Function Codes........................................................................................................ 6-7
I/O Device Definition (FC 221) .............................................................................. 6-8
I/O Channel (FC 222, 223, 224, 225).................................................................... 6-9
I/O Channel Data........................................................................................... 6-11
Suspect Condition .......................................................................................... 6-11
Exception Reporting ....................................................................................... 6-13
Engineering Units (EU) ................................................................................... 6-13
I/O Source ..................................................................................................... 6-14
Hnet Stall Mode (Default State) ....................................................................... 6-15
Status Reporting ............................................................................................ 6-15
Alarming ........................................................................................................ 6-15
Shaping Algorithms ........................................................................................ 6-16
WBPEEUI240751C0
v
Table of Contents (continued)
Section 6 Configuration (continued)
Test Status (FC 226) ...........................................................................................6-16
Section 7 Operating Procedures .................................................................................7-1
Introduction .............................................................................................................7-1
I/O Block .................................................................................................................7-1
I/O Module Front Panel ........................................................................................7-1
Block Type and Model .......................................................................................7-1
Operating Mode - Normal and Fault ..................................................................7-2
Status...............................................................................................................7-2
Block Power ......................................................................................................7-3
Field Power .......................................................................................................7-4
Digital Channels ...............................................................................................7-4
ID Labels ..........................................................................................................7-5
I/O Module Rear Panel..........................................................................................7-5
Termination Base Color Coding and Markings .......................................................7-6
Operation .............................................................................................................7-7
Startup .............................................................................................................7-7
Stop/Reset Button ............................................................................................7-7
Initialization......................................................................................................7-8
Auxiliary Block .........................................................................................................7-9
Section 8 Troubleshooting ..........................................................................................8-1
Introduction .............................................................................................................8-1
Troubleshooting Procedures......................................................................................8-1
Operating Mode - Normal and Fault LEDs.................................................................8-1
Power LEDs ..............................................................................................................8-2
Status Code LEDs ....................................................................................................8-2
I/O Block Problem Reports .......................................................................................8-6
Station Problem Reports ...........................................................................................8-9
I/O Block Status ....................................................................................................8-11
Diagnostics ............................................................................................................8-12
Online ................................................................................................................8-12
Offline ................................................................................................................8-12
I/O Block Connectors .............................................................................................8-13
I/O Module (P1, P4, P5).......................................................................................8-13
CIO-100 (P7, P8) .................................................................................................8-14
DIO (P17) ............................................................................................................8-15
vi
WBPEEUI240751C0
Table of Contents (continued)
Section 9 Maintenance .................................................................................................9-1
Introduction............................................................................................................. 9-1
Preventive Maintenance Schedule............................................................................. 9-1
Section 10 Repair and Replacement .........................................................................10-1
Introduction........................................................................................................... 10-1
Repair.................................................................................................................... 10-1
Replacement .......................................................................................................... 10-1
Section 11 Replacement and Spare Parts ................................................................11-1
Introduction........................................................................................................... 11-1
I/O and Auxiliary Block Nomenclature ................................................................... 11-1
Cable Nomenclature............................................................................................... 11-4
Miscellaneous Parts ............................................................................................... 11-6
Appendix A Hardware Drawings ................................................................................ A-1
Introduction............................................................................................................. A-1
I/O Block................................................................................................................. A-1
Auxiliary Block......................................................................................................... A-4
List of Procedures
No.
PR1
PR2
PR3
PR4
PR5
PR6
PR7
PR8
PR9
PR10
PR11
PR12
PR13
PR14
WBPEEUI240751C0
Title
Installation Preparation
I/O Block Base Installation
I/O Module Installation
Auxiliary Block Installation
BLK-100 Installation
AIN-120 Setup
AIN-200 Setup
AIN-220 Setup
AIN-300 Setup
AOT-150 Setup
CIO-100 Setup
DIO-400 Setup
DOT-100 Setup
DOT-120 Setup
vii
List of Procedures (continued)
No.
PR15
PR16
PR17
PR18
PR19
PR20
PR21
PR22
PR23
PR24
PR25
PR26
PR27
PR28
PR29
PR30
PR31
PR32
PR33
PR34
Title
CIO-110 Setup
RLY-200 Setup
CIO-100/110 Cable Connection
RLY-100/200 Cable Connection
Field Wiring (S Type Base)
Field Wiring (C Type Base)
Field Wiring (Cable Connection)
CIO-110 Wiring
RLY-100/200 Wiring
Offline Diagnostics
Device Label Definition
I/O System Configuration
Connections Check
I/O Module Removal
I/O Block Base Removal
Auxiliary Block Removal
Wiring and Cabling Disconnection
DOT-100/120 Relay Replacement
RLY-100 Relay Replacement
RLY-200 Relay Replacement
List of Worksheets
No.
WS1
WS2
WS3
WS4
WS5
WS6
WS7
WS8
WS9
viii
Title
AIN-120
AIN-200
AIN-220
AIN-300
AOT-150
CIO-100
DIO-400
DOT-100
DOT-120
WBPEEUI240751C0
List of Figures
No.
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
7-1.
7-2.
WBPEEUI240751C0
Title
Page
Harmony Area Controller with Harmony I/O Blocks .................................. 1-2
Harmony Bridge Controller with Harmony I/O Blocks ............................... 1-3
Harmony I/O System ................................................................................ 1-4
Controller I/O Communication.................................................................. 1-7
Analog Control Station Interface................................................................ 2-9
Station Connection ................................................................................... 2-9
Analog Input ............................................................................................. 3-2
Analog Output .......................................................................................... 3-3
Digital Input ............................................................................................. 3-4
Digital Output........................................................................................... 3-5
I/O Block.................................................................................................. 3-7
Configuration Jumper Access.................................................................... 3-8
Block Diagram - I/O Module ..................................................................... 3-9
Block Power ............................................................................................ 3-10
Hnet Interface ......................................................................................... 3-11
Serial Link Interface................................................................................ 3-13
Screw Terminal Base (S Type).................................................................. 3-16
Clamp Terminal Base (C Type) ................................................................ 3-17
Terminal Markings (Door Removed) ......................................................... 3-18
C Type Base for Cable Connection ........................................................... 3-19
Redundant I/O Block .............................................................................. 3-21
Auxiliary Block........................................................................................ 3-24
Example I/O Connection, Setup, and Configuration ................................ 3-25
AIN-120 Block - Voltage Mode (Differential or Single -Ended) ..................... 4-4
AIN-120 Block - Current Mode (IFP or LFP Powered) .................................. 4-5
AIN-120 Block - Current Mode (RFP Powered)............................................ 4-6
AIN-200/220 Block - Voltage and Thermocouple Mode .............................. 4-7
AIN-220 Block - Current Mode (IFP or LFP Powered) .................................. 4-8
AIN-220 Block - Current Mode (RFP Powered)............................................ 4-9
AIN-300 Block......................................................................................... 4-10
AOT-150 Block ....................................................................................... 4-11
DIO-400 Block (IFP or LFP Powered) ........................................................ 4-12
DIO-400 Block (RFP Powered) ................................................................. 4-13
DOT-100 Block ....................................................................................... 4-14
DOT-120 Block ....................................................................................... 4-15
I/O and Auxiliary Block Installation and Connection Flowchart ................. 5-4
AIN Block Flowchart.................................................................................. 5-4
AOT Block Flowchart................................................................................. 5-5
CIO Block Flowchart ................................................................................. 5-6
DIO and RLY Blocks Flowchart.................................................................. 5-7
DOT Block Flowchart ................................................................................ 5-8
I/O Block Front Panel ............................................................................... 7-2
I/O Module Rear Panel.............................................................................. 7-6
ix
List of Figures (continued)
No.
7-3.
10-1.
10-2.
10-3.
10-4.
A-1.
A-2.
A-3.
A-4.
PR2-1.
PR3-1.
PR4-1.
PR5-1.
PR5-2.
PR6-1.
PR6-2.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR11-7.
PR11-8.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR14-3.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
x
Title
Page
Auxiliary Block Front Panel .....................................................................7-10
Replacement Flowchart (1 of 4) ................................................................10-2
I/O Module Replacement Flowchart (2 of 4)..............................................10-2
I/O Block and Auxiliary Block Replacement Flowchart (3 of 4) .................10-3
Relay Replacement Flowchart (4 of 4) .......................................................10-3
I/O Module............................................................................................... A-1
Nonredundant Base.................................................................................. A-2
Redundant Base ....................................................................................... A-3
Auxiliary Block ......................................................................................... A-4
Base Attachment .................................................................................. PR2-2
I/O Module Attachment ........................................................................ PR3-2
Auxiliary Block Installation................................................................... PR4-2
Base Attachment .................................................................................. PR5-2
Blank Module Attachment .................................................................... PR5-3
User-Configurable Jumpers - Base ....................................................... PR6-4
Analog Input Field Power Selection (J17/J18) ....................................... PR6-5
Analog Input (Simplified) ...................................................................... PR7-2
User-Configurable Jumpers - Base ....................................................... PR8-4
Analog Input Field Power Selection (J17/J18) ....................................... PR8-5
Analog Input (Simplified) ...................................................................... PR8-6
Analog Input (Simplified) ...................................................................... PR9-2
Analog Output (Simplified) .................................................................. PR10-2
User-Configurable Jumpers - Base ..................................................... PR11-5
Analog Input Field Power Selection (J15/J16) ..................................... PR11-6
Configuration Jumper Access ............................................................. PR11-6
User-Configurable Jumpers - I/O Board ............................................. PR11-7
Analog Input (Simplified) .................................................................... PR11-8
Analog Output (Simplified) .................................................................. PR11-9
Digital Input (Simplified) ..................................................................... PR11-9
Digital Output (Simplified) .................................................................PR11-10
Configuration Jumper Access ............................................................. PR12-5
User-Configurable Jumpers - I/O Board ............................................. PR12-6
Digital Input (Simplified) ..................................................................... PR12-7
Digital Output (Simplified) .................................................................. PR12-7
DIO with RLY - Digital Output (Simplified) .......................................... PR12-8
Digital Output (Simplified) .................................................................. PR13-2
Configuration Jumper Access ............................................................. PR14-3
User-Configurable Jumpers - I/O Board ............................................. PR14-4
Digital Output (Simplified) .................................................................. PR14-5
I/O Board Layout ............................................................................... PR15-2
I/O Board Layout (Shown Without Relays) .......................................... PR16-3
CIO Connection .................................................................................. PR17-1
Current Mode Bypass Cable Connection ............................................. PR17-3
WBPEEUI240751C0
List of Figures (continued)
No.
PR17-3.
PR18-1.
PR18-2.
PR19-1.
PR19-2.
PR19-3.
PR19-4.
PR19-5.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR22-1.
PR23-1.
PR23-2.
PR24-1.
PR28-1.
PR29-1.
PR30-1.
PR32-1.
PR32-2.
PR33-1.
PR34-1.
Title
Page
Electric Drive/Pulse Positioner Bypass Cable Connection .................... PR17-4
DIO to RLY Connection ....................................................................... PR18-1
DIO Block to RLY Block Cable Connection........................................... PR18-2
Screw Terminal Base........................................................................... PR19-2
Analog Input ....................................................................................... PR19-5
Analog Output .................................................................................... PR19-6
Digital Input ....................................................................................... PR19-6
Digital Output..................................................................................... PR19-7
Clamp Terminal Base.......................................................................... PR20-2
Analog Input ....................................................................................... PR20-5
Analog Output .................................................................................... PR20-5
Digital Input ....................................................................................... PR20-6
Digital Output..................................................................................... PR20-6
C Type Base for Cable Connection ....................................................... PR21-2
Shield Wire Faston Adapter ................................................................. PR21-4
Analog Input ....................................................................................... PR21-6
Analog Output .................................................................................... PR21-6
Digital Input ....................................................................................... PR21-7
Digital Output..................................................................................... PR21-7
Wiring Terminals and Assignments ..................................................... PR22-2
Wiring Terminals and Assignments (RLY-100) ..................................... PR23-3
Wiring Terminals and Assignments (RLY-200) ..................................... PR23-4
Diagnostics Status LED Indications..................................................... PR24-1
I/O Module Removal ........................................................................... PR28-2
Base Removal ..................................................................................... PR29-2
Auxiliary Block Removal...................................................................... PR30-2
Configuration Jumper Access.............................................................. PR32-2
I/O Board Layout (Shown Without Relays)........................................... PR32-3
RLY-100 Board Layout (Shown Without Relays)................................... PR33-3
RLY-200 Board Layout (Shown Without Relays)................................... PR34-3
List of Tables
No.
1-1.
1-2.
1-3.
1-4.
1-5.
WBPEEUI240751C0
Title
Page
Available I/O and Auxiliary Blocks ............................................................ 1-5
I/O Block Capabilities............................................................................... 1-6
Glossary of Terms and Abbreviations....................................................... 1-12
Reference Documents.............................................................................. 1-13
Abbreviated Harmony I/O System Nomenclature..................................... 1-14
xi
List of Tables (continued)
No.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
5-1.
6-1.
6-2.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
9-1.
11-1.
11-2.
11-3.
xii
Title
Page
Related Nomenclature..............................................................................1-14
Design Standards ....................................................................................1-15
General I/O Block Specifications .............................................................1-16
General Auxiliary Block Specifications .....................................................1-17
Environmental Specifications...................................................................1-18
AIN-120 Specifications...............................................................................2-1
AIN-200 Specifications...............................................................................2-3
AIN-220 Specifications...............................................................................2-4
AIN-300 Specifications...............................................................................2-5
AOT-150 Specifications..............................................................................2-6
BLK-100 Specifications..............................................................................2-8
CIO-100 Specifications ............................................................................2-10
CIO-110 Specifications ............................................................................2-13
DIO-400 Specifications ............................................................................2-13
DOT-100 Specifications ...........................................................................2-15
DOT-120 Specifications ...........................................................................2-16
RLY-100 Specifications (Electromechanical Relays) ..................................2-17
RLY-200 Specifications (Solid State Relays) ..............................................2-19
I/O Block Failure Mode Output Conditions ..............................................3-22
Channel Fault Currents (Nominal) Under Short Conditions ......................3-23
Installation Procedures ..............................................................................5-2
I/O Channel Function Code Summary .......................................................6-9
I/O Channel Specifications Summary ........................................................6-9
Operating Mode - Normal and Fault LEDs..................................................7-3
Normal Operating Mode Status Codes........................................................7-3
Digital Channel Status ..............................................................................7-4
Special Operations Switch (SW2) Settings ..................................................7-6
Terminal Strip Markings and Color Coding ................................................7-6
Startup Sequence ......................................................................................7-8
Operating Mode - Normal and Fault LEDs..................................................8-2
Block and Field Power LEDs ......................................................................8-3
Status Codes .............................................................................................8-4
I/O Block Problem Reports ........................................................................8-7
Station Problem Reports ..........................................................................8-10
P1 Power Pins..........................................................................................8-13
P4 Redundancy Link Pins ........................................................................8-13
P5 Communication Pins ..........................................................................8-14
CIO-100 P7 and P8 Connector Pins..........................................................8-14
DIO P17 Connector Pins ..........................................................................8-15
Preventive Maintenance Schedule ..............................................................9-2
Analog Input Nomenclature .....................................................................11-1
Analog Output Nomenclature...................................................................11-2
Control Input/Output Nomenclature .......................................................11-2
WBPEEUI240751C0
List of Tables (continued)
No.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
PR1-1.
PR1-2.
PR6-1.
PR6-2.
PR6-3.
PR6-4.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
PR19-1.
PR19-2.
PR19-3.
WBPEEUI240751C0
Title
Page
Digital Input/Output Nomenclature ........................................................ 11-3
Digital Output Nomenclature .................................................................. 11-3
Auxiliary Relay Assembly Nomenclature .................................................. 11-4
Blank Block Nomenclature...................................................................... 11-4
DIO to RLY Cable Nomenclature .............................................................. 11-4
I/O Block to Remote Termination Cable Nomenclature ............................ 11-5
CIO Cable Nomenclature ......................................................................... 11-5
Fuses...................................................................................................... 11-6
Relays..................................................................................................... 11-6
Miscellaneous ......................................................................................... 11-7
Worksheets ........................................................................................... PR1-2
Worksheet Information.......................................................................... PR1-3
Field Power Select Jumpers (Module)..................................................... PR6-2
Analog Input Field Power Select Jumpers (Base) .................................... PR6-2
Input Channel Jumpers ........................................................................ PR6-2
Analog Input (Simplified) ....................................................................... PR6-6
Field Power Select Jumpers................................................................... PR7-1
Field Power Select Jumpers (Module)..................................................... PR8-2
Analog Input Field Power Select Jumpers (Base) .................................... PR8-2
Input Channel Jumpers ........................................................................ PR8-2
Field Power Select Jumpers................................................................... PR9-1
Field Power Select Jumpers................................................................. PR10-1
Field Power Select Jumpers................................................................. PR11-2
Analog Input Field Power Select Jumpers (Base) .................................. PR11-2
Analog Input Channel Jumpers........................................................... PR11-3
Analog Output Channel Jumpers ........................................................ PR11-3
Digital Input Channel Jumpers ........................................................... PR11-4
Digital Output Channel Jumpers ........................................................ PR11-4
Digital Output Field Power Select Jumpers.......................................... PR12-2
Digital Input Field Power Select Jumper .............................................. PR12-2
Digital Input Field Power Monitor Jumper ........................................... PR12-2
Digital Input Channel Jumpers ........................................................... PR12-3
Digital Output Channel Jumpers ........................................................ PR12-4
Field Power Select Jumpers................................................................. PR13-2
Field Power Select Jumpers................................................................. PR14-2
Readback/Fusing Select Jumpers ....................................................... PR14-2
M/A Power Select Jumpers ................................................................. PR15-1
Fuses.................................................................................................. PR16-2
CIO-100 to CIO-110 Connector Relationship ....................................... PR17-2
CIO-100 and IISAC01 Analog Input Relationship ................................. PR17-2
Terminal Strip Markings and Color Coding .......................................... PR19-3
Terminal Assignments Tables .............................................................. PR19-4
AIN-120 and AIN-220 .......................................................................... PR19-8
xiii
List of Tables (continued)
No.
PR19-4.
PR19-5.
PR19-6.
PR19-7.
PR19-8.
PR19-9.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR20-6.
PR20-7.
PR20-8.
PR20-9.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR21-7.
PR21-8.
PR21-9.
PR21-10.
PR22-1.
PR22-2.
PR23-1.
PR23-2.
PR23-3.
PR24-1.
PR24-2.
PR24-3.
PR24-4.
xiv
Title
Page
AIN-200.............................................................................................. PR19-9
AIN-300.............................................................................................PR19-10
AOT-150............................................................................................PR19-11
CIO-100 ............................................................................................PR19-12
DIO-400 ............................................................................................PR19-13
DOT-100 and DOT-120......................................................................PR19-14
Terminal Strip Markings and Color Coding ......................................... PR20-3
Terminal Assignments Tables ............................................................. PR20-3
AIN-120 and AIN-220 ......................................................................... PR20-7
AIN-200.............................................................................................. PR20-8
AIN-300.............................................................................................. PR20-9
AOT-150............................................................................................PR20-10
CIO-100 ............................................................................................PR20-11
DIO-400 ............................................................................................PR20-12
DOT-100 and DOT-120......................................................................PR20-13
HRM-RTS Cable Requirements ........................................................... PR21-3
Terminal Strip Markings and Color Coding ......................................... PR21-5
Connector Pin Assignments Tables ..................................................... PR21-5
AIN-120 and AIN-220 ......................................................................... PR21-8
AIN-200.............................................................................................. PR21-9
AIN-300.............................................................................................PR21-10
AOT-150............................................................................................PR21-11
CIO-100 ............................................................................................PR21-12
DIO-400 ............................................................................................PR21-13
DOT-100 and DOT-120......................................................................PR21-14
Station to Wiring Terminal Relationship.............................................. PR22-3
Terminal Assignments ........................................................................ PR22-3
Channel Label Makings ...................................................................... PR23-2
RLY-100 Terminal Assignments .......................................................... PR23-5
RLY-200 Terminal Assignments .......................................................... PR23-6
Offline Diagnostic Tests - Switch Settings ........................................... PR24-2
Group 1 Diagnostic Tests.................................................................... PR24-3
Group 2 Diagnostic Tests.................................................................... PR24-4
Group 3 Diagnostic Tests.................................................................... PR24-5
WBPEEUI240751C0
Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as described in the installation section.
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous. (p. 3-7, PR3-1,
PR28-1)
Verify the main power, field power, and power entry panel circuit
breakers/switches are turned off before starting installation, retrofit,
upgrade, or wiring procedures. Failure to do so could result in
severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete. (p. PR19-1,
PR20-1, PR21-2, PR22-1, PR23-1, PR31-1)
Turn off all power before attempting the connections check maintenance procedure. Failure to do so could result in severe or fatal
shock, or equipment damage. (p. PR27-1)
Verify power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal shock. Do not
turn the power on until the replacement procedure is complete.
(p. PR33-1, PR34-1)
WBPEEUI240751C0
xv
Safety Summary (continued)
SPECIFIC
CAUTIONS
For analog input channels, if the fused AI IFP/LFP option is selected
to power a 4 to 20 milliampere input, removing the I/O module from
the base in nonredundant applications will result in a loss of power
to all input current loops. (p. PR6-1, PR8-1, PR11-1, PR28-1)
Insure the setting for the digital input field power monitor jumper
DIFP-J2 matches the actual field power voltage (IFP or LFP). Circuit
damage will occur if the LFP voltage is greater than the voltage setting of jumper DIFP-J2. (p. PR12-1)
Use only ABB Automation approved relays on the relay assembly.
Using unapproved relays could improperly route signals and damage equipment connected to the relay and the relay itself. CSA certification is voided when unapproved relays are used. (p. PR16-1,
PR32-1, PR33-1, PR34-1)
xvi
WBPEEUI240751C0
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and
scheduling.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI240751C0
xvii
Trademarks and Registrations
Registrations and trademarks used in this document include:
™ Composer
® INFI 90
® INFI-NET
xviii
Trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
WBPEEUI240751C0
Preface
The Harmony Input/Output (I/O) System sets new standards
for user convenience in industrial I/O. A wide variety of I/O
building blocks can be combined to form an optimum solution
for a specific application. The Harmony I/O system is part of
the Symphony Enterprise Management and Control System. It
is, however, fully compatible with the INFI 90® OPEN Strategic
Enterprise Management System.
This instruction overviews the Harmony I/O system; describes
the analog, digital, and control I/O blocks and auxiliary blocks
used for field I/O interface; and provides I/O and auxiliary
block installation and connection procedures.
WBPEEUI240751C0
List of Effective Pages
Total number of pages in this instruction is 368, consisting of the following:
Page No.
Preface
List of Effective Pages
iii through xviii
1-1 through 1-18
2-1 through 2-19
3-1 through 3-26
4-1 through 4-15
5-1 through 5-8
6-1 through 6-16
7-1 through 7-10
8-1 through 8-15
9-1 through 9-2
10-1 through 10-3
11-1 through 11-7
A-1 through A-4
PR1-1 through PR1-3
PR2-1 through PR2-2
PR3-1 through PR3-2
PR4-1 through PR4-2
PR5-1 through PR5-3
PR6-1 through PR6-6
PR7-1 through PR7-2
PR8-1 through PR8-6
PR9-1 through PR9-2
PR10-1 through PR10-2
PR11-1 through PR11-10
PR12-1 through PR12-8
PR13-1 through PR13-2
PR14-1 through PR14-5
PR15-1 through PR15-2
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
PR16-1
PR17-1
PR18-1
PR19-1
PR20-1
PR21-1
PR22-1
PR23-1
PR24-1
PR25-1
PR26-1
PR27-1
PR28-1
PR29-1
PR30-1
PR31-1
PR32-1
PR33-1
PR34-1
WS1-1
WS2-1
WS3-1
WS4-1
WS5-1
WS6-1
WS7-1
WS8-1
WS9-1
Index-1
Page No.
through PR16-3
through PR17-4
through PR18-2
through PR19-14
through PR20-13
through PR21-14
through PR22-3
through PR23-6
through PR24-5
through PR25-2
through PR26-2
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
PR28-2
PR29-2
PR30-2
PR31-2
PR32-3
PR33-3
PR34-3
WS1-7
WS2-7
WS3-9
WS4-9
WS5-5
WS6-5
WS7-9
WS8-4
WS9-4
Index-5
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
WBPEEUI240751C0
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Purpose ................................................................................................................... 1-1
Harmony I/O System Documentation....................................................................... 1-1
System Overview ...................................................................................................... 1-2
Input/Output .......................................................................................................... 1-4
Harmony Controllers................................................................................................ 1-5
Harmony Bridge Controller................................................................................... 1-5
Harmony Area Controller...................................................................................... 1-7
Function Codes........................................................................................................ 1-8
Compatibility ........................................................................................................... 1-8
Features .................................................................................................................. 1-8
Intended User .......................................................................................................... 1-9
Instruction Content................................................................................................ 1-10
How to Use this Instruction .................................................................................... 1-11
Document Conventions .......................................................................................... 1-12
Glossary of Terms and Abbreviations...................................................................... 1-12
Reference Documents............................................................................................. 1-13
Abbreviated Harmony I/O Nomenclature ................................................................ 1-13
Related Nomenclature ............................................................................................ 1-14
Design Standards................................................................................................... 1-14
Specifications......................................................................................................... 1-16
Section 2 Input/Output Blocks ....................................................................................2-1
Introduction............................................................................................................. 2-1
AIN-120 ................................................................................................................... 2-1
AIN-200 ................................................................................................................... 2-2
AIN-220 ................................................................................................................... 2-4
AIN-300 ................................................................................................................... 2-5
AOT-150 .................................................................................................................. 2-6
BLK-100 .................................................................................................................. 2-7
CIO-100 ................................................................................................................... 2-8
CIO-110 ................................................................................................................. 2-12
DIO-400................................................................................................................. 2-13
DOT-100................................................................................................................ 2-15
DOT-120................................................................................................................ 2-16
RLY-100................................................................................................................. 2-17
RLY-200................................................................................................................. 2-18
Section 3 Description and Operation .........................................................................3-1
Introduction............................................................................................................. 3-1
Inputs and Outputs ................................................................................................. 3-1
WBPEEUI240751C0
iii
Table of Contents (continued)
Section 3 Description and Operation (continued)
Analog Input .........................................................................................................3-1
Data Conversion ...............................................................................................3-2
Calibrations ......................................................................................................3-3
Analog Output ......................................................................................................3-3
Data Conversion ...............................................................................................3-3
Calibrations ......................................................................................................3-3
Readback ..........................................................................................................3-4
Digital Input .........................................................................................................3-4
Digital Output ......................................................................................................3-5
I/O Block .................................................................................................................3-6
I/O Module ...........................................................................................................3-7
Block Power ......................................................................................................3-8
Central Processing Unit...................................................................................3-10
Memory ..........................................................................................................3-11
Hnet Interface .................................................................................................3-11
Machine Fault Timer .......................................................................................3-12
Serial Link Interface ........................................................................................3-12
LED Drivers and Status LEDs .........................................................................3-14
I/O Channel Interface .....................................................................................3-14
I/O Section .....................................................................................................3-14
Special Operations Switch (SW2) .....................................................................3-15
Base ...................................................................................................................3-15
Screw and Clamp Termination Bases ..............................................................3-15
Cable Connection............................................................................................3-18
Shield Terminations (Chassis Ground) ............................................................3-19
I/O Module Mounting .....................................................................................3-19
Hardware Keying ................................................................................................3-20
I/O Redundancy .................................................................................................3-20
Failure Mode (Outputs) .......................................................................................3-20
Short Circuit Protection ......................................................................................3-22
Auxiliary Block .......................................................................................................3-24
I/O System Configuration.......................................................................................3-24
I/O Block Hardware............................................................................................3-25
I/O Block Function Codes...................................................................................3-25
Section 4 Redundancy .................................................................................................4-1
Introduction .............................................................................................................4-1
Description...............................................................................................................4-1
Redundancy Arbitration........................................................................................4-2
Failover ................................................................................................................4-2
Analog Input.............................................................................................................4-3
iv
WBPEEUI240751C0
Table of Contents (continued)
Section 4 Redundancy (continued)
Analog Output ......................................................................................................... 4-4
Digital Input ............................................................................................................ 4-7
Digital Output.......................................................................................................... 4-9
Section 5 Installation ....................................................................................................5-1
Introduction............................................................................................................. 5-1
Special Handling ...................................................................................................... 5-1
Unpacking and Inspection........................................................................................ 5-2
Installation Procedures ............................................................................................ 5-2
Installation and Connection Sequence...................................................................... 5-3
Section 6 Configuration ...............................................................................................6-1
Introduction............................................................................................................. 6-1
Configuration Tools.................................................................................................. 6-1
Harmony Controller ................................................................................................. 6-1
Download............................................................................................................. 6-1
Verification........................................................................................................... 6-2
Changes............................................................................................................... 6-2
Time Synchronization........................................................................................... 6-3
Firmware Download ............................................................................................. 6-3
Labels ...................................................................................................................... 6-3
Device Label ......................................................................................................... 6-4
Electronic ID .................................................................................................... 6-4
Establishing a Device Label .............................................................................. 6-4
Predefining a Device Label ................................................................................ 6-5
Online Configuration ........................................................................................ 6-5
Channel Label ...................................................................................................... 6-6
Duplicate Labels................................................................................................... 6-6
Function Codes........................................................................................................ 6-7
I/O Device Definition (FC 221) .............................................................................. 6-8
I/O Channel (FC 222, 223, 224, 225).................................................................... 6-9
I/O Channel Data........................................................................................... 6-11
Suspect Condition .......................................................................................... 6-11
Exception Reporting ....................................................................................... 6-13
Engineering Units (EU) ................................................................................... 6-13
I/O Source ..................................................................................................... 6-14
Hnet Stall Mode (Default State) ....................................................................... 6-15
Status Reporting ............................................................................................ 6-15
Alarming ........................................................................................................ 6-15
Shaping Algorithms ........................................................................................ 6-16
WBPEEUI240751C0
v
Table of Contents (continued)
Section 6 Configuration (continued)
Test Status (FC 226) ...........................................................................................6-16
Section 7 Operating Procedures .................................................................................7-1
Introduction .............................................................................................................7-1
I/O Block .................................................................................................................7-1
I/O Module Front Panel ........................................................................................7-1
Block Type and Model .......................................................................................7-1
Operating Mode - Normal and Fault ..................................................................7-2
Status...............................................................................................................7-2
Block Power ......................................................................................................7-3
Field Power .......................................................................................................7-4
Digital Channels ...............................................................................................7-4
ID Labels ..........................................................................................................7-5
I/O Module Rear Panel..........................................................................................7-5
Termination Base Color Coding and Markings .......................................................7-6
Operation .............................................................................................................7-7
Startup .............................................................................................................7-7
Stop/Reset Button ............................................................................................7-7
Initialization......................................................................................................7-8
Auxiliary Block .........................................................................................................7-9
Section 8 Troubleshooting ..........................................................................................8-1
Introduction .............................................................................................................8-1
Troubleshooting Procedures......................................................................................8-1
Operating Mode - Normal and Fault LEDs.................................................................8-1
Power LEDs ..............................................................................................................8-2
Status Code LEDs ....................................................................................................8-2
I/O Block Problem Reports .......................................................................................8-6
Station Problem Reports ...........................................................................................8-9
I/O Block Status ....................................................................................................8-11
Diagnostics ............................................................................................................8-12
Online ................................................................................................................8-12
Offline ................................................................................................................8-12
I/O Block Connectors .............................................................................................8-13
I/O Module (P1, P4, P5).......................................................................................8-13
CIO-100 (P7, P8) .................................................................................................8-14
DIO (P17) ............................................................................................................8-15
vi
WBPEEUI240751C0
Table of Contents (continued)
Section 9 Maintenance .................................................................................................9-1
Introduction............................................................................................................. 9-1
Preventive Maintenance Schedule............................................................................. 9-1
Section 10 Repair and Replacement .........................................................................10-1
Introduction........................................................................................................... 10-1
Repair.................................................................................................................... 10-1
Replacement .......................................................................................................... 10-1
Section 11 Replacement and Spare Parts ................................................................11-1
Introduction........................................................................................................... 11-1
I/O and Auxiliary Block Nomenclature ................................................................... 11-1
Cable Nomenclature............................................................................................... 11-4
Miscellaneous Parts ............................................................................................... 11-6
Appendix A Hardware Drawings ................................................................................ A-1
Introduction............................................................................................................. A-1
I/O Block................................................................................................................. A-1
Auxiliary Block......................................................................................................... A-4
List of Procedures
No.
PR1
PR2
PR3
PR4
PR5
PR6
PR7
PR8
PR9
PR10
PR11
PR12
PR13
PR14
WBPEEUI240751C0
Title
Installation Preparation
I/O Block Base Installation
I/O Module Installation
Auxiliary Block Installation
BLK-100 Installation
AIN-120 Setup
AIN-200 Setup
AIN-220 Setup
AIN-300 Setup
AOT-150 Setup
CIO-100 Setup
DIO-400 Setup
DOT-100 Setup
DOT-120 Setup
vii
List of Procedures (continued)
No.
PR15
PR16
PR17
PR18
PR19
PR20
PR21
PR22
PR23
PR24
PR25
PR26
PR27
PR28
PR29
PR30
PR31
PR32
PR33
PR34
Title
CIO-110 Setup
RLY-200 Setup
CIO-100/110 Cable Connection
RLY-100/200 Cable Connection
Field Wiring (S Type Base)
Field Wiring (C Type Base)
Field Wiring (Cable Connection)
CIO-110 Wiring
RLY-100/200 Wiring
Offline Diagnostics
Device Label Definition
I/O System Configuration
Connections Check
I/O Module Removal
I/O Block Base Removal
Auxiliary Block Removal
Wiring and Cabling Disconnection
DOT-100/120 Relay Replacement
RLY-100 Relay Replacement
RLY-200 Relay Replacement
List of Worksheets
No.
WS1
WS2
WS3
WS4
WS5
WS6
WS7
WS8
WS9
viii
Title
AIN-120
AIN-200
AIN-220
AIN-300
AOT-150
CIO-100
DIO-400
DOT-100
DOT-120
WBPEEUI240751C0
List of Figures
No.
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
7-1.
7-2.
WBPEEUI240751C0
Title
Page
Harmony Area Controller with Harmony I/O Blocks .................................. 1-2
Harmony Bridge Controller with Harmony I/O Blocks ............................... 1-3
Harmony I/O System ................................................................................ 1-4
Controller I/O Communication.................................................................. 1-7
Analog Control Station Interface................................................................ 2-9
Station Connection ................................................................................... 2-9
Analog Input ............................................................................................. 3-2
Analog Output .......................................................................................... 3-3
Digital Input ............................................................................................. 3-4
Digital Output........................................................................................... 3-5
I/O Block.................................................................................................. 3-7
Configuration Jumper Access.................................................................... 3-8
Block Diagram - I/O Module ..................................................................... 3-9
Block Power ............................................................................................ 3-10
Hnet Interface ......................................................................................... 3-11
Serial Link Interface................................................................................ 3-13
Screw Terminal Base (S Type).................................................................. 3-16
Clamp Terminal Base (C Type) ................................................................ 3-17
Terminal Markings (Door Removed) ......................................................... 3-18
C Type Base for Cable Connection ........................................................... 3-19
Redundant I/O Block .............................................................................. 3-21
Auxiliary Block........................................................................................ 3-24
Example I/O Connection, Setup, and Configuration ................................ 3-25
AIN-120 Block - Voltage Mode (Differential or Single -Ended) ..................... 4-4
AIN-120 Block - Current Mode (IFP or LFP Powered) .................................. 4-5
AIN-120 Block - Current Mode (RFP Powered)............................................ 4-6
AIN-200/220 Block - Voltage and Thermocouple Mode .............................. 4-7
AIN-220 Block - Current Mode (IFP or LFP Powered) .................................. 4-8
AIN-220 Block - Current Mode (RFP Powered)............................................ 4-9
AIN-300 Block......................................................................................... 4-10
AOT-150 Block ....................................................................................... 4-11
DIO-400 Block (IFP or LFP Powered) ........................................................ 4-12
DIO-400 Block (RFP Powered) ................................................................. 4-13
DOT-100 Block ....................................................................................... 4-14
DOT-120 Block ....................................................................................... 4-15
I/O and Auxiliary Block Installation and Connection Flowchart ................. 5-4
AIN Block Flowchart.................................................................................. 5-4
AOT Block Flowchart................................................................................. 5-5
CIO Block Flowchart ................................................................................. 5-6
DIO and RLY Blocks Flowchart.................................................................. 5-7
DOT Block Flowchart ................................................................................ 5-8
I/O Block Front Panel ............................................................................... 7-2
I/O Module Rear Panel.............................................................................. 7-6
ix
List of Figures (continued)
No.
7-3.
10-1.
10-2.
10-3.
10-4.
A-1.
A-2.
A-3.
A-4.
PR2-1.
PR3-1.
PR4-1.
PR5-1.
PR5-2.
PR6-1.
PR6-2.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR11-7.
PR11-8.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR14-3.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
x
Title
Page
Auxiliary Block Front Panel .....................................................................7-10
Replacement Flowchart (1 of 4) ................................................................10-2
I/O Module Replacement Flowchart (2 of 4)..............................................10-2
I/O Block and Auxiliary Block Replacement Flowchart (3 of 4) .................10-3
Relay Replacement Flowchart (4 of 4) .......................................................10-3
I/O Module............................................................................................... A-1
Nonredundant Base.................................................................................. A-2
Redundant Base ....................................................................................... A-3
Auxiliary Block ......................................................................................... A-4
Base Attachment .................................................................................. PR2-2
I/O Module Attachment ........................................................................ PR3-2
Auxiliary Block Installation................................................................... PR4-2
Base Attachment .................................................................................. PR5-2
Blank Module Attachment .................................................................... PR5-3
User-Configurable Jumpers - Base ....................................................... PR6-4
Analog Input Field Power Selection (J17/J18) ....................................... PR6-5
Analog Input (Simplified) ...................................................................... PR7-2
User-Configurable Jumpers - Base ....................................................... PR8-4
Analog Input Field Power Selection (J17/J18) ....................................... PR8-5
Analog Input (Simplified) ...................................................................... PR8-6
Analog Input (Simplified) ...................................................................... PR9-2
Analog Output (Simplified) .................................................................. PR10-2
User-Configurable Jumpers - Base ..................................................... PR11-5
Analog Input Field Power Selection (J15/J16) ..................................... PR11-6
Configuration Jumper Access ............................................................. PR11-6
User-Configurable Jumpers - I/O Board ............................................. PR11-7
Analog Input (Simplified) .................................................................... PR11-8
Analog Output (Simplified) .................................................................. PR11-9
Digital Input (Simplified) ..................................................................... PR11-9
Digital Output (Simplified) .................................................................PR11-10
Configuration Jumper Access ............................................................. PR12-5
User-Configurable Jumpers - I/O Board ............................................. PR12-6
Digital Input (Simplified) ..................................................................... PR12-7
Digital Output (Simplified) .................................................................. PR12-7
DIO with RLY - Digital Output (Simplified) .......................................... PR12-8
Digital Output (Simplified) .................................................................. PR13-2
Configuration Jumper Access ............................................................. PR14-3
User-Configurable Jumpers - I/O Board ............................................. PR14-4
Digital Output (Simplified) .................................................................. PR14-5
I/O Board Layout ............................................................................... PR15-2
I/O Board Layout (Shown Without Relays) .......................................... PR16-3
CIO Connection .................................................................................. PR17-1
Current Mode Bypass Cable Connection ............................................. PR17-3
WBPEEUI240751C0
List of Figures (continued)
No.
PR17-3.
PR18-1.
PR18-2.
PR19-1.
PR19-2.
PR19-3.
PR19-4.
PR19-5.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR22-1.
PR23-1.
PR23-2.
PR24-1.
PR28-1.
PR29-1.
PR30-1.
PR32-1.
PR32-2.
PR33-1.
PR34-1.
Title
Page
Electric Drive/Pulse Positioner Bypass Cable Connection .................... PR17-4
DIO to RLY Connection ....................................................................... PR18-1
DIO Block to RLY Block Cable Connection........................................... PR18-2
Screw Terminal Base........................................................................... PR19-2
Analog Input ....................................................................................... PR19-5
Analog Output .................................................................................... PR19-6
Digital Input ....................................................................................... PR19-6
Digital Output..................................................................................... PR19-7
Clamp Terminal Base.......................................................................... PR20-2
Analog Input ....................................................................................... PR20-5
Analog Output .................................................................................... PR20-5
Digital Input ....................................................................................... PR20-6
Digital Output..................................................................................... PR20-6
C Type Base for Cable Connection ....................................................... PR21-2
Shield Wire Faston Adapter ................................................................. PR21-4
Analog Input ....................................................................................... PR21-6
Analog Output .................................................................................... PR21-6
Digital Input ....................................................................................... PR21-7
Digital Output..................................................................................... PR21-7
Wiring Terminals and Assignments ..................................................... PR22-2
Wiring Terminals and Assignments (RLY-100) ..................................... PR23-3
Wiring Terminals and Assignments (RLY-200) ..................................... PR23-4
Diagnostics Status LED Indications..................................................... PR24-1
I/O Module Removal ........................................................................... PR28-2
Base Removal ..................................................................................... PR29-2
Auxiliary Block Removal...................................................................... PR30-2
Configuration Jumper Access.............................................................. PR32-2
I/O Board Layout (Shown Without Relays)........................................... PR32-3
RLY-100 Board Layout (Shown Without Relays)................................... PR33-3
RLY-200 Board Layout (Shown Without Relays)................................... PR34-3
List of Tables
No.
1-1.
1-2.
1-3.
1-4.
1-5.
WBPEEUI240751C0
Title
Page
Available I/O and Auxiliary Blocks ............................................................ 1-5
I/O Block Capabilities............................................................................... 1-6
Glossary of Terms and Abbreviations....................................................... 1-12
Reference Documents.............................................................................. 1-13
Abbreviated Harmony I/O System Nomenclature..................................... 1-14
xi
List of Tables (continued)
No.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
5-1.
6-1.
6-2.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
9-1.
11-1.
11-2.
11-3.
xii
Title
Page
Related Nomenclature..............................................................................1-14
Design Standards ....................................................................................1-15
General I/O Block Specifications .............................................................1-16
General Auxiliary Block Specifications .....................................................1-17
Environmental Specifications...................................................................1-18
AIN-120 Specifications...............................................................................2-1
AIN-200 Specifications...............................................................................2-3
AIN-220 Specifications...............................................................................2-4
AIN-300 Specifications...............................................................................2-5
AOT-150 Specifications..............................................................................2-6
BLK-100 Specifications..............................................................................2-8
CIO-100 Specifications ............................................................................2-10
CIO-110 Specifications ............................................................................2-13
DIO-400 Specifications ............................................................................2-13
DOT-100 Specifications ...........................................................................2-15
DOT-120 Specifications ...........................................................................2-16
RLY-100 Specifications (Electromechanical Relays) ..................................2-17
RLY-200 Specifications (Solid State Relays) ..............................................2-19
I/O Block Failure Mode Output Conditions ..............................................3-22
Channel Fault Currents (Nominal) Under Short Conditions ......................3-23
Installation Procedures ..............................................................................5-2
I/O Channel Function Code Summary .......................................................6-9
I/O Channel Specifications Summary ........................................................6-9
Operating Mode - Normal and Fault LEDs..................................................7-3
Normal Operating Mode Status Codes........................................................7-3
Digital Channel Status ..............................................................................7-4
Special Operations Switch (SW2) Settings ..................................................7-6
Terminal Strip Markings and Color Coding ................................................7-6
Startup Sequence ......................................................................................7-8
Operating Mode - Normal and Fault LEDs..................................................8-2
Block and Field Power LEDs ......................................................................8-3
Status Codes .............................................................................................8-4
I/O Block Problem Reports ........................................................................8-7
Station Problem Reports ..........................................................................8-10
P1 Power Pins..........................................................................................8-13
P4 Redundancy Link Pins ........................................................................8-13
P5 Communication Pins ..........................................................................8-14
CIO-100 P7 and P8 Connector Pins..........................................................8-14
DIO P17 Connector Pins ..........................................................................8-15
Preventive Maintenance Schedule ..............................................................9-2
Analog Input Nomenclature .....................................................................11-1
Analog Output Nomenclature...................................................................11-2
Control Input/Output Nomenclature .......................................................11-2
WBPEEUI240751C0
List of Tables (continued)
No.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
PR1-1.
PR1-2.
PR6-1.
PR6-2.
PR6-3.
PR6-4.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
PR19-1.
PR19-2.
PR19-3.
WBPEEUI240751C0
Title
Page
Digital Input/Output Nomenclature ........................................................ 11-3
Digital Output Nomenclature .................................................................. 11-3
Auxiliary Relay Assembly Nomenclature .................................................. 11-4
Blank Block Nomenclature...................................................................... 11-4
DIO to RLY Cable Nomenclature .............................................................. 11-4
I/O Block to Remote Termination Cable Nomenclature ............................ 11-5
CIO Cable Nomenclature ......................................................................... 11-5
Fuses...................................................................................................... 11-6
Relays..................................................................................................... 11-6
Miscellaneous ......................................................................................... 11-7
Worksheets ........................................................................................... PR1-2
Worksheet Information.......................................................................... PR1-3
Field Power Select Jumpers (Module)..................................................... PR6-2
Analog Input Field Power Select Jumpers (Base) .................................... PR6-2
Input Channel Jumpers ........................................................................ PR6-2
Analog Input (Simplified) ....................................................................... PR6-6
Field Power Select Jumpers................................................................... PR7-1
Field Power Select Jumpers (Module)..................................................... PR8-2
Analog Input Field Power Select Jumpers (Base) .................................... PR8-2
Input Channel Jumpers ........................................................................ PR8-2
Field Power Select Jumpers................................................................... PR9-1
Field Power Select Jumpers................................................................. PR10-1
Field Power Select Jumpers................................................................. PR11-2
Analog Input Field Power Select Jumpers (Base) .................................. PR11-2
Analog Input Channel Jumpers........................................................... PR11-3
Analog Output Channel Jumpers ........................................................ PR11-3
Digital Input Channel Jumpers ........................................................... PR11-4
Digital Output Channel Jumpers ........................................................ PR11-4
Digital Output Field Power Select Jumpers.......................................... PR12-2
Digital Input Field Power Select Jumper .............................................. PR12-2
Digital Input Field Power Monitor Jumper ........................................... PR12-2
Digital Input Channel Jumpers ........................................................... PR12-3
Digital Output Channel Jumpers ........................................................ PR12-4
Field Power Select Jumpers................................................................. PR13-2
Field Power Select Jumpers................................................................. PR14-2
Readback/Fusing Select Jumpers ....................................................... PR14-2
M/A Power Select Jumpers ................................................................. PR15-1
Fuses.................................................................................................. PR16-2
CIO-100 to CIO-110 Connector Relationship ....................................... PR17-2
CIO-100 and IISAC01 Analog Input Relationship ................................. PR17-2
Terminal Strip Markings and Color Coding .......................................... PR19-3
Terminal Assignments Tables .............................................................. PR19-4
AIN-120 and AIN-220 .......................................................................... PR19-8
xiii
List of Tables (continued)
No.
PR19-4.
PR19-5.
PR19-6.
PR19-7.
PR19-8.
PR19-9.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR20-6.
PR20-7.
PR20-8.
PR20-9.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR21-7.
PR21-8.
PR21-9.
PR21-10.
PR22-1.
PR22-2.
PR23-1.
PR23-2.
PR23-3.
PR24-1.
PR24-2.
PR24-3.
PR24-4.
xiv
Title
Page
AIN-200.............................................................................................. PR19-9
AIN-300.............................................................................................PR19-10
AOT-150............................................................................................PR19-11
CIO-100 ............................................................................................PR19-12
DIO-400 ............................................................................................PR19-13
DOT-100 and DOT-120......................................................................PR19-14
Terminal Strip Markings and Color Coding ......................................... PR20-3
Terminal Assignments Tables ............................................................. PR20-3
AIN-120 and AIN-220 ......................................................................... PR20-7
AIN-200.............................................................................................. PR20-8
AIN-300.............................................................................................. PR20-9
AOT-150............................................................................................PR20-10
CIO-100 ............................................................................................PR20-11
DIO-400 ............................................................................................PR20-12
DOT-100 and DOT-120......................................................................PR20-13
HRM-RTS Cable Requirements ........................................................... PR21-3
Terminal Strip Markings and Color Coding ......................................... PR21-5
Connector Pin Assignments Tables ..................................................... PR21-5
AIN-120 and AIN-220 ......................................................................... PR21-8
AIN-200.............................................................................................. PR21-9
AIN-300.............................................................................................PR21-10
AOT-150............................................................................................PR21-11
CIO-100 ............................................................................................PR21-12
DIO-400 ............................................................................................PR21-13
DOT-100 and DOT-120......................................................................PR21-14
Station to Wiring Terminal Relationship.............................................. PR22-3
Terminal Assignments ........................................................................ PR22-3
Channel Label Makings ...................................................................... PR23-2
RLY-100 Terminal Assignments .......................................................... PR23-5
RLY-200 Terminal Assignments .......................................................... PR23-6
Offline Diagnostic Tests - Switch Settings ........................................... PR24-2
Group 1 Diagnostic Tests.................................................................... PR24-3
Group 2 Diagnostic Tests.................................................................... PR24-4
Group 3 Diagnostic Tests.................................................................... PR24-5
WBPEEUI240751C0
Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as described in the installation section.
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous. (p. 3-7, PR3-1,
PR28-1)
Verify the main power, field power, and power entry panel circuit
breakers/switches are turned off before starting installation, retrofit,
upgrade, or wiring procedures. Failure to do so could result in
severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete. (p. PR19-1,
PR20-1, PR21-2, PR22-1, PR23-1, PR31-1)
Turn off all power before attempting the connections check maintenance procedure. Failure to do so could result in severe or fatal
shock, or equipment damage. (p. PR27-1)
Verify power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal shock. Do not
turn the power on until the replacement procedure is complete.
(p. PR33-1, PR34-1)
WBPEEUI240751C0
xv
Safety Summary (continued)
SPECIFIC
CAUTIONS
For analog input channels, if the fused AI IFP/LFP option is selected
to power a 4 to 20 milliampere input, removing the I/O module from
the base in nonredundant applications will result in a loss of power
to all input current loops. (p. PR6-1, PR8-1, PR11-1, PR28-1)
Insure the setting for the digital input field power monitor jumper
DIFP-J2 matches the actual field power voltage (IFP or LFP). Circuit
damage will occur if the LFP voltage is greater than the voltage setting of jumper DIFP-J2. (p. PR12-1)
Use only ABB Automation approved relays on the relay assembly.
Using unapproved relays could improperly route signals and damage equipment connected to the relay and the relay itself. CSA certification is voided when unapproved relays are used. (p. PR16-1,
PR32-1, PR33-1, PR34-1)
xvi
WBPEEUI240751C0
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and
scheduling.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI240751C0
xvii
Trademarks and Registrations
Registrations and trademarks used in this document include:
™ Composer
® INFI 90
® INFI-NET
xviii
Trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
WBPEEUI240751C0
Preface
The Harmony Input/Output (I/O) System sets new standards
for user convenience in industrial I/O. A wide variety of I/O
building blocks can be combined to form an optimum solution
for a specific application. The Harmony I/O system is part of
the Symphony Enterprise Management and Control System. It
is, however, fully compatible with the INFI 90® OPEN Strategic
Enterprise Management System.
This instruction overviews the Harmony I/O system; describes
the analog, digital, and control I/O blocks and auxiliary blocks
used for field I/O interface; and provides I/O and auxiliary
block installation and connection procedures.
WBPEEUI240751C0
List of Effective Pages
Total number of pages in this instruction is 368, consisting of the following:
Page No.
Preface
List of Effective Pages
iii through xviii
1-1 through 1-18
2-1 through 2-19
3-1 through 3-26
4-1 through 4-15
5-1 through 5-8
6-1 through 6-16
7-1 through 7-10
8-1 through 8-15
9-1 through 9-2
10-1 through 10-3
11-1 through 11-7
A-1 through A-4
PR1-1 through PR1-3
PR2-1 through PR2-2
PR3-1 through PR3-2
PR4-1 through PR4-2
PR5-1 through PR5-3
PR6-1 through PR6-6
PR7-1 through PR7-2
PR8-1 through PR8-6
PR9-1 through PR9-2
PR10-1 through PR10-2
PR11-1 through PR11-10
PR12-1 through PR12-8
PR13-1 through PR13-2
PR14-1 through PR14-5
PR15-1 through PR15-2
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
PR16-1
PR17-1
PR18-1
PR19-1
PR20-1
PR21-1
PR22-1
PR23-1
PR24-1
PR25-1
PR26-1
PR27-1
PR28-1
PR29-1
PR30-1
PR31-1
PR32-1
PR33-1
PR34-1
WS1-1
WS2-1
WS3-1
WS4-1
WS5-1
WS6-1
WS7-1
WS8-1
WS9-1
Index-1
Page No.
through PR16-3
through PR17-4
through PR18-2
through PR19-14
through PR20-13
through PR21-14
through PR22-3
through PR23-6
through PR24-5
through PR25-2
through PR26-2
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
PR28-2
PR29-2
PR30-2
PR31-2
PR32-3
PR33-3
PR34-3
WS1-7
WS2-7
WS3-9
WS4-9
WS5-5
WS6-5
WS7-9
WS8-4
WS9-4
Index-5
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
WBPEEUI240751C0
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Purpose ................................................................................................................... 1-1
Harmony I/O System Documentation....................................................................... 1-1
System Overview ...................................................................................................... 1-2
Input/Output .......................................................................................................... 1-4
Harmony Controllers................................................................................................ 1-5
Harmony Bridge Controller................................................................................... 1-5
Harmony Area Controller...................................................................................... 1-7
Function Codes........................................................................................................ 1-8
Compatibility ........................................................................................................... 1-8
Features .................................................................................................................. 1-8
Intended User .......................................................................................................... 1-9
Instruction Content................................................................................................ 1-10
How to Use this Instruction .................................................................................... 1-11
Document Conventions .......................................................................................... 1-12
Glossary of Terms and Abbreviations...................................................................... 1-12
Reference Documents............................................................................................. 1-13
Abbreviated Harmony I/O Nomenclature ................................................................ 1-13
Related Nomenclature ............................................................................................ 1-14
Design Standards................................................................................................... 1-14
Specifications......................................................................................................... 1-16
Section 2 Input/Output Blocks ....................................................................................2-1
Introduction............................................................................................................. 2-1
AIN-120 ................................................................................................................... 2-1
AIN-200 ................................................................................................................... 2-2
AIN-220 ................................................................................................................... 2-4
AIN-300 ................................................................................................................... 2-5
AOT-150 .................................................................................................................. 2-6
BLK-100 .................................................................................................................. 2-7
CIO-100 ................................................................................................................... 2-8
CIO-110 ................................................................................................................. 2-12
DIO-400................................................................................................................. 2-13
DOT-100................................................................................................................ 2-15
DOT-120................................................................................................................ 2-16
RLY-100................................................................................................................. 2-17
RLY-200................................................................................................................. 2-18
Section 3 Description and Operation .........................................................................3-1
Introduction............................................................................................................. 3-1
Inputs and Outputs ................................................................................................. 3-1
WBPEEUI240751C0
iii
Table of Contents (continued)
Section 3 Description and Operation (continued)
Analog Input .........................................................................................................3-1
Data Conversion ...............................................................................................3-2
Calibrations ......................................................................................................3-3
Analog Output ......................................................................................................3-3
Data Conversion ...............................................................................................3-3
Calibrations ......................................................................................................3-3
Readback ..........................................................................................................3-4
Digital Input .........................................................................................................3-4
Digital Output ......................................................................................................3-5
I/O Block .................................................................................................................3-6
I/O Module ...........................................................................................................3-7
Block Power ......................................................................................................3-8
Central Processing Unit...................................................................................3-10
Memory ..........................................................................................................3-11
Hnet Interface .................................................................................................3-11
Machine Fault Timer .......................................................................................3-12
Serial Link Interface ........................................................................................3-12
LED Drivers and Status LEDs .........................................................................3-14
I/O Channel Interface .....................................................................................3-14
I/O Section .....................................................................................................3-14
Special Operations Switch (SW2) .....................................................................3-15
Base ...................................................................................................................3-15
Screw and Clamp Termination Bases ..............................................................3-15
Cable Connection............................................................................................3-18
Shield Terminations (Chassis Ground) ............................................................3-19
I/O Module Mounting .....................................................................................3-19
Hardware Keying ................................................................................................3-20
I/O Redundancy .................................................................................................3-20
Failure Mode (Outputs) .......................................................................................3-20
Short Circuit Protection ......................................................................................3-22
Auxiliary Block .......................................................................................................3-24
I/O System Configuration.......................................................................................3-24
I/O Block Hardware............................................................................................3-25
I/O Block Function Codes...................................................................................3-25
Section 4 Redundancy .................................................................................................4-1
Introduction .............................................................................................................4-1
Description...............................................................................................................4-1
Redundancy Arbitration........................................................................................4-2
Failover ................................................................................................................4-2
Analog Input.............................................................................................................4-3
iv
WBPEEUI240751C0
Table of Contents (continued)
Section 4 Redundancy (continued)
Analog Output ......................................................................................................... 4-4
Digital Input ............................................................................................................ 4-7
Digital Output.......................................................................................................... 4-9
Section 5 Installation ....................................................................................................5-1
Introduction............................................................................................................. 5-1
Special Handling ...................................................................................................... 5-1
Unpacking and Inspection........................................................................................ 5-2
Installation Procedures ............................................................................................ 5-2
Installation and Connection Sequence...................................................................... 5-3
Section 6 Configuration ...............................................................................................6-1
Introduction............................................................................................................. 6-1
Configuration Tools.................................................................................................. 6-1
Harmony Controller ................................................................................................. 6-1
Download............................................................................................................. 6-1
Verification........................................................................................................... 6-2
Changes............................................................................................................... 6-2
Time Synchronization........................................................................................... 6-3
Firmware Download ............................................................................................. 6-3
Labels ...................................................................................................................... 6-3
Device Label ......................................................................................................... 6-4
Electronic ID .................................................................................................... 6-4
Establishing a Device Label .............................................................................. 6-4
Predefining a Device Label ................................................................................ 6-5
Online Configuration ........................................................................................ 6-5
Channel Label ...................................................................................................... 6-6
Duplicate Labels................................................................................................... 6-6
Function Codes........................................................................................................ 6-7
I/O Device Definition (FC 221) .............................................................................. 6-8
I/O Channel (FC 222, 223, 224, 225).................................................................... 6-9
I/O Channel Data........................................................................................... 6-11
Suspect Condition .......................................................................................... 6-11
Exception Reporting ....................................................................................... 6-13
Engineering Units (EU) ................................................................................... 6-13
I/O Source ..................................................................................................... 6-14
Hnet Stall Mode (Default State) ....................................................................... 6-15
Status Reporting ............................................................................................ 6-15
Alarming ........................................................................................................ 6-15
Shaping Algorithms ........................................................................................ 6-16
WBPEEUI240751C0
v
Table of Contents (continued)
Section 6 Configuration (continued)
Test Status (FC 226) ...........................................................................................6-16
Section 7 Operating Procedures .................................................................................7-1
Introduction .............................................................................................................7-1
I/O Block .................................................................................................................7-1
I/O Module Front Panel ........................................................................................7-1
Block Type and Model .......................................................................................7-1
Operating Mode - Normal and Fault ..................................................................7-2
Status...............................................................................................................7-2
Block Power ......................................................................................................7-3
Field Power .......................................................................................................7-4
Digital Channels ...............................................................................................7-4
ID Labels ..........................................................................................................7-5
I/O Module Rear Panel..........................................................................................7-5
Termination Base Color Coding and Markings .......................................................7-6
Operation .............................................................................................................7-7
Startup .............................................................................................................7-7
Stop/Reset Button ............................................................................................7-7
Initialization......................................................................................................7-8
Auxiliary Block .........................................................................................................7-9
Section 8 Troubleshooting ..........................................................................................8-1
Introduction .............................................................................................................8-1
Troubleshooting Procedures......................................................................................8-1
Operating Mode - Normal and Fault LEDs.................................................................8-1
Power LEDs ..............................................................................................................8-2
Status Code LEDs ....................................................................................................8-2
I/O Block Problem Reports .......................................................................................8-6
Station Problem Reports ...........................................................................................8-9
I/O Block Status ....................................................................................................8-11
Diagnostics ............................................................................................................8-12
Online ................................................................................................................8-12
Offline ................................................................................................................8-12
I/O Block Connectors .............................................................................................8-13
I/O Module (P1, P4, P5).......................................................................................8-13
CIO-100 (P7, P8) .................................................................................................8-14
DIO (P17) ............................................................................................................8-15
vi
WBPEEUI240751C0
Table of Contents (continued)
Section 9 Maintenance .................................................................................................9-1
Introduction............................................................................................................. 9-1
Preventive Maintenance Schedule............................................................................. 9-1
Section 10 Repair and Replacement .........................................................................10-1
Introduction........................................................................................................... 10-1
Repair.................................................................................................................... 10-1
Replacement .......................................................................................................... 10-1
Section 11 Replacement and Spare Parts ................................................................11-1
Introduction........................................................................................................... 11-1
I/O and Auxiliary Block Nomenclature ................................................................... 11-1
Cable Nomenclature............................................................................................... 11-4
Miscellaneous Parts ............................................................................................... 11-6
Appendix A Hardware Drawings ................................................................................ A-1
Introduction............................................................................................................. A-1
I/O Block................................................................................................................. A-1
Auxiliary Block......................................................................................................... A-4
List of Procedures
No.
PR1
PR2
PR3
PR4
PR5
PR6
PR7
PR8
PR9
PR10
PR11
PR12
PR13
PR14
WBPEEUI240751C0
Title
Installation Preparation
I/O Block Base Installation
I/O Module Installation
Auxiliary Block Installation
BLK-100 Installation
AIN-120 Setup
AIN-200 Setup
AIN-220 Setup
AIN-300 Setup
AOT-150 Setup
CIO-100 Setup
DIO-400 Setup
DOT-100 Setup
DOT-120 Setup
vii
List of Procedures (continued)
No.
PR15
PR16
PR17
PR18
PR19
PR20
PR21
PR22
PR23
PR24
PR25
PR26
PR27
PR28
PR29
PR30
PR31
PR32
PR33
PR34
Title
CIO-110 Setup
RLY-200 Setup
CIO-100/110 Cable Connection
RLY-100/200 Cable Connection
Field Wiring (S Type Base)
Field Wiring (C Type Base)
Field Wiring (Cable Connection)
CIO-110 Wiring
RLY-100/200 Wiring
Offline Diagnostics
Device Label Definition
I/O System Configuration
Connections Check
I/O Module Removal
I/O Block Base Removal
Auxiliary Block Removal
Wiring and Cabling Disconnection
DOT-100/120 Relay Replacement
RLY-100 Relay Replacement
RLY-200 Relay Replacement
List of Worksheets
No.
WS1
WS2
WS3
WS4
WS5
WS6
WS7
WS8
WS9
viii
Title
AIN-120
AIN-200
AIN-220
AIN-300
AOT-150
CIO-100
DIO-400
DOT-100
DOT-120
WBPEEUI240751C0
List of Figures
No.
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
7-1.
7-2.
WBPEEUI240751C0
Title
Page
Harmony Area Controller with Harmony I/O Blocks .................................. 1-2
Harmony Bridge Controller with Harmony I/O Blocks ............................... 1-3
Harmony I/O System ................................................................................ 1-4
Controller I/O Communication.................................................................. 1-7
Analog Control Station Interface................................................................ 2-9
Station Connection ................................................................................... 2-9
Analog Input ............................................................................................. 3-2
Analog Output .......................................................................................... 3-3
Digital Input ............................................................................................. 3-4
Digital Output........................................................................................... 3-5
I/O Block.................................................................................................. 3-7
Configuration Jumper Access.................................................................... 3-8
Block Diagram - I/O Module ..................................................................... 3-9
Block Power ............................................................................................ 3-10
Hnet Interface ......................................................................................... 3-11
Serial Link Interface................................................................................ 3-13
Screw Terminal Base (S Type).................................................................. 3-16
Clamp Terminal Base (C Type) ................................................................ 3-17
Terminal Markings (Door Removed) ......................................................... 3-18
C Type Base for Cable Connection ........................................................... 3-19
Redundant I/O Block .............................................................................. 3-21
Auxiliary Block........................................................................................ 3-24
Example I/O Connection, Setup, and Configuration ................................ 3-25
AIN-120 Block - Voltage Mode (Differential or Single -Ended) ..................... 4-4
AIN-120 Block - Current Mode (IFP or LFP Powered) .................................. 4-5
AIN-120 Block - Current Mode (RFP Powered)............................................ 4-6
AIN-200/220 Block - Voltage and Thermocouple Mode .............................. 4-7
AIN-220 Block - Current Mode (IFP or LFP Powered) .................................. 4-8
AIN-220 Block - Current Mode (RFP Powered)............................................ 4-9
AIN-300 Block......................................................................................... 4-10
AOT-150 Block ....................................................................................... 4-11
DIO-400 Block (IFP or LFP Powered) ........................................................ 4-12
DIO-400 Block (RFP Powered) ................................................................. 4-13
DOT-100 Block ....................................................................................... 4-14
DOT-120 Block ....................................................................................... 4-15
I/O and Auxiliary Block Installation and Connection Flowchart ................. 5-4
AIN Block Flowchart.................................................................................. 5-4
AOT Block Flowchart................................................................................. 5-5
CIO Block Flowchart ................................................................................. 5-6
DIO and RLY Blocks Flowchart.................................................................. 5-7
DOT Block Flowchart ................................................................................ 5-8
I/O Block Front Panel ............................................................................... 7-2
I/O Module Rear Panel.............................................................................. 7-6
ix
List of Figures (continued)
No.
7-3.
10-1.
10-2.
10-3.
10-4.
A-1.
A-2.
A-3.
A-4.
PR2-1.
PR3-1.
PR4-1.
PR5-1.
PR5-2.
PR6-1.
PR6-2.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR11-7.
PR11-8.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR14-3.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
x
Title
Page
Auxiliary Block Front Panel .....................................................................7-10
Replacement Flowchart (1 of 4) ................................................................10-2
I/O Module Replacement Flowchart (2 of 4)..............................................10-2
I/O Block and Auxiliary Block Replacement Flowchart (3 of 4) .................10-3
Relay Replacement Flowchart (4 of 4) .......................................................10-3
I/O Module............................................................................................... A-1
Nonredundant Base.................................................................................. A-2
Redundant Base ....................................................................................... A-3
Auxiliary Block ......................................................................................... A-4
Base Attachment .................................................................................. PR2-2
I/O Module Attachment ........................................................................ PR3-2
Auxiliary Block Installation................................................................... PR4-2
Base Attachment .................................................................................. PR5-2
Blank Module Attachment .................................................................... PR5-3
User-Configurable Jumpers - Base ....................................................... PR6-4
Analog Input Field Power Selection (J17/J18) ....................................... PR6-5
Analog Input (Simplified) ...................................................................... PR7-2
User-Configurable Jumpers - Base ....................................................... PR8-4
Analog Input Field Power Selection (J17/J18) ....................................... PR8-5
Analog Input (Simplified) ...................................................................... PR8-6
Analog Input (Simplified) ...................................................................... PR9-2
Analog Output (Simplified) .................................................................. PR10-2
User-Configurable Jumpers - Base ..................................................... PR11-5
Analog Input Field Power Selection (J15/J16) ..................................... PR11-6
Configuration Jumper Access ............................................................. PR11-6
User-Configurable Jumpers - I/O Board ............................................. PR11-7
Analog Input (Simplified) .................................................................... PR11-8
Analog Output (Simplified) .................................................................. PR11-9
Digital Input (Simplified) ..................................................................... PR11-9
Digital Output (Simplified) .................................................................PR11-10
Configuration Jumper Access ............................................................. PR12-5
User-Configurable Jumpers - I/O Board ............................................. PR12-6
Digital Input (Simplified) ..................................................................... PR12-7
Digital Output (Simplified) .................................................................. PR12-7
DIO with RLY - Digital Output (Simplified) .......................................... PR12-8
Digital Output (Simplified) .................................................................. PR13-2
Configuration Jumper Access ............................................................. PR14-3
User-Configurable Jumpers - I/O Board ............................................. PR14-4
Digital Output (Simplified) .................................................................. PR14-5
I/O Board Layout ............................................................................... PR15-2
I/O Board Layout (Shown Without Relays) .......................................... PR16-3
CIO Connection .................................................................................. PR17-1
Current Mode Bypass Cable Connection ............................................. PR17-3
WBPEEUI240751C0
List of Figures (continued)
No.
PR17-3.
PR18-1.
PR18-2.
PR19-1.
PR19-2.
PR19-3.
PR19-4.
PR19-5.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR22-1.
PR23-1.
PR23-2.
PR24-1.
PR28-1.
PR29-1.
PR30-1.
PR32-1.
PR32-2.
PR33-1.
PR34-1.
Title
Page
Electric Drive/Pulse Positioner Bypass Cable Connection .................... PR17-4
DIO to RLY Connection ....................................................................... PR18-1
DIO Block to RLY Block Cable Connection........................................... PR18-2
Screw Terminal Base........................................................................... PR19-2
Analog Input ....................................................................................... PR19-5
Analog Output .................................................................................... PR19-6
Digital Input ....................................................................................... PR19-6
Digital Output..................................................................................... PR19-7
Clamp Terminal Base.......................................................................... PR20-2
Analog Input ....................................................................................... PR20-5
Analog Output .................................................................................... PR20-5
Digital Input ....................................................................................... PR20-6
Digital Output..................................................................................... PR20-6
C Type Base for Cable Connection ....................................................... PR21-2
Shield Wire Faston Adapter ................................................................. PR21-4
Analog Input ....................................................................................... PR21-6
Analog Output .................................................................................... PR21-6
Digital Input ....................................................................................... PR21-7
Digital Output..................................................................................... PR21-7
Wiring Terminals and Assignments ..................................................... PR22-2
Wiring Terminals and Assignments (RLY-100) ..................................... PR23-3
Wiring Terminals and Assignments (RLY-200) ..................................... PR23-4
Diagnostics Status LED Indications..................................................... PR24-1
I/O Module Removal ........................................................................... PR28-2
Base Removal ..................................................................................... PR29-2
Auxiliary Block Removal...................................................................... PR30-2
Configuration Jumper Access.............................................................. PR32-2
I/O Board Layout (Shown Without Relays)........................................... PR32-3
RLY-100 Board Layout (Shown Without Relays)................................... PR33-3
RLY-200 Board Layout (Shown Without Relays)................................... PR34-3
List of Tables
No.
1-1.
1-2.
1-3.
1-4.
1-5.
WBPEEUI240751C0
Title
Page
Available I/O and Auxiliary Blocks ............................................................ 1-5
I/O Block Capabilities............................................................................... 1-6
Glossary of Terms and Abbreviations....................................................... 1-12
Reference Documents.............................................................................. 1-13
Abbreviated Harmony I/O System Nomenclature..................................... 1-14
xi
List of Tables (continued)
No.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
5-1.
6-1.
6-2.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
9-1.
11-1.
11-2.
11-3.
xii
Title
Page
Related Nomenclature..............................................................................1-14
Design Standards ....................................................................................1-15
General I/O Block Specifications .............................................................1-16
General Auxiliary Block Specifications .....................................................1-17
Environmental Specifications...................................................................1-18
AIN-120 Specifications...............................................................................2-1
AIN-200 Specifications...............................................................................2-3
AIN-220 Specifications...............................................................................2-4
AIN-300 Specifications...............................................................................2-5
AOT-150 Specifications..............................................................................2-6
BLK-100 Specifications..............................................................................2-8
CIO-100 Specifications ............................................................................2-10
CIO-110 Specifications ............................................................................2-13
DIO-400 Specifications ............................................................................2-13
DOT-100 Specifications ...........................................................................2-15
DOT-120 Specifications ...........................................................................2-16
RLY-100 Specifications (Electromechanical Relays) ..................................2-17
RLY-200 Specifications (Solid State Relays) ..............................................2-19
I/O Block Failure Mode Output Conditions ..............................................3-22
Channel Fault Currents (Nominal) Under Short Conditions ......................3-23
Installation Procedures ..............................................................................5-2
I/O Channel Function Code Summary .......................................................6-9
I/O Channel Specifications Summary ........................................................6-9
Operating Mode - Normal and Fault LEDs..................................................7-3
Normal Operating Mode Status Codes........................................................7-3
Digital Channel Status ..............................................................................7-4
Special Operations Switch (SW2) Settings ..................................................7-6
Terminal Strip Markings and Color Coding ................................................7-6
Startup Sequence ......................................................................................7-8
Operating Mode - Normal and Fault LEDs..................................................8-2
Block and Field Power LEDs ......................................................................8-3
Status Codes .............................................................................................8-4
I/O Block Problem Reports ........................................................................8-7
Station Problem Reports ..........................................................................8-10
P1 Power Pins..........................................................................................8-13
P4 Redundancy Link Pins ........................................................................8-13
P5 Communication Pins ..........................................................................8-14
CIO-100 P7 and P8 Connector Pins..........................................................8-14
DIO P17 Connector Pins ..........................................................................8-15
Preventive Maintenance Schedule ..............................................................9-2
Analog Input Nomenclature .....................................................................11-1
Analog Output Nomenclature...................................................................11-2
Control Input/Output Nomenclature .......................................................11-2
WBPEEUI240751C0
List of Tables (continued)
No.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
PR1-1.
PR1-2.
PR6-1.
PR6-2.
PR6-3.
PR6-4.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
PR19-1.
PR19-2.
PR19-3.
WBPEEUI240751C0
Title
Page
Digital Input/Output Nomenclature ........................................................ 11-3
Digital Output Nomenclature .................................................................. 11-3
Auxiliary Relay Assembly Nomenclature .................................................. 11-4
Blank Block Nomenclature...................................................................... 11-4
DIO to RLY Cable Nomenclature .............................................................. 11-4
I/O Block to Remote Termination Cable Nomenclature ............................ 11-5
CIO Cable Nomenclature ......................................................................... 11-5
Fuses...................................................................................................... 11-6
Relays..................................................................................................... 11-6
Miscellaneous ......................................................................................... 11-7
Worksheets ........................................................................................... PR1-2
Worksheet Information.......................................................................... PR1-3
Field Power Select Jumpers (Module)..................................................... PR6-2
Analog Input Field Power Select Jumpers (Base) .................................... PR6-2
Input Channel Jumpers ........................................................................ PR6-2
Analog Input (Simplified) ....................................................................... PR6-6
Field Power Select Jumpers................................................................... PR7-1
Field Power Select Jumpers (Module)..................................................... PR8-2
Analog Input Field Power Select Jumpers (Base) .................................... PR8-2
Input Channel Jumpers ........................................................................ PR8-2
Field Power Select Jumpers................................................................... PR9-1
Field Power Select Jumpers................................................................. PR10-1
Field Power Select Jumpers................................................................. PR11-2
Analog Input Field Power Select Jumpers (Base) .................................. PR11-2
Analog Input Channel Jumpers........................................................... PR11-3
Analog Output Channel Jumpers ........................................................ PR11-3
Digital Input Channel Jumpers ........................................................... PR11-4
Digital Output Channel Jumpers ........................................................ PR11-4
Digital Output Field Power Select Jumpers.......................................... PR12-2
Digital Input Field Power Select Jumper .............................................. PR12-2
Digital Input Field Power Monitor Jumper ........................................... PR12-2
Digital Input Channel Jumpers ........................................................... PR12-3
Digital Output Channel Jumpers ........................................................ PR12-4
Field Power Select Jumpers................................................................. PR13-2
Field Power Select Jumpers................................................................. PR14-2
Readback/Fusing Select Jumpers ....................................................... PR14-2
M/A Power Select Jumpers ................................................................. PR15-1
Fuses.................................................................................................. PR16-2
CIO-100 to CIO-110 Connector Relationship ....................................... PR17-2
CIO-100 and IISAC01 Analog Input Relationship ................................. PR17-2
Terminal Strip Markings and Color Coding .......................................... PR19-3
Terminal Assignments Tables .............................................................. PR19-4
AIN-120 and AIN-220 .......................................................................... PR19-8
xiii
List of Tables (continued)
No.
PR19-4.
PR19-5.
PR19-6.
PR19-7.
PR19-8.
PR19-9.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR20-6.
PR20-7.
PR20-8.
PR20-9.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR21-7.
PR21-8.
PR21-9.
PR21-10.
PR22-1.
PR22-2.
PR23-1.
PR23-2.
PR23-3.
PR24-1.
PR24-2.
PR24-3.
PR24-4.
xiv
Title
Page
AIN-200.............................................................................................. PR19-9
AIN-300.............................................................................................PR19-10
AOT-150............................................................................................PR19-11
CIO-100 ............................................................................................PR19-12
DIO-400 ............................................................................................PR19-13
DOT-100 and DOT-120......................................................................PR19-14
Terminal Strip Markings and Color Coding ......................................... PR20-3
Terminal Assignments Tables ............................................................. PR20-3
AIN-120 and AIN-220 ......................................................................... PR20-7
AIN-200.............................................................................................. PR20-8
AIN-300.............................................................................................. PR20-9
AOT-150............................................................................................PR20-10
CIO-100 ............................................................................................PR20-11
DIO-400 ............................................................................................PR20-12
DOT-100 and DOT-120......................................................................PR20-13
HRM-RTS Cable Requirements ........................................................... PR21-3
Terminal Strip Markings and Color Coding ......................................... PR21-5
Connector Pin Assignments Tables ..................................................... PR21-5
AIN-120 and AIN-220 ......................................................................... PR21-8
AIN-200.............................................................................................. PR21-9
AIN-300.............................................................................................PR21-10
AOT-150............................................................................................PR21-11
CIO-100 ............................................................................................PR21-12
DIO-400 ............................................................................................PR21-13
DOT-100 and DOT-120......................................................................PR21-14
Station to Wiring Terminal Relationship.............................................. PR22-3
Terminal Assignments ........................................................................ PR22-3
Channel Label Makings ...................................................................... PR23-2
RLY-100 Terminal Assignments .......................................................... PR23-5
RLY-200 Terminal Assignments .......................................................... PR23-6
Offline Diagnostic Tests - Switch Settings ........................................... PR24-2
Group 1 Diagnostic Tests.................................................................... PR24-3
Group 2 Diagnostic Tests.................................................................... PR24-4
Group 3 Diagnostic Tests.................................................................... PR24-5
WBPEEUI240751C0
Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as described in the installation section.
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous. (p. 3-7, PR3-1,
PR28-1)
Verify the main power, field power, and power entry panel circuit
breakers/switches are turned off before starting installation, retrofit,
upgrade, or wiring procedures. Failure to do so could result in
severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete. (p. PR19-1,
PR20-1, PR21-2, PR22-1, PR23-1, PR31-1)
Turn off all power before attempting the connections check maintenance procedure. Failure to do so could result in severe or fatal
shock, or equipment damage. (p. PR27-1)
Verify power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal shock. Do not
turn the power on until the replacement procedure is complete.
(p. PR33-1, PR34-1)
WBPEEUI240751C0
xv
Safety Summary (continued)
SPECIFIC
CAUTIONS
For analog input channels, if the fused AI IFP/LFP option is selected
to power a 4 to 20 milliampere input, removing the I/O module from
the base in nonredundant applications will result in a loss of power
to all input current loops. (p. PR6-1, PR8-1, PR11-1, PR28-1)
Insure the setting for the digital input field power monitor jumper
DIFP-J2 matches the actual field power voltage (IFP or LFP). Circuit
damage will occur if the LFP voltage is greater than the voltage setting of jumper DIFP-J2. (p. PR12-1)
Use only ABB Automation approved relays on the relay assembly.
Using unapproved relays could improperly route signals and damage equipment connected to the relay and the relay itself. CSA certification is voided when unapproved relays are used. (p. PR16-1,
PR32-1, PR33-1, PR34-1)
xvi
WBPEEUI240751C0
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and
scheduling.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI240751C0
xvii
Trademarks and Registrations
Registrations and trademarks used in this document include:
™ Composer
® INFI 90
® INFI-NET
xviii
Trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
WBPEEUI240751C0
Preface
The Harmony Input/Output (I/O) System sets new standards
for user convenience in industrial I/O. A wide variety of I/O
building blocks can be combined to form an optimum solution
for a specific application. The Harmony I/O system is part of
the Symphony Enterprise Management and Control System. It
is, however, fully compatible with the INFI 90® OPEN Strategic
Enterprise Management System.
This instruction overviews the Harmony I/O system; describes
the analog, digital, and control I/O blocks and auxiliary blocks
used for field I/O interface; and provides I/O and auxiliary
block installation and connection procedures.
WBPEEUI240751C0
List of Effective Pages
Total number of pages in this instruction is 368, consisting of the following:
Page No.
Preface
List of Effective Pages
iii through xviii
1-1 through 1-18
2-1 through 2-19
3-1 through 3-26
4-1 through 4-15
5-1 through 5-8
6-1 through 6-16
7-1 through 7-10
8-1 through 8-15
9-1 through 9-2
10-1 through 10-3
11-1 through 11-7
A-1 through A-4
PR1-1 through PR1-3
PR2-1 through PR2-2
PR3-1 through PR3-2
PR4-1 through PR4-2
PR5-1 through PR5-3
PR6-1 through PR6-6
PR7-1 through PR7-2
PR8-1 through PR8-6
PR9-1 through PR9-2
PR10-1 through PR10-2
PR11-1 through PR11-10
PR12-1 through PR12-8
PR13-1 through PR13-2
PR14-1 through PR14-5
PR15-1 through PR15-2
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
PR16-1
PR17-1
PR18-1
PR19-1
PR20-1
PR21-1
PR22-1
PR23-1
PR24-1
PR25-1
PR26-1
PR27-1
PR28-1
PR29-1
PR30-1
PR31-1
PR32-1
PR33-1
PR34-1
WS1-1
WS2-1
WS3-1
WS4-1
WS5-1
WS6-1
WS7-1
WS8-1
WS9-1
Index-1
Page No.
through PR16-3
through PR17-4
through PR18-2
through PR19-14
through PR20-13
through PR21-14
through PR22-3
through PR23-6
through PR24-5
through PR25-2
through PR26-2
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
through
PR28-2
PR29-2
PR30-2
PR31-2
PR32-3
PR33-3
PR34-3
WS1-7
WS2-7
WS3-9
WS4-9
WS5-5
WS6-5
WS7-9
WS8-4
WS9-4
Index-5
Change Date
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
Original
NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.
WBPEEUI240751C0
Table of Contents
Section 1 Introduction ..................................................................................................1-1
Purpose ................................................................................................................... 1-1
Harmony I/O System Documentation....................................................................... 1-1
System Overview ...................................................................................................... 1-2
Input/Output .......................................................................................................... 1-4
Harmony Controllers................................................................................................ 1-5
Harmony Bridge Controller................................................................................... 1-5
Harmony Area Controller...................................................................................... 1-7
Function Codes........................................................................................................ 1-8
Compatibility ........................................................................................................... 1-8
Features .................................................................................................................. 1-8
Intended User .......................................................................................................... 1-9
Instruction Content................................................................................................ 1-10
How to Use this Instruction .................................................................................... 1-11
Document Conventions .......................................................................................... 1-12
Glossary of Terms and Abbreviations...................................................................... 1-12
Reference Documents............................................................................................. 1-13
Abbreviated Harmony I/O Nomenclature ................................................................ 1-13
Related Nomenclature ............................................................................................ 1-14
Design Standards................................................................................................... 1-14
Specifications......................................................................................................... 1-16
Section 2 Input/Output Blocks ....................................................................................2-1
Introduction............................................................................................................. 2-1
AIN-120 ................................................................................................................... 2-1
AIN-200 ................................................................................................................... 2-2
AIN-220 ................................................................................................................... 2-4
AIN-300 ................................................................................................................... 2-5
AOT-150 .................................................................................................................. 2-6
BLK-100 .................................................................................................................. 2-7
CIO-100 ................................................................................................................... 2-8
CIO-110 ................................................................................................................. 2-12
DIO-400................................................................................................................. 2-13
DOT-100................................................................................................................ 2-15
DOT-120................................................................................................................ 2-16
RLY-100................................................................................................................. 2-17
RLY-200................................................................................................................. 2-18
Section 3 Description and Operation .........................................................................3-1
Introduction............................................................................................................. 3-1
Inputs and Outputs ................................................................................................. 3-1
WBPEEUI240751C0
iii
Table of Contents (continued)
Section 3 Description and Operation (continued)
Analog Input .........................................................................................................3-1
Data Conversion ...............................................................................................3-2
Calibrations ......................................................................................................3-3
Analog Output ......................................................................................................3-3
Data Conversion ...............................................................................................3-3
Calibrations ......................................................................................................3-3
Readback ..........................................................................................................3-4
Digital Input .........................................................................................................3-4
Digital Output ......................................................................................................3-5
I/O Block .................................................................................................................3-6
I/O Module ...........................................................................................................3-7
Block Power ......................................................................................................3-8
Central Processing Unit...................................................................................3-10
Memory ..........................................................................................................3-11
Hnet Interface .................................................................................................3-11
Machine Fault Timer .......................................................................................3-12
Serial Link Interface ........................................................................................3-12
LED Drivers and Status LEDs .........................................................................3-14
I/O Channel Interface .....................................................................................3-14
I/O Section .....................................................................................................3-14
Special Operations Switch (SW2) .....................................................................3-15
Base ...................................................................................................................3-15
Screw and Clamp Termination Bases ..............................................................3-15
Cable Connection............................................................................................3-18
Shield Terminations (Chassis Ground) ............................................................3-19
I/O Module Mounting .....................................................................................3-19
Hardware Keying ................................................................................................3-20
I/O Redundancy .................................................................................................3-20
Failure Mode (Outputs) .......................................................................................3-20
Short Circuit Protection ......................................................................................3-22
Auxiliary Block .......................................................................................................3-24
I/O System Configuration.......................................................................................3-24
I/O Block Hardware............................................................................................3-25
I/O Block Function Codes...................................................................................3-25
Section 4 Redundancy .................................................................................................4-1
Introduction .............................................................................................................4-1
Description...............................................................................................................4-1
Redundancy Arbitration........................................................................................4-2
Failover ................................................................................................................4-2
Analog Input.............................................................................................................4-3
iv
WBPEEUI240751C0
Table of Contents (continued)
Section 4 Redundancy (continued)
Analog Output ......................................................................................................... 4-4
Digital Input ............................................................................................................ 4-7
Digital Output.......................................................................................................... 4-9
Section 5 Installation ....................................................................................................5-1
Introduction............................................................................................................. 5-1
Special Handling ...................................................................................................... 5-1
Unpacking and Inspection........................................................................................ 5-2
Installation Procedures ............................................................................................ 5-2
Installation and Connection Sequence...................................................................... 5-3
Section 6 Configuration ...............................................................................................6-1
Introduction............................................................................................................. 6-1
Configuration Tools.................................................................................................. 6-1
Harmony Controller ................................................................................................. 6-1
Download............................................................................................................. 6-1
Verification........................................................................................................... 6-2
Changes............................................................................................................... 6-2
Time Synchronization........................................................................................... 6-3
Firmware Download ............................................................................................. 6-3
Labels ...................................................................................................................... 6-3
Device Label ......................................................................................................... 6-4
Electronic ID .................................................................................................... 6-4
Establishing a Device Label .............................................................................. 6-4
Predefining a Device Label ................................................................................ 6-5
Online Configuration ........................................................................................ 6-5
Channel Label ...................................................................................................... 6-6
Duplicate Labels................................................................................................... 6-6
Function Codes........................................................................................................ 6-7
I/O Device Definition (FC 221) .............................................................................. 6-8
I/O Channel (FC 222, 223, 224, 225).................................................................... 6-9
I/O Channel Data........................................................................................... 6-11
Suspect Condition .......................................................................................... 6-11
Exception Reporting ....................................................................................... 6-13
Engineering Units (EU) ................................................................................... 6-13
I/O Source ..................................................................................................... 6-14
Hnet Stall Mode (Default State) ....................................................................... 6-15
Status Reporting ............................................................................................ 6-15
Alarming ........................................................................................................ 6-15
Shaping Algorithms ........................................................................................ 6-16
WBPEEUI240751C0
v
Table of Contents (continued)
Section 6 Configuration (continued)
Test Status (FC 226) ...........................................................................................6-16
Section 7 Operating Procedures .................................................................................7-1
Introduction .............................................................................................................7-1
I/O Block .................................................................................................................7-1
I/O Module Front Panel ........................................................................................7-1
Block Type and Model .......................................................................................7-1
Operating Mode - Normal and Fault ..................................................................7-2
Status...............................................................................................................7-2
Block Power ......................................................................................................7-3
Field Power .......................................................................................................7-4
Digital Channels ...............................................................................................7-4
ID Labels ..........................................................................................................7-5
I/O Module Rear Panel..........................................................................................7-5
Termination Base Color Coding and Markings .......................................................7-6
Operation .............................................................................................................7-7
Startup .............................................................................................................7-7
Stop/Reset Button ............................................................................................7-7
Initialization......................................................................................................7-8
Auxiliary Block .........................................................................................................7-9
Section 8 Troubleshooting ..........................................................................................8-1
Introduction .............................................................................................................8-1
Troubleshooting Procedures......................................................................................8-1
Operating Mode - Normal and Fault LEDs.................................................................8-1
Power LEDs ..............................................................................................................8-2
Status Code LEDs ....................................................................................................8-2
I/O Block Problem Reports .......................................................................................8-6
Station Problem Reports ...........................................................................................8-9
I/O Block Status ....................................................................................................8-11
Diagnostics ............................................................................................................8-12
Online ................................................................................................................8-12
Offline ................................................................................................................8-12
I/O Block Connectors .............................................................................................8-13
I/O Module (P1, P4, P5).......................................................................................8-13
CIO-100 (P7, P8) .................................................................................................8-14
DIO (P17) ............................................................................................................8-15
vi
WBPEEUI240751C0
Table of Contents (continued)
Section 9 Maintenance .................................................................................................9-1
Introduction............................................................................................................. 9-1
Preventive Maintenance Schedule............................................................................. 9-1
Section 10 Repair and Replacement .........................................................................10-1
Introduction........................................................................................................... 10-1
Repair.................................................................................................................... 10-1
Replacement .......................................................................................................... 10-1
Section 11 Replacement and Spare Parts ................................................................11-1
Introduction........................................................................................................... 11-1
I/O and Auxiliary Block Nomenclature ................................................................... 11-1
Cable Nomenclature............................................................................................... 11-4
Miscellaneous Parts ............................................................................................... 11-6
Appendix A Hardware Drawings ................................................................................ A-1
Introduction............................................................................................................. A-1
I/O Block................................................................................................................. A-1
Auxiliary Block......................................................................................................... A-4
List of Procedures
No.
PR1
PR2
PR3
PR4
PR5
PR6
PR7
PR8
PR9
PR10
PR11
PR12
PR13
PR14
WBPEEUI240751C0
Title
Installation Preparation
I/O Block Base Installation
I/O Module Installation
Auxiliary Block Installation
BLK-100 Installation
AIN-120 Setup
AIN-200 Setup
AIN-220 Setup
AIN-300 Setup
AOT-150 Setup
CIO-100 Setup
DIO-400 Setup
DOT-100 Setup
DOT-120 Setup
vii
List of Procedures (continued)
No.
PR15
PR16
PR17
PR18
PR19
PR20
PR21
PR22
PR23
PR24
PR25
PR26
PR27
PR28
PR29
PR30
PR31
PR32
PR33
PR34
Title
CIO-110 Setup
RLY-200 Setup
CIO-100/110 Cable Connection
RLY-100/200 Cable Connection
Field Wiring (S Type Base)
Field Wiring (C Type Base)
Field Wiring (Cable Connection)
CIO-110 Wiring
RLY-100/200 Wiring
Offline Diagnostics
Device Label Definition
I/O System Configuration
Connections Check
I/O Module Removal
I/O Block Base Removal
Auxiliary Block Removal
Wiring and Cabling Disconnection
DOT-100/120 Relay Replacement
RLY-100 Relay Replacement
RLY-200 Relay Replacement
List of Worksheets
No.
WS1
WS2
WS3
WS4
WS5
WS6
WS7
WS8
WS9
viii
Title
AIN-120
AIN-200
AIN-220
AIN-300
AOT-150
CIO-100
DIO-400
DOT-100
DOT-120
WBPEEUI240751C0
List of Figures
No.
1-1.
1-2.
1-3.
1-4.
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
7-1.
7-2.
WBPEEUI240751C0
Title
Page
Harmony Area Controller with Harmony I/O Blocks .................................. 1-2
Harmony Bridge Controller with Harmony I/O Blocks ............................... 1-3
Harmony I/O System ................................................................................ 1-4
Controller I/O Communication.................................................................. 1-7
Analog Control Station Interface................................................................ 2-9
Station Connection ................................................................................... 2-9
Analog Input ............................................................................................. 3-2
Analog Output .......................................................................................... 3-3
Digital Input ............................................................................................. 3-4
Digital Output........................................................................................... 3-5
I/O Block.................................................................................................. 3-7
Configuration Jumper Access.................................................................... 3-8
Block Diagram - I/O Module ..................................................................... 3-9
Block Power ............................................................................................ 3-10
Hnet Interface ......................................................................................... 3-11
Serial Link Interface................................................................................ 3-13
Screw Terminal Base (S Type).................................................................. 3-16
Clamp Terminal Base (C Type) ................................................................ 3-17
Terminal Markings (Door Removed) ......................................................... 3-18
C Type Base for Cable Connection ........................................................... 3-19
Redundant I/O Block .............................................................................. 3-21
Auxiliary Block........................................................................................ 3-24
Example I/O Connection, Setup, and Configuration ................................ 3-25
AIN-120 Block - Voltage Mode (Differential or Single -Ended) ..................... 4-4
AIN-120 Block - Current Mode (IFP or LFP Powered) .................................. 4-5
AIN-120 Block - Current Mode (RFP Powered)............................................ 4-6
AIN-200/220 Block - Voltage and Thermocouple Mode .............................. 4-7
AIN-220 Block - Current Mode (IFP or LFP Powered) .................................. 4-8
AIN-220 Block - Current Mode (RFP Powered)............................................ 4-9
AIN-300 Block......................................................................................... 4-10
AOT-150 Block ....................................................................................... 4-11
DIO-400 Block (IFP or LFP Powered) ........................................................ 4-12
DIO-400 Block (RFP Powered) ................................................................. 4-13
DOT-100 Block ....................................................................................... 4-14
DOT-120 Block ....................................................................................... 4-15
I/O and Auxiliary Block Installation and Connection Flowchart ................. 5-4
AIN Block Flowchart.................................................................................. 5-4
AOT Block Flowchart................................................................................. 5-5
CIO Block Flowchart ................................................................................. 5-6
DIO and RLY Blocks Flowchart.................................................................. 5-7
DOT Block Flowchart ................................................................................ 5-8
I/O Block Front Panel ............................................................................... 7-2
I/O Module Rear Panel.............................................................................. 7-6
ix
List of Figures (continued)
No.
7-3.
10-1.
10-2.
10-3.
10-4.
A-1.
A-2.
A-3.
A-4.
PR2-1.
PR3-1.
PR4-1.
PR5-1.
PR5-2.
PR6-1.
PR6-2.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR11-7.
PR11-8.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR14-3.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
x
Title
Page
Auxiliary Block Front Panel .....................................................................7-10
Replacement Flowchart (1 of 4) ................................................................10-2
I/O Module Replacement Flowchart (2 of 4)..............................................10-2
I/O Block and Auxiliary Block Replacement Flowchart (3 of 4) .................10-3
Relay Replacement Flowchart (4 of 4) .......................................................10-3
I/O Module............................................................................................... A-1
Nonredundant Base.................................................................................. A-2
Redundant Base ....................................................................................... A-3
Auxiliary Block ......................................................................................... A-4
Base Attachment .................................................................................. PR2-2
I/O Module Attachment ........................................................................ PR3-2
Auxiliary Block Installation................................................................... PR4-2
Base Attachment .................................................................................. PR5-2
Blank Module Attachment .................................................................... PR5-3
User-Configurable Jumpers - Base ....................................................... PR6-4
Analog Input Field Power Selection (J17/J18) ....................................... PR6-5
Analog Input (Simplified) ...................................................................... PR7-2
User-Configurable Jumpers - Base ....................................................... PR8-4
Analog Input Field Power Selection (J17/J18) ....................................... PR8-5
Analog Input (Simplified) ...................................................................... PR8-6
Analog Input (Simplified) ...................................................................... PR9-2
Analog Output (Simplified) .................................................................. PR10-2
User-Configurable Jumpers - Base ..................................................... PR11-5
Analog Input Field Power Selection (J15/J16) ..................................... PR11-6
Configuration Jumper Access ............................................................. PR11-6
User-Configurable Jumpers - I/O Board ............................................. PR11-7
Analog Input (Simplified) .................................................................... PR11-8
Analog Output (Simplified) .................................................................. PR11-9
Digital Input (Simplified) ..................................................................... PR11-9
Digital Output (Simplified) .................................................................PR11-10
Configuration Jumper Access ............................................................. PR12-5
User-Configurable Jumpers - I/O Board ............................................. PR12-6
Digital Input (Simplified) ..................................................................... PR12-7
Digital Output (Simplified) .................................................................. PR12-7
DIO with RLY - Digital Output (Simplified) .......................................... PR12-8
Digital Output (Simplified) .................................................................. PR13-2
Configuration Jumper Access ............................................................. PR14-3
User-Configurable Jumpers - I/O Board ............................................. PR14-4
Digital Output (Simplified) .................................................................. PR14-5
I/O Board Layout ............................................................................... PR15-2
I/O Board Layout (Shown Without Relays) .......................................... PR16-3
CIO Connection .................................................................................. PR17-1
Current Mode Bypass Cable Connection ............................................. PR17-3
WBPEEUI240751C0
List of Figures (continued)
No.
PR17-3.
PR18-1.
PR18-2.
PR19-1.
PR19-2.
PR19-3.
PR19-4.
PR19-5.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR22-1.
PR23-1.
PR23-2.
PR24-1.
PR28-1.
PR29-1.
PR30-1.
PR32-1.
PR32-2.
PR33-1.
PR34-1.
Title
Page
Electric Drive/Pulse Positioner Bypass Cable Connection .................... PR17-4
DIO to RLY Connection ....................................................................... PR18-1
DIO Block to RLY Block Cable Connection........................................... PR18-2
Screw Terminal Base........................................................................... PR19-2
Analog Input ....................................................................................... PR19-5
Analog Output .................................................................................... PR19-6
Digital Input ....................................................................................... PR19-6
Digital Output..................................................................................... PR19-7
Clamp Terminal Base.......................................................................... PR20-2
Analog Input ....................................................................................... PR20-5
Analog Output .................................................................................... PR20-5
Digital Input ....................................................................................... PR20-6
Digital Output..................................................................................... PR20-6
C Type Base for Cable Connection ....................................................... PR21-2
Shield Wire Faston Adapter ................................................................. PR21-4
Analog Input ....................................................................................... PR21-6
Analog Output .................................................................................... PR21-6
Digital Input ....................................................................................... PR21-7
Digital Output..................................................................................... PR21-7
Wiring Terminals and Assignments ..................................................... PR22-2
Wiring Terminals and Assignments (RLY-100) ..................................... PR23-3
Wiring Terminals and Assignments (RLY-200) ..................................... PR23-4
Diagnostics Status LED Indications..................................................... PR24-1
I/O Module Removal ........................................................................... PR28-2
Base Removal ..................................................................................... PR29-2
Auxiliary Block Removal...................................................................... PR30-2
Configuration Jumper Access.............................................................. PR32-2
I/O Board Layout (Shown Without Relays)........................................... PR32-3
RLY-100 Board Layout (Shown Without Relays)................................... PR33-3
RLY-200 Board Layout (Shown Without Relays)................................... PR34-3
List of Tables
No.
1-1.
1-2.
1-3.
1-4.
1-5.
WBPEEUI240751C0
Title
Page
Available I/O and Auxiliary Blocks ............................................................ 1-5
I/O Block Capabilities............................................................................... 1-6
Glossary of Terms and Abbreviations....................................................... 1-12
Reference Documents.............................................................................. 1-13
Abbreviated Harmony I/O System Nomenclature..................................... 1-14
xi
List of Tables (continued)
No.
1-6.
1-7.
1-8.
1-9.
1-10.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
5-1.
6-1.
6-2.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
9-1.
11-1.
11-2.
11-3.
xii
Title
Page
Related Nomenclature..............................................................................1-14
Design Standards ....................................................................................1-15
General I/O Block Specifications .............................................................1-16
General Auxiliary Block Specifications .....................................................1-17
Environmental Specifications...................................................................1-18
AIN-120 Specifications...............................................................................2-1
AIN-200 Specifications...............................................................................2-3
AIN-220 Specifications...............................................................................2-4
AIN-300 Specifications...............................................................................2-5
AOT-150 Specifications..............................................................................2-6
BLK-100 Specifications..............................................................................2-8
CIO-100 Specifications ............................................................................2-10
CIO-110 Specifications ............................................................................2-13
DIO-400 Specifications ............................................................................2-13
DOT-100 Specifications ...........................................................................2-15
DOT-120 Specifications ...........................................................................2-16
RLY-100 Specifications (Electromechanical Relays) ..................................2-17
RLY-200 Specifications (Solid State Relays) ..............................................2-19
I/O Block Failure Mode Output Conditions ..............................................3-22
Channel Fault Currents (Nominal) Under Short Conditions ......................3-23
Installation Procedures ..............................................................................5-2
I/O Channel Function Code Summary .......................................................6-9
I/O Channel Specifications Summary ........................................................6-9
Operating Mode - Normal and Fault LEDs..................................................7-3
Normal Operating Mode Status Codes........................................................7-3
Digital Channel Status ..............................................................................7-4
Special Operations Switch (SW2) Settings ..................................................7-6
Terminal Strip Markings and Color Coding ................................................7-6
Startup Sequence ......................................................................................7-8
Operating Mode - Normal and Fault LEDs..................................................8-2
Block and Field Power LEDs ......................................................................8-3
Status Codes .............................................................................................8-4
I/O Block Problem Reports ........................................................................8-7
Station Problem Reports ..........................................................................8-10
P1 Power Pins..........................................................................................8-13
P4 Redundancy Link Pins ........................................................................8-13
P5 Communication Pins ..........................................................................8-14
CIO-100 P7 and P8 Connector Pins..........................................................8-14
DIO P17 Connector Pins ..........................................................................8-15
Preventive Maintenance Schedule ..............................................................9-2
Analog Input Nomenclature .....................................................................11-1
Analog Output Nomenclature...................................................................11-2
Control Input/Output Nomenclature .......................................................11-2
WBPEEUI240751C0
List of Tables (continued)
No.
11-4.
11-5.
11-6.
11-7.
11-8.
11-9.
11-10.
11-11.
11-12.
11-13.
PR1-1.
PR1-2.
PR6-1.
PR6-2.
PR6-3.
PR6-4.
PR7-1.
PR8-1.
PR8-2.
PR8-3.
PR9-1.
PR10-1.
PR11-1.
PR11-2.
PR11-3.
PR11-4.
PR11-5.
PR11-6.
PR12-1.
PR12-2.
PR12-3.
PR12-4.
PR12-5.
PR13-1.
PR14-1.
PR14-2.
PR15-1.
PR16-1.
PR17-1.
PR17-2.
PR19-1.
PR19-2.
PR19-3.
WBPEEUI240751C0
Title
Page
Digital Input/Output Nomenclature ........................................................ 11-3
Digital Output Nomenclature .................................................................. 11-3
Auxiliary Relay Assembly Nomenclature .................................................. 11-4
Blank Block Nomenclature...................................................................... 11-4
DIO to RLY Cable Nomenclature .............................................................. 11-4
I/O Block to Remote Termination Cable Nomenclature ............................ 11-5
CIO Cable Nomenclature ......................................................................... 11-5
Fuses...................................................................................................... 11-6
Relays..................................................................................................... 11-6
Miscellaneous ......................................................................................... 11-7
Worksheets ........................................................................................... PR1-2
Worksheet Information.......................................................................... PR1-3
Field Power Select Jumpers (Module)..................................................... PR6-2
Analog Input Field Power Select Jumpers (Base) .................................... PR6-2
Input Channel Jumpers ........................................................................ PR6-2
Analog Input (Simplified) ....................................................................... PR6-6
Field Power Select Jumpers................................................................... PR7-1
Field Power Select Jumpers (Module)..................................................... PR8-2
Analog Input Field Power Select Jumpers (Base) .................................... PR8-2
Input Channel Jumpers ........................................................................ PR8-2
Field Power Select Jumpers................................................................... PR9-1
Field Power Select Jumpers................................................................. PR10-1
Field Power Select Jumpers................................................................. PR11-2
Analog Input Field Power Select Jumpers (Base) .................................. PR11-2
Analog Input Channel Jumpers........................................................... PR11-3
Analog Output Channel Jumpers ........................................................ PR11-3
Digital Input Channel Jumpers ........................................................... PR11-4
Digital Output Channel Jumpers ........................................................ PR11-4
Digital Output Field Power Select Jumpers.......................................... PR12-2
Digital Input Field Power Select Jumper .............................................. PR12-2
Digital Input Field Power Monitor Jumper ........................................... PR12-2
Digital Input Channel Jumpers ........................................................... PR12-3
Digital Output Channel Jumpers ........................................................ PR12-4
Field Power Select Jumpers................................................................. PR13-2
Field Power Select Jumpers................................................................. PR14-2
Readback/Fusing Select Jumpers ....................................................... PR14-2
M/A Power Select Jumpers ................................................................. PR15-1
Fuses.................................................................................................. PR16-2
CIO-100 to CIO-110 Connector Relationship ....................................... PR17-2
CIO-100 and IISAC01 Analog Input Relationship ................................. PR17-2
Terminal Strip Markings and Color Coding .......................................... PR19-3
Terminal Assignments Tables .............................................................. PR19-4
AIN-120 and AIN-220 .......................................................................... PR19-8
xiii
List of Tables (continued)
No.
PR19-4.
PR19-5.
PR19-6.
PR19-7.
PR19-8.
PR19-9.
PR20-1.
PR20-2.
PR20-3.
PR20-4.
PR20-5.
PR20-6.
PR20-7.
PR20-8.
PR20-9.
PR21-1.
PR21-2.
PR21-3.
PR21-4.
PR21-5.
PR21-6.
PR21-7.
PR21-8.
PR21-9.
PR21-10.
PR22-1.
PR22-2.
PR23-1.
PR23-2.
PR23-3.
PR24-1.
PR24-2.
PR24-3.
PR24-4.
xiv
Title
Page
AIN-200.............................................................................................. PR19-9
AIN-300.............................................................................................PR19-10
AOT-150............................................................................................PR19-11
CIO-100 ............................................................................................PR19-12
DIO-400 ............................................................................................PR19-13
DOT-100 and DOT-120......................................................................PR19-14
Terminal Strip Markings and Color Coding ......................................... PR20-3
Terminal Assignments Tables ............................................................. PR20-3
AIN-120 and AIN-220 ......................................................................... PR20-7
AIN-200.............................................................................................. PR20-8
AIN-300.............................................................................................. PR20-9
AOT-150............................................................................................PR20-10
CIO-100 ............................................................................................PR20-11
DIO-400 ............................................................................................PR20-12
DOT-100 and DOT-120......................................................................PR20-13
HRM-RTS Cable Requirements ........................................................... PR21-3
Terminal Strip Markings and Color Coding ......................................... PR21-5
Connector Pin Assignments Tables ..................................................... PR21-5
AIN-120 and AIN-220 ......................................................................... PR21-8
AIN-200.............................................................................................. PR21-9
AIN-300.............................................................................................PR21-10
AOT-150............................................................................................PR21-11
CIO-100 ............................................................................................PR21-12
DIO-400 ............................................................................................PR21-13
DOT-100 and DOT-120......................................................................PR21-14
Station to Wiring Terminal Relationship.............................................. PR22-3
Terminal Assignments ........................................................................ PR22-3
Channel Label Makings ...................................................................... PR23-2
RLY-100 Terminal Assignments .......................................................... PR23-5
RLY-200 Terminal Assignments .......................................................... PR23-6
Offline Diagnostic Tests - Switch Settings ........................................... PR24-2
Group 1 Diagnostic Tests.................................................................... PR24-3
Group 2 Diagnostic Tests.................................................................... PR24-4
Group 3 Diagnostic Tests.................................................................... PR24-5
WBPEEUI240751C0
Safety Summary
Electrostatic Sensitive Device
Devices labeled with this symbol require special handling precautions as described in the installation section.
GENERAL
WARNINGS
Equipment Environment
All components, whether in transportation, operation or storage,
must be in a noncorrosive environment.
Electrical Shock Hazard During Maintenance
Disconnect power or take precautions to insure that contact with
energized parts is avoided when servicing.
SPECIFIC
WARNINGS
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous. (p. 3-7, PR3-1,
PR28-1)
Verify the main power, field power, and power entry panel circuit
breakers/switches are turned off before starting installation, retrofit,
upgrade, or wiring procedures. Failure to do so could result in
severe or fatal shock. Do not turn the power on until the installation,
retrofit, upgrade, or wiring procedures are complete. (p. PR19-1,
PR20-1, PR21-2, PR22-1, PR23-1, PR31-1)
Turn off all power before attempting the connections check maintenance procedure. Failure to do so could result in severe or fatal
shock, or equipment damage. (p. PR27-1)
Verify power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal shock. Do not
turn the power on until the replacement procedure is complete.
(p. PR33-1, PR34-1)
WBPEEUI240751C0
xv
Safety Summary (continued)
SPECIFIC
CAUTIONS
For analog input channels, if the fused AI IFP/LFP option is selected
to power a 4 to 20 milliampere input, removing the I/O module from
the base in nonredundant applications will result in a loss of power
to all input current loops. (p. PR6-1, PR8-1, PR11-1, PR28-1)
Insure the setting for the digital input field power monitor jumper
DIFP-J2 matches the actual field power voltage (IFP or LFP). Circuit
damage will occur if the LFP voltage is greater than the voltage setting of jumper DIFP-J2. (p. PR12-1)
Use only ABB Automation approved relays on the relay assembly.
Using unapproved relays could improperly route signals and damage equipment connected to the relay and the relay itself. CSA certification is voided when unapproved relays are used. (p. PR16-1,
PR32-1, PR33-1, PR34-1)
xvi
WBPEEUI240751C0
Support Services
ABB will provide assistance in the operation and repair of its
products. Requests for sales or application services should be
made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.
When ordering parts, use nomenclature or part numbers and
part descriptions from equipment manuals. Parts without a
description must be ordered from the nearest sales or service
office. Recommended spare parts lists, including prices are
available through the nearest sales or service office.
ABB has modern training facilities available for training your
personnel. On-site training is also available. Contact your
nearest ABB sales office for specific information and
scheduling.
Additional copies of this instruction, or other instructions, can
be obtained from the nearest ABB sales office at a reasonable
charge.
WBPEEUI240751C0
xvii
Trademarks and Registrations
Registrations and trademarks used in this document include:
™ Composer
® INFI 90
® INFI-NET
xviii
Trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
Registered trademark of Elsag Bailey Process Automation
WBPEEUI240751C0
Introduction
Section 1
Purpose
The Harmony Input/Output (I/O) System interfaces field
inputs and outputs for the Symphony Enterprise Management
and Control System to monitor and control a process. The
Harmony I/O system incorporates a variety of input and output devices (blocks) to interface process signals. Blocks for
analog, digital, and control I/O interface along with remote
I/O communication combine to create a complete I/O system.
The Harmony I/O system offers a complete solution in a modular, easy to use package. In addition to the I/O devices, the
Harmony solution provides many options for ready-to-use I/O
communications, I/O mounting, field wiring management,
power distribution, and cooling.
The Harmony I/O system is intended to be an alternative to
rack I/O modules and terminations. It provides flexibility in
system design, enhanced I/O signal processing, and reduced
installation complexity and installation time.
NOTE: Abbreviated nomenclature is used in this instruction whenever possible
(refer to Table 1-5). Refer to Section 11 for complete nomenclature.
Harmony I/O System Documentation
Complete information about Harmony I/O system installation
and operation is contained in the following instructions:
I/O and Auxiliary Blocks - overviews the Harmony I/O system; describes the analog, digital, and control I/O blocks and
auxiliary blocks used for field I/O interface; and provides I/O
and auxiliary block installation and connection procedures.
Block Power and Mounting Hardware - describes the block
mounting hardware, describes the block operating power and
field power options, and provides mounting hardware installation and power connection procedures.
Harmony Communications Network (Hnet) - describes the
Harmony Communications Network or Hnet, details network
WBPEEUI240751C0
1-1
System Overview
architecture options, and provides Hnet component installation and connection procedures.
Harmony I/O data sheets supplement the information provided in these instructions.
System Overview
Figures 1-1 and 1-2 are hierarchical views of the Symphony
system showing the various system communication levels and
the position of the Harmony I/O system within these levels.
Figure 1-1 shows a Harmony area controller with I/O blocks.
Figure 1-2 shows a rack-mounted Harmony bridge controller
with I/O blocks.
CNET
HARM ONY
AREA
CON TROLLER
I/O H N E T
I/O H N E T
I/O
B LO C K
R E P E ATE R
M O U N T IN G
U N IT (R M U )
HNET
RMU
I/O B LO C K S
R E M OT E
LO C AT IO N
A N A LO G C O N T R O L
S TAT IO N S
T 0 19 7 6C
Figure 1-1. Harmony Area Controller with Harmony I/O Blocks
The main components of the Harmony I/O system are I/O
blocks and Hnet (Fig. 1-3). Together they operate as a subsystem dedicated to the Harmony controller. Hnet is the
redundant network over which Harmony controllers and Harmony I/O blocks communicate. The controller performs the
actual control functions. The I/O blocks process any inputs
1-2
WBPEEUI240751C0
System Overview
CNET
H A R M O N Y R AC K
C O M M U N IC AT IO N
M O D U LE S
HARM ONY
B R ID G E
CON TROLLER
I/O H N E T
I/O H N E T
I/O
B LO C K
R E P E ATE R
M O U N T IN G
U N IT (R M U )
HNET
RMU
I/O B LO C K S
R E M OT E
LO C AT IO N
A N A LO G C O N T R O L
S TAT IO N S
T 0 10 7 9C
Figure 1-2. Harmony Bridge Controller with Harmony I/O Blocks
from and outputs to field devices for the controller. The controller can communicate with up to 64 Hnet devices.
The I/O types include:
•
•
•
•
•
Analog input (AIN).
Analog output (AOT).
Control loop input/output (CIO).
Digital input/output (DIO).
Digital output (DOT).
The repeater mounting unit (RMU) is also an important component of the Harmony I/O system. The repeater mounting
unit provides mounting slots for Hnet repeaters used to communicate with remote enclosures over fiber optic cables.
WBPEEUI240751C0
1-3
Input/Output
H ARM ONY
C O N TR O LLE R
A IN
AOT
D OT
I/O H N E T (R E D U N DA N T )
RMU
W IT H H N E T
R E P E AT E R S
C IO
C IO
D IO
D IO
H N ET
(R E D U N DA N T)
S AC
TO R E M OT E
I/O B LO C K S
LE G E N D :
A IN = A N A LO G IN P U T
AOT = A N A LO G O U T P U T
C IO = C O N T R O L IN P U T /O U T P U T
D IO = D IG ITA L IN P U T /O U T P U T
D OT = D IG ITA L O U T P U T
R LY
H N ET = H A R M O N Y C O M M U N IC AT IO N S N E T W O R K
R LY = R E LAY A S S E M B LY
R M U = R E P E AT E R M O U N T IN G U N IT
S AC = A N A LO G C O N T R O L S TAT IO N
T 02056B
Figure 1-3. Harmony I/O System
The Harmony I/O system is powered by redundant 24 VDC
and provides for separate distribution of field power. The I/O
system can be powered by the Modular Power System II.
One or more control enclosures house all I/O system components. The block mounting hardware within the enclosure
supports a variety of arrangements. Small cabinet or enclosure
mounting is also supported.
Although not specifically part of the Harmony I/O system,
analog control stations (SAC) can connect and communicate
through CIO blocks as shown in Figure 1-3. Communication is
over an RS-485 serial station link.
Input/Output
The Harmony I/O system supports a variety of input/output
blocks to interface analog, digital, and control I/O. Table 1-1
1-4
WBPEEUI240751C0
Harmony Controllers
lists the currently available I/O and auxiliary blocks.
Table 1-2 summarizes I/O block capabilities. Refer to
Section 2 for a description of each block and its specifications.
Table 1-1. Available I/O and Auxiliary Blocks
Block
Description
AIN-120
Current, high level voltage in
AIN-200
Isolated high level voltage, low level voltage, TC in
AIN-220
Isolated current, high level voltage, low level voltage, TC in
AIN-300
Isolated RTD in
AOT-150
Current out
CIO-100
Control loop in/out
CIO-110
Electric drive/pulse positioner termination (for CIO-100)1
DIO-400
Universal digital in, 24 or 48 VDC digital out
DOT-100
Onboard electromechanical relay out
DOT-120
Onboard monitored electromechanical relay out (with fusing)
RLY-100
Electromechanical relay assembly (for DIO-400)1
RLY-200
Solid state relay assembly (for DIO-400)1
NOTE:
1. Auxiliary block used to extend I/O block capabilities.
Harmony Controllers
A Harmony controller, either a Harmony bridge controller or
Harmony area controller, performs the actual process control.
It receives its process inputs from either or both Harmony I/O
blocks and Harmony rack I/O devices and provides the control
outputs through these blocks and devices.
The controller can communicate with Harmony I/O blocks and
Harmony rack I/O devices simultaneously. All Harmony I/O
system configuration is performed through the controller.
Harmony Bridge Controller
A Harmony bridge controller (BRC) is a rack-mounted controller that occupies one slot in a module mounting unit. It supports Hnet communication protocol, device labeling, and the
function code environment necessary to configure and operate
the Harmony I/O system. Refer to the Harmony Bridge Controller instruction for a detailed description.
WBPEEUI240751C0
1-5
Harmony Controllers
•
Low level VDC
Thermocouple
3-wire RTD
10 Ω copper
100 Ω platinum: U.S. Lab. Standard
100 Ω platinum: U.S. Industry Standard
100 Ω platinum: European Standard
120 Ω nickel
Chinese 53 Ω copper
•
•
•
•
•1
-100 to +100 mV
•
•
B, E, J, K, L, N (14/28 AWG), R, S, T, U,
Chinese E, S
•
•
Channels
16
Analog Out
Digital In
Current
4 to 20 mA
High level VDC
1 to 5 VDC
DIO-400
•
Isolated
16
16
16
•
•
•
4
•
•
•
Channels
16
2
Isolated
24 VDC
19.5 to 28 VDC
•
•
48 VDC
39 to 56 VDC
•
•
125 VDC
95 to 144 VDC
•
•
120 VAC
85 to 138 VAC
•
•
240 VAC
190 to 265 VAC
•
•
4
16
•
•
Channels
Isolated
Open collector
Digital Out
CIO-100
DOT-120
Analog In
•
-10 to + 10 VDC
AIN-300
•
4 to 20 mA
High level VDC
AOT-150
•
•
Current
AIN-220
•
Range/Type
AIN-200
24, 48, 125 VDC
120, 240 VAC
I/O
AIN-120
DOT-100
Table 1-2. I/O Block Capabilities
24 VDC at 250 mA
•
48 VDC at 250 mA
SPDT EM relay
Channels
Isolated
Supports redundant I/O electronics
•
•
•
•
•
•
•
4
8
16
16
•
•
•
•
•
•
•
NOTE:
1. 1 to 5 VDC only.
1-6
WBPEEUI240751C0
Harmony Controllers
The controller can read and send I/O block channel data, configuration information, and status over Hnet (Fig. 1-4). The
controller can also simultaneously communicate with rack I/O
devices over the I/O expander bus.
HARM ONY
C O N T R O LL E R
I/O E X PA N D E R BU S
R AC K
I/O M O D U LE
I/O H N E T
I/O
B LO C K
T E R M IN AT IO N
U N IT
T 00 5 52 B
Figure 1-4. Controller I/O Communication
Harmony Area Controller
Like the bridge controller, the Harmony area controller (HAC)
supports the communications protocol and configuration environment necessary to operate the Harmony I/O system. It collects process I/O data, performs control algorithms, and
outputs control signals to final control elements through either
or both Harmony I/O blocks and rack I/O devices (Fig. 1-4).
The controller offers enhanced communications and process
interface abilities. Refer to the Harmony Area Controller
instruction for a detailed description.
WBPEEUI240751C0
1-7
Function Codes
Function Codes
When interfacing to Harmony I/O blocks, the controller utilizes single channel I/O function codes:
•
•
•
•
Analog input/channel (FC 222).
Analog output/channel (FC 223).
Digital input/channel (FC 224).
Digital output/channel (FC 225).
These single channel function codes simplify configuration:
one function code configures one channel. A single I/O device
definition function code (FC 221) groups the single channel
function codes for an entire I/O block. Refer to the Function
Code Application Manual for detailed function code
descriptions.
Compatibility
The Harmony I/O system is fully compatible with existing
INFI 90 OPEN systems. The I/O system can be integrated into
established installations that currently use INFI 90 OPEN I/O
to interface and process input and output signals. Or, the I/O
system can be installed to replace existing INFI 90 OPEN I/O.
The Harmony controller can communicate with Harmony I/O
and INFI 90 OPEN I/O simultaneously. Communication is over
Hnet for Harmony I/O blocks and over I/O expander bus for
INFI 90 OPEN I/O.
Features
Intelligent I/O system: A microprocessor in each I/O assembly executes the I/O portion of the control strategy and provides advanced functions and diagnostics.
High performance, deterministic I/O network: Uses a redundant, high speed serial communication network with an inherent capability for remote communication.
Distributed capability: A high speed I/O communication network designed for long distances combined with flexible enclosure mounting options enables both centralized and remote
I/O locations.
1-8
WBPEEUI240751C0
Intended User
Inherent redundancy design: Designed with redundant block
power inputs (24 VDC), redundant communications, and
optionally redundant I/O modules.
Wide variety of I/O types: Analog (high level, low level, and
temperature), digital, and control I/O.
Significant reduction of installation costs: I/O assemblies
combine chassis, cabling, I/O electronics, power conversion,
and termination into one device. Distribution of I/O reduces
cable costs.
Reduction in total operating costs: Simplified user configuration with no calibration required, no address switches to set,
and downloadable firmware.
Compatibility with existing systems: Works with both the
Harmony bridge controller and Harmony area controller;
works in combination with Harmony rack I/O and INFI 90
OPEN I/O.
Advanced features:
•
Downloadable firmware eliminates PROM changes.
•
User-assignable software device labels eliminate the need
to manually set hardware addresses.
•
User-assignable I/O channel labels simplify configuration.
The same label can be used to identify an I/O channel and
to define a tag in the system database for easier I/O point
recognition.
•
Advanced diagnostics of I/O block, I/O channel, and Hnet
traffic identifies system problems.
•
I/O status can be inhibited from contributing to block status, eliminating nuisance alarms.
•
Manual override of I/O channel values simplifies system
maintenance.
Intended User
This instruction is intended for technical personnel responsible for installation, operation, maintenance, and repair of the
Harmony I/O system. System engineers and technicians with
WBPEEUI240751C0
1-9
Instruction Content
a background in process control systems should read this
instruction thoroughly before installing and using the system.
Instruction Content
Introduction
Input/Output Blocks
Description and
Operation
Redundancy
Provides a brief description of the available I/O and auxiliary
blocks, and provides specifications for each.
Provides a general description of Harmony I/O blocks and
details functional operation.
Provides a general description of block redundancy, and
details redundancy for specific block types.
Installation
Describes I/O and auxiliary block installation and connection.
Configuration
Describes controller and I/O block function code configuration
and operation.
Operating Procedures
Troubleshooting
Details I/O block and auxiliary block front and rear panel
items, startup, stop/reset, and initialization procedures.
Provides troubleshooting information including LED error
indications, status codes, and problem reports; and describes
online and offline diagnostics for testing I/O electronics integrity.
Maintenance
Includes a preventive maintenance schedule and lists the
related procedures.
Repair and
Replacement
Describes repair and replacement procedures for I/O and auxiliary blocks.
Replacement and
Spare Parts
Procedures
1 - 10
Gives an overview of the Harmony I/O system and describes
the content and intended user of this instruction. It also highlights I/O system features, lists reference documents, and
contains system and general block specification information.
Provides a list of part nomenclature and part numbers.
Individual procedure sections (e.g., PR1, PR6, PR27, etc.)
detail installation, maintenance, and replacement actions. A
procedure section typically gives the steps for a single task.
Installation flowcharts and replacement flowcharts indicate
the order in which these procedures are to be performed.
WBPEEUI240751C0
How to Use this Instruction
Worksheets
Worksheets are provided for each I/O block type and are only
intended to aid in the installation process. In some cases, the
information recorded on the worksheets may already be available or provided in some other form.
How to Use this Instruction
When installing a complete Harmony I/O system:
1. Refer to the Block Power and Mounting Hardware instruction to install and connect the block mounting hardware and
to connect power.
2. Refer to the Harmony Communication Network (Hnet)
instruction to install and connect Hnet components for communication.
3. Refer to this instruction when installing, operating, troubleshooting, maintaining, and replacing individual I/O and
auxiliary blocks.
To use this instruction:
1. Read Section 1 for an overview of the Harmony I/O system
and a description of the instruction content.
2. Refer to Section 2 for I/O and auxiliary block descriptions
and specifications.
3. Read Section 3 and Section 4 to become familiar with I/O
and auxiliary blocks.
4. Read Section 5 to install I/O and auxiliary blocks. The section contains flowcharts that point to the various procedures
that must be performed to complete installation and
connection.
5. Read Section 6 for controller and function code configuration information.
6. Read Section 7 for I/O block operating details.
7. Refer to Sections 8, 9, and 10 for troubleshooting, maintenance, and replacement information respectively.
8. Refer to Section 11 for installation, replacement, and spare
part nomenclature and part numbers.
WBPEEUI240751C0
1 - 11
Document Conventions
Document Conventions
The ? in a nomenclature or part number indicates a variable
for that position (e.g., 1949480?1). In a part number and document number, the ? is a place holder for the revision letter.
Glossary of Terms and Abbreviations
Table 1-3 is a glossary of terms and abbreviations used in the
instruction. It contains those terms and abbreviations that are
unique to ABB Automation or have a definition that is different
from standard industry usage.
Table 1-3. Glossary of Terms and Abbreviations
Term
Definition
Auxiliary block
I/O system device that enhances I/O block capabilities.
Base
Mounting base for a block. For I/O blocks it supports screw terminals,
clamp terminals, or cable connection of field wiring.
BRC
Harmony bridge controller.
Channel label
Optional name (i.e., character string) assigned to an I/O channel.
Device label
Name (i.e., character string) assigned to an I/O block. The device label
identifies a block instead of a hardware address.
Exception report
Information update generated when the status or value of a point
changes by more than a specified significant amount.
Function code (FC)
An algorithm that manipulates specific functions. These functions are
linked together to form the control strategy.
HAC
Harmony area controller.
Harmony network
(Hnet)
Redundant serial communications system that allows data to be transmitted between Harmony devices.
I/O block
Generic name for a processor based Harmony input/output device:
AIN-120, AOT-150, DIO-400, etc.; comprised of an I/O module and a
base.
I/O expander bus
Parallel communication bus between the Harmony controller and rack
I/O.
I/O module
Houses the I/O block circuitry that processes inputs and outputs; part of
an I/O block.
Machine fault time
(MFT)
Reset by the block processor during normal operation. If not reset regularly, the MFT times out and the I/O block stops.
Module mounting unit
(MMU)
Card cage that provides electrical and communication support for
Harmony rack I/O.
1 - 12
WBPEEUI240751C0
Reference Documents
Table 1-3. Glossary of Terms and Abbreviations (continued)
Term
Definition
PBA
Processor bus adapter.
Processor bus adapter
Adapter that connects a Harmony bridge controller to Hnet.
Repeater mounting unit Generic name for a block that contains Hnet repeaters.
RFO
Fiber optic repeater used to connect Hnet between enclosures.
RMU
Repeater mounting unit.
Reference Documents
Table 1-4 lists additional documents that relate to the Harmony I/O system and are referenced in this instruction.
Table 1-4. Reference Documents
Number
Document Title
WBPEEUD240001?? Harmony Analog I/O Data Sheet
WBPEEUD240002?? Harmony Digital I/O Data Sheet
WBPEEUD240003?? Harmony Control I/O Data Sheet
WBPEEUI200505??
Symphony Site Planning and Preparation
WBPEEUI210504??
Symphony Function Code Application Manual
WBPEEUI230017??
Harmony Bridge Controller
WBPEEUI230022??
IISAC01 Analog Control Station
WBPEEUI230023??
Harmony Area Controller
WBPEEUI240760??
Harmony I/O System, Block Power and Mounting
Hardware
WBPEEUI240761??
Harmony Communications Network (Hnet)
WBPEEUI270002??
Composer™, Primary Interface
WBPEEUI270003??
Composer, Automation Architect
Abbreviated Harmony I/O Nomenclature
Table 1-5 lists the abbreviated nomenclature used throughout
the instruction to identify various Harmony I/O system components and related hardware. Refer to Section 11 for complete Harmony I/O system component nomenclature.
WBPEEUI240751C0
1 - 13
Related Nomenclature
Table 1-5. Abbreviated Harmony I/O System Nomenclature
Nomenclature
Description
AIN-120, AIN-200,
AIN-220, AIN-300
Analog input block
AOT-150
Analog output block
BLK-100
Blank block
BRC-PBA
Processor bus adapter
CIO-100
Control input/output block
CIO-110
Electric drive/pulse positioner
termination block
DIO-400
Digital input/output block
DOT-100, DOT-120
Digital output block
HRM-RLY, HRM-RTS
Cables
RLY-100, RLY-200
Auxiliary relay assembly
Related Nomenclature
Refer to Section 11 for a listing of Harmony I/O system
nomenclature and part numbers. Table 1-6 provides a listing
of Harmony I/O related nomenclature.
Table 1-6. Related Nomenclature
Nomenclature
IISAC01
Description
Analog control station
P-HC-BRC-10000000
Harmony bridge controller
P-HC-PLT-20221100
P-HC-DOC-220??000
Harmony area controller
Design Standards
Table 1-7 lists the design standards for the Harmony I/O
system.
1 - 14
WBPEEUI240751C0
Design Standards
Table 1-7. Design Standards
Category
Safety
Standard
CSA C22.2 No. 142
ANSI/ISA S82.01-1994
IEC 61010-1
Environmental
Description
Safety standards for process control
equipment
CSA C22.2 No. 1010.1
Safety standards for process control
equipment
IEC 60068-2-1,2,14
Operating temperature
IEC 60068-2-3,30
Operating relative humidity
MIL-STD-810E 502.3 & 501.3 Storage/transportation temperature
ISA S71.04 (level 1 liquids,
solids, gases)
Vibration
EMI, RFI, and
electrical surge
Flammable
atmospheres
IEC 60068-2-6
Operating vibration (sinusoidal)
MIL-STD-810E 514.4
Storage/transportation vibration
Category 1, basic transportation
MIL-STD-810E 514.4
Transportation
IEC 60068-2-27
Shock
IEC 61298-3
Endurance
IEC 61000-4-2 (level 3)
ESD
IEC 61000-4-3 (level 3)
EMI susceptibility
IEC 61000-4-4 (level 3)
Electrical fast transient
IEC 61000-4-5 (level 3)
Electrical surges
IEC 61000-4-6 (level 3)
Conducted immunity
IEC 61000-4-8 (level 3)
Magnetic fields
CISPR-11
Radiated emissions
CSA C22.2 No. 213
Nonincendive equipment
ISA S12.12
Nonincendive equipment
FM Class 3611
Division 2 equipment
Flammability of
IEEE 383
product components UL rating VW-1
UL 94 V-0, V-1, or V-2
WBPEEUI240751C0
Air quality
Intercabinet cables
Intracabinet cables
Flammability of plastic materials
1 - 15
Specifications
Table 1-7. Design Standards (continued)
Category
Standard
CE Mark directives
Description
73/23/EEC
Low voltage directive
89/336/EEC
EMC directive
92/31/EEC
90/683/EEC
CE marking directives
93/68/EEC
93/465/EEC
Certifications
CSA
Certified for use as process control
equipment in an ordinary (nonhazardous)
location
Factory Mutual (FM)
Approved for use in Class I; Division 2;
Groups A, B, C, D; hazardous locations.
SUBJECT TO CHANGE WITHOUT NOTICE
Specifications
Tables 1-8 through 1-10 are general I/O and auxiliary block
specifications.
NOTE: Refer to the Harmony I/O data sheets (Table 1-4) for current consumption and heat dissipation specifications.
Table 1-8. General I/O Block Specifications
Characteristic/Value1
Property
I/O blocks
(Refer to indicated table for
individual block specifications)
Block
Refer To
Block
Table 2-1
CIO-100
Table 2-7
AIN-200
Table 2-2
DIO-400
Table 2-9
AIN-220
Table 2-3
DOT-100
Table 2-10
AIN-300
Table 2-4
DOT-120
Table 2-11
AOT-150
Table 2-5
Microprocessor
16-bit processor running at 16 MHz
Memory
64 kb SRAM
512 kb flash ROM
Redundancy link data rate
1 Mbaud
Block logic power (BLP)
21.6 VDC minimum
24.0 VDC nominal
28.0 VDC maximum
1 - 16
Refer To
AIN-120
WBPEEUI240751C0
Specifications
Table 1-8. General I/O Block Specifications (continued)
Characteristic/Value1
Property
Field power (IFP/LFP)
24.0 VDC nominal
48.0 VDC nominal
125.0 VDC nominal
120.0 VAC nominal
240.0 VAC nominal
LFP terminals
3.0 A
Fusing
Refer to the individual block specifications in Section 2
Common mode isolation2
Tested
300 VDC/VRMS at 60 Hz
1,400 VRMS at 60 Hz for 2 sec
Differential input voltage without
damage
±15 VDC/VRMS continuous
Common mode voltage3
±5 VDC/VRMS continuous
Input/output protection
Continuous short to ground - protected with current limiting
Dimensions
Type
I/O module
Height
Width
Depth
mm
in.
mm
in.
mm
in.
266
10.5
76
3.0
162
6.4
Nonredundant base
267
10.5
138
5.4
169
6.7
Redundant base
267
10.5
217
8.5
169
6.7
NOTE: Refer to Appendix A for hardware drawings.
Overvoltage (installation) category ANSI/ISA-S82.01-1994 and IEC 1010-1
I for circuits above 150 V
II for circuits below 150 V
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Applies only to blocks with isolated input and output channels. Refer to Section 2 to determine if a block has isolated channels.
3. Applies only to blocks with nonisolated input and output channels. Refer to Section 2 to determine if a block has isolated
channels.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Table 1-9. General Auxiliary Block Specifications
Property
Auxiliary blocks
(Refer to indicated table for
individual block specifications)
WBPEEUI240751C0
Characteristic/Value
Block
Refer To
CIO-110
Table 2-8
RLY-100
Table 2-12
RLY-200
Table 2-13
1 - 17
Specifications
Table 1-9. General Auxiliary Block Specifications (continued)
Property
Dimensions
Characteristic/Value
Height
Width
Depth
mm
in.
mm
in.
mm
in.
266
10.5
144
5.7
169
6.7
NOTE: Refer to Appendix A for hardware drawings.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
Table 1-10. Environmental Specifications
Environment
Air quality
Operating
Noncorrosive
Storage and Transportation
Noncorrosive
Altitude
Sea level to 3,048 m (10,000 ft)
Sea level to 12,000 m (40,000 ft)
Relative humidity
(noncondensing)
20% to 95% up to 55°C (131°F)
20% to 95% up to 55°C (131°F)
20% to 45% at 55° to 70°C
(131° to 158°F)
20% to 45% at 55° to 70°C
(131° to 158°F)
Temperature
0° to 70°C (32° to 158°F)
(internal enclosure)
-40° to +85°C (-40° to 185°F)
Vibration
10 to 60 Hz, 1.37 mm (0.054 in.) pp
60 to 150 Hz, 1.0 G sine
0.74 GRMS longitudinal
0.20 GRMS transverse
1.04 GRMS vertical
10 to 500 Hz random
—
15 G, 11 msec
Shock
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
1 - 18
WBPEEUI240751C0
Input/Output Blocks
Section 2
Introduction
This section provides a brief description of the available I/O
and auxiliary blocks, and provides specifications for each.
Refer to Tables 1-8 and 1-9 for general specifications that
apply to all I/O and auxiliary blocks.
NOTES:
1. Refer to Inputs and Outputs in Section 3 for further explanation of analog and digital input and output capabilities.
2. Refer to the Harmony I/O data sheets (Table 1-4) for current consumption
and heat dissipation specifications.
AIN-120
Current, High Level Voltage In
Analog input signals:
•
•
•
4 to 20 milliampere.
–10 to +10 VDC high level, differential.
–10 to +10 VDC high level, single-ended.
The AIN-120 block supports 16 nonisolated input channels
that are individually hardware configurable for either voltage
or current mode and software configurable for voltage range.
The block supports redundant I/O electronics.
Table 2-1. AIN-120 Specifications
Characteristic/Value1
Property
Input range
4 to 20 mA
–10 to +10 VDC
Channels
16 nonisolated
Input impedance
10 MΩ minimum
Full scale range
20 V
Maximum error2
Current
Voltage
±0.06% of full scale range
±0.05% of full scale range
WBPEEUI240751C0
2-1
AIN-200
Table 2-1. AIN-120 Specifications (continued)
Characteristic/Value1
Property
Temperature effect (0° to 70°C)
±0.005%/°C
Settling time for all 16 channels
(100% step change)
75 msec to 95% of final value
Update rate3
All channels 40 times per second (25 msec)
Rejection (50-60 Hz)
Normal mode
Common mode
–70 dB
–90 dB
Number of A-to-D converters
1
Full scale resolution
16 bit resolution for –10 to +10 VDC range
Fault currents per channel4
(current mode)
Shorted transmitter
Each channel provides current limiting and automatic recovery
Shorted positive to ground
60 mA nominal (IFP/LFP)
100 mA nominal (RFP)
160 mA nominal (IFP/LFP)
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.2 lb)
1.3 kg (2.8 lb)
1.7 kg (3.9 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
4. Remote field powered I/O may need external protection.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
AIN-200
Isolated High Level Voltage, Low Level Voltage,
Thermocouple In
Analog input signals:
•
•
•
2-2
–10 to +10 VDC high level, differential.
–100 to +100 millivolt (DC) low level, differential.
Thermocouple (refer to Table 2-2 for types supported).
WBPEEUI240751C0
AIN-200
The AIN-200 block supports 16 isolated input channels that
operate in voltage mode only. Each input channel is individually software configurable for voltage range or thermocouple
type. Cold junction compensation for thermocouple inputs is
included. The block supports redundant I/O electronics.
Table 2-2. AIN-200 Specifications
Characteristic/Value1
Property
Input range
–10 to +10 VDC
–100 to +100 mVDC
Thermocouple types
B, E, J, K, L, N (14 AWG), N (28 AWG), R, S, T, U
Chinese E, S
Channels
16 isolated
Input impedance
10 MΩ minimum
Full scale range
20 V or 200 mV
Maximum error2
±0.05% of full scale range
Temperature effect (0° to 70°C)
±0.005%/°C
Settling time per channel
(100% step change)
170 msec to 95% of final value
Update rate3
All channels 18 times per second (56 msec)
Rejection (50-60 Hz)
Normal mode
Common mode
–70 dB
–120 dB
Number of A-to-D converters
16 + 1 for cold junction
Full scale resolution
18 bit resolution for –10 to +10 VDC range or –100 to
+100 mVDC range
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.2 lb)
1.2 kg (2.7 lb)
1.6 kg (3.4 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
WBPEEUI240751C0
2-3
AIN-220
AIN-220
Isolated Current, High Level Voltage, Low Level Voltage,
Thermocouple In
Analog input signals:
•
•
•
•
•
•
4 to 20 milliampere.
–10 to +10 VDC high level, differential.
–10 to +10 VDC high level, single-ended.
–100 to +100 millivolt (DC) low level, differential.
–100 to +100 millivolt (DC) low level, single-ended.
Thermocouple (refer to Table 2-3 for types supported).
The AIN-220 block supports 16 isolated input channels that
are individually hardware configurable for either voltage or
current mode and software configurable for voltage range or
thermocouple type. Cold junction compensation for thermocouple inputs is included. The block supports redundant I/O
electronics.
Table 2-3. AIN-220 Specifications
Characteristic/Value1
Property
Input range
4 to 20 mA
–10 to +10 VDC
–100 to +100 mVDC
Thermocouple types
B, E, J, K, L, N (14 AWG), N (28 AWG), R, S, T, U
Chinese E, S
Channels
16 isolated
Input impedance
10 MΩ minimum
Full scale range
20 V or 200 mV
Maximum error2
Current
Voltage
±0.06% of full scale range
±0.05% of full scale range
Temperature effect (0° to 70°C)
±0.005%/°C
Settling time per channel
(100% step change)
170 msec to 95% of final value
Update rate3
All channels 18 times per second (56 msec)
Rejection (50-60 Hz)
Normal mode
Common mode
–70 dB
–120 dB
Number of A-to-D converters
16 + 1 for cold junction
2-4
WBPEEUI240751C0
AIN-300
Table 2-3. AIN-220 Specifications (continued)
Characteristic/Value1
Property
Full scale resolution
18 bit resolution for –10 to +10 VDC range or –100 to
+100 mVDC range
Fault currents per channel4
(current mode)
Shorted transmitter
Each channel provides current limiting and automatic recovery
Shorted positive to ground
60 mA nominal (IFP/LFP)
100 mA nominal (RFP)
160 mA nominal (IFP/LFP)
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.2 lb)
1.2 kg (2.7 lb)
1.6 kg (3.4 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
4. Remote field powered I/O may need external protection.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
AIN-300
Isolated RTD In
The AIN-300 block interfaces three-wire RTD analog input signals. It supports 16 isolated input channels individually software configurable for RTD type (refer to Table 2-4 for types
supported). The block supports redundant I/O electronics.
Table 2-4. AIN-300 Specifications
Characteristic/Value1
Property
RTD types (3-wire)
10 Ω copper
100 Ω platinum: U.S. Lab. Standard
100 Ω platinum: U.S. Industry Standard
100 Ω platinum: European Standard
120 Ω nickel
Chinese 53 Ω copper
Channels
16 isolated
Full scale range
500 Ω
WBPEEUI240751C0
2-5
AOT-150
Table 2-4. AIN-300 Specifications (continued)
Characteristic/Value1
Property
2
Maximum error
±0.10% of full scale range
Temperature effect (0° to 70°C)
±0.005%/°C
Settling time per channel
(100% step change)
170 msec to 95% of final value
Update rate3
All channels 18 times per second (56 msec)
Rejection (50-60 Hz)
Normal mode
Common mode
–70 dB
–120 dB
Number of A-to-D converters
16
Full scale resolution
18 bit
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.2 lb)
1.4 kg (3.1 lb)
1.7 kg (3.7 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
AOT-150
Current Out
The AOT-150 block interfaces high level analog output signals.
It supports 16 nonisolated output channels that operate in
current mode (4 to 20 milliamperes). Special output circuitry
allows this block to support redundant I/O electronics.
Table 2-5. AOT-150 Specifications
Characteristic/Value1
Property
Output range
4 to 20 mA
Channels
16 nonisolated
Full scale range
18 mA
2-6
WBPEEUI240751C0
BLK-100
Table 2-5. AOT-150 Specifications (continued)
Characteristic/Value1
Property
2
Maximum error
±0.15% of full scale range
Temperature effect (0° to 70°C)
±0.005%/°C
Update rate3
All channels 16 times per second (63 msec)
Settling time per channel
(100% step change)
50 µsec (resistive load) to 95% of final value
Number of D-to-A converters
1
D-to-A full scale resolution
12 bit
Number of A-to-D converters
1 (readback)
A-to-D full scale resolution
16 bit (readback)
Load compliance
Resistive
Inductive
0 to 750 Ω
600 mH
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.3 lb)
1.3 kg (2.9 lb)
1.5 kg (3.4 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
BLK-100
Blank Block
The BLK-100 block is used to fill empty block positions on a
column. Any empty positions within a column of blocks must
be filled to maintain airflow. Blank blocks are not required,
however, in empty positions at the bottom of a column. The
block supports redundant blank modules.
WBPEEUI240751C0
2-7
CIO-100
Table 2-6. BLK-100 Specifications
Property
Weight
Module
Nonredundant base
Redundant base
Characteristic/Value
0.9 kg (2.1 lb)
1.1 kg (2.4 lb)
1.4 kg (3.2 lb)
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
CIO-100
Control Loop In/Out
The CIO-100 supports the following control inputs and outputs:
•
Four nonisolated 4 to 20 milliampere or 1 to 5 VDC high
level, analog inputs.
•
Two nonisolated 4 to 20 milliampere or 1 to 5 VDC high
level, analog outputs.
•
Four isolated digital inputs individually selectable for
24 VDC, 48 VDC, 125 VDC, 120 VAC, and 240 VAC.
•
Four isolated 24 VDC digital outputs with a maximum load
current of 250 milliamperes.
Analog input and output channels are individually hardware
configurable for either voltage or current mode. Digital input
channels are individually hardware configurable for input voltage range. The digital outputs are open-collector output channels.
The CIO-100 block provides two station connectors to support
connection of up to eight IISAC01 Analog Control Stations
(Fig. 2-1). Up to four stations can be daisy-chained from each
connector. The first station connected can be configured as a
bypass control station while the remaining three daisy-chained
from the first station operate as indicator stations (i.e., no
bypass capability).
A bypass station can be setup as a current bypass station or
an electric drive/pulse positioner bypass station. A current
bypass station connects directly to the CIO-100 block. An electric drive/pulse positioner bypass station requires a CIO-100
and CIO-110 block pair for connection (Fig. 2-2).
2-8
WBPEEUI240751C0
CIO-100
C IO
SAC
(BY PAS S)
C IO
SAC
(BY PAS S)
SAC
(BY PAS S)
SAC
(BY PAS S)
SAC
(N O BY PA SS )
SAC
(N O BY PA SS )
SAC
(N O BY PA SS )
SAC
(N O BY PA SS )
T 02 0 40 A
Figure 2-1. Analog Control Station Interface
C IO -100
C IO -100
IIS AC 0 1
C U R R E N T BY PA S S
STAT IO N
C IO -110
IIS AC 0 1
EL EC T R IC D R IVE /
PU LSE PO S ITIO N E R
BY PAS S S TAT IO N
T 02 0 43 A
Figure 2-2. Station Connection
WBPEEUI240751C0
2-9
CIO-100
The CIO-100 does not support redundant I/O electronics.
Instead, the analog control station (IISAC01) can be used with
the CIO block to provide automatic or manual backup.
Table 2-7. CIO-100 Specifications
Characteristic/Value1
Property
Channels
AI
AI
Input range
4 to 20 mA
1 to 5 VDC
Input impedance
1 MΩ minimum
Full scale range
Current
Voltage
18 mA
4.5 V
Maximum error2
Current
Voltage
±0.20% of full scale range
±0.05% of full scale range
Temperature effect
(0° to 70°C)
±0.005%/°C
Update rate3
All channels 40 times per second (25 msec)
Settling time for all four channels(100% step change)
700 msec to 95% of final value
Number of A-to-D converters
1
A-to-D full scale resolution
16 bit
Rejection (50-60 Hz)
Normal mode
Common mode
–70 dB
–90 dB
Fault currents per channel
Shorted transmitter
Shorted + to ground
Each channel provides current limiting and automatic recovery
70 mA nominal (IFP/LFP)
186 mA nominal (IFP/LFP)
AO Output range
2 - 10
4 nonisolated analog inputs
2 nonisolated analog outputs
4 isolated digital inputs
4 isolated digital outputs
4 to 20 mA
1 to 5 VDC
Full scale range
Current
Voltage
18 mA
4.5 V
Maximum error2
Current
Voltage
±0.20% of full scale range
±0.10% of full scale range
WBPEEUI240751C0
CIO-100
Table 2-7. CIO-100 Specifications (continued)
Characteristic/Value1
Property
AO Temperature effect
±0.005%/°C
(0° to 70°C)
DI
Update rate3
All channels 40 times per second (25 msec)
Settling time per channel
(100% step change)
500 µsec (resistive load) to 95% of final value
Number of D-to-A converters
2
D-to-A full scale resolution
12 bit
Number of A-to-D converters
1 (readback)
A-to-D full scale resolution
16 bit (readback)
Load compliance
Resistive (current)
Resistive (voltage)
Inductive
0 to 600 Ω
>1 kΩ
600 mH
Fault currents per channel
(voltage and current modes)
50 mA nominal (IFP/LFP)
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
19.5 to 28 VDC
39 to 56 VDC
95 to 144 VDC
85 to 138 VAC
190 to 265 VAC
Sample rate
All channels 1,000 times per second (1 msec)
Update rate
All channels 63 times per second (16 msec) when
debounce4 = 0
Turn ON voltage
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
19.5 VDC minimum
39 VDC minimum
95 VDC minimum
85 VAC minimum
190 VAC minimum
Turn OFF voltage
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
12 VDC
18 VDC
58 VDC
40 VAC
87 VAC
ON current5
4.6 to 7.3 mA typical
OFF leakage current
<1.5 mA
AC frequency
47 to 63 Hz
WBPEEUI240751C0
2 - 11
CIO-110
Table 2-7. CIO-100 Specifications (continued)
DI
Property
Characteristic/Value1
Fault currents per channel:
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
Each channel provides current limiting and automatic recovery
31 mA nominal
8.1 mA nominal
14 mA nominal
15 mA nominal
15 mA nominal
DO Open collector outputs
Output
24 VDC
Off
On
28 VDC 2.5 VDC
Load
250 mA
Update rate
All channels 63 times per second (16 msec)
Switching speed
<0.25 msec
OFF leakage current
<1 mA
Station connectors
2
Station fuse (24 VDC LFP)
6.3 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Station link (RS-485)
40 kbaud
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Base
1.0 kg (2.2 lb)
1.4 kg (3.1 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Maximum error includes effects of nonlinearity, repeatability, hysteresis, noise, and quantization error.
3. This is the rate at which the block reads and updates values. The rate at which the values are actually read and become available to the system depends on the scan cycle of the controller.
4. Software selectable in 1-msec increments up to 255 msec (debounce period).
5. Actual input current depends on input type selection.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
CIO-110
Electric Drive/Pulse Positioner Termination
The CIO-110 block is an auxiliary block used with a CIO-100
block to connect a manual/auto station that operates in electric drive/pulse positioner bypass mode. The CIO-110 block
provides the terminals necessary for proper wiring connection.
The CIO-110 block cable connects to the CIO-100 block.
2 - 12
WBPEEUI240751C0
DIO-400
Table 2-8. CIO-110 Specifications
Property
Characteristic/Value
Station connectors
2
Field power (LFP) voltage1
24.0 VDC nominal
Station fuse (24 VDC LFP)
4.0 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
Weight
1.5 kg (3.2 lb)
NOTE:
1. 24 VDC to power manual/auto stations. Refer to IISAC01 Analog Control Station instruction for station current requirements.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
DIO-400
Universal Digital In, 24 or 48 VDC Digital Out
The DIO-400 block interfaces digital input and output signals
used to read on or off device states and to switch DC voltages.
It supports 16 isolated input channels and eight isolated output channels. Input channels are individually hardware configurable for input voltage range. Open-collector output channels
can switch voltages of 24 or 48 VDC with a maximum load current of 250 milliamperes. The DIO block can cable connect to
an RLY-100 or RLY-200 auxiliary relay block to provide relay
outputs. The block supports redundant I/O electronics.
Table 2-9. DIO-400 Specifications
Characteristic/Value1
Property
Channels
16 isolated digital input
8 isolated digital output
In
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
19.5 to 28 VDC
39 to 56 VDC
95 to 144 VDC
85 to 138 VAC
190 to 265 VAC
AC frequency
47 to 63 Hz
Sample rate
All channels 1,000 times per second (1 msec)
Update rate
All channels 83 times per second (12 msec) when
debounce2 = 0
WBPEEUI240751C0
2 - 13
DIO-400
Table 2-9. DIO-400 Specifications (continued)
Characteristic/Value1
Property
In
Out
Turn ON voltage
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
19.5 VDC minimum
39 VDC minimum
95 VDC minimum
85 VAC minimum
190 VAC minimum
Turn OFF voltage
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
12 VDC
18 VDC
58 VDC
40 VAC
87 VAC
ON current3
4.6 to 7.3 mA typical
OFF leakage current
<1.5 mA
Fault currents per channel
24 VDC
48 VDC
125 VDC
120 VAC
240 VAC
Each channel provides current limiting and automatic recovery
31 mA nominal
8.1 mA nominal
14 mA nominal
15 mA nominal
15 mA nominal
Open collector
Output
Off
On
Load
24 VDC
28 VDC 2.5 VDC
250 mA
48 VDC
56 VDC 2.5 VDC
250 mA
Update rate
All channels 83 times per second (12 msec)
Switching speed
<0.25 msec
OFF leakage current
<1 mA
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.0 kg (2.2 lb)
1.3 kg (2.9 lb)
1.7 kg (3.7 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. Software selectable in 1-msec increments up to 255 msec (debounce period).
3. Actual input current depends on input type selection.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
2 - 14
WBPEEUI240751C0
DOT-100
DOT-100
Onboard Electromechanical Relay Out
The DOT-100 block interfaces digital output signals and is
used in AC/DC switching applications. It supports 16 isolated
output channels (i.e., relay contacts). Each channel can be
wired as either a normally open or normally closed output.
Relays are socketed for easy replacement. Output channels
can switch voltages up to 240 VAC and maximum load currents up to 3.0 amperes. Arc suppressors protect the contacts
when driving inductive loads. The block supports redundant
I/O electronics.
Table 2-10. DOT-100 Specifications
Characteristic/Value1
Property
Outputs
24 VDC, 48 VDC, 125 VDC
120 VAC, 240 VAC
Channels
16 isolated (relay contacts)
Update rate
All channels 83 times per second (12 msec)
Relay Type
Magnacraft miniature epoxy sealed PC board EM relay
Coil nominal voltage
24 VDC
Coil nominal current
23 mA
Contact configuration
Contact material
Contact resistance
SPDT (1 form C)
Silver cadmium oxide
100 mΩ
Cycle rate
Minimum switching
load
Switching speed
Bounce time
30 operations per minute at rated load
10 VDC at 10 mA
No. of operations
150,000
Currents
15 msecs
1.2 msecs (average)
24 VDC
48 VDC
Make
Property
6.0 A
6.0 A
125 VDC 120 VAC
6.0 A
6.0 A
240 VAC
3.0 A
Carry
3.0 A
3.0 A
3.0 A
3.0 A
1.5 A
Resistive break
3.0 A
3.0 A
3.0 A
3.0 A
1.5 A
Inductive break
1.0 A
1.0 A
1.0 A
1.0 A
0.5 A
NOTE: L/R = 7.0 msecs; pf = 40%
BLP fuse (A and B)
WBPEEUI240751C0
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
2 - 15
DOT-120
Table 2-10. DOT-100 Specifications (continued)
Characteristic/Value1
Property
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.3 kg (2.8 lb)
1.4 kg (3.0 lb)
1.6 kg (3.5 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
DOT-120
Onboard Monitored Electromechanical Relay Out (with Fusing)
The DIO-120 block is the same as the DOT-100 block, but provides contact readback circuitry for digital output verification
and output channel fusing. The block supports redundant I/O
electronics.
Table 2-11. DOT-120 Specifications
Characteristic/Value1
Property
Outputs
24 VDC, 48 VDC, 125 VDC
120 VAC, 240 VAC
Channels
16 isolated (relay contacts)
Update rate
All channels 83 times per second (12 msec)
Channel fuse
6.3 A, 250 V, 5 x 20 mm, time-lag, high break capacity
(IEC 127-2/VI)
Relay Type
Magnacraft miniature epoxy sealed PC board EM relay
2 - 16
Coil nominal voltage
24 VDC
Coil nominal current
23 mA
Contact configuration
Contact material
Contact resistance
SPDT (1 form C)
Silver cadmium oxide
100 mΩ
Cycle rate
Minimum switching
load
Switching speed
Bounce time
30 operations per minute at rated load
10 VDC at 10 mA
No. of operations
150,000
15 msecs
1.2 msecs (average)
WBPEEUI240751C0
RLY-100
Table 2-11. DOT-120 Specifications (continued)
Characteristic/Value1
Property
Relay Currents
Property
(cont)
24 VDC
48 VDC
Make
6.0 A
6.0 A
125 VDC 120 VAC
6.0 A
6.0 A
240 VAC
3.0 A
Carry
3.0 A
3.0 A
3.0 A
3.0 A
1.5 A
Resistive break
3.0 A
3.0 A
3.0 A
3.0 A
1.5 A
Inductive break
1.0 A
1.0 A
1.0 A
1.0 A
0.5 A
NOTE: L/R = 7.0 msecs; pf = 40%
OFF leakage current
3 mA
BLP fuse (A and B)
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
IFP/LFP fuse
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
(IEC 127-2/VI)
Weight
Module
Nonredundant base
Redundant base
1.4 kg (3.1 lb)
1.4 kg (3.0 lb)
1.6 kg (3.5 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
RLY-100
Electromechanical Relay Assembly
The RLY-100 block is an auxiliary block that connects eight
electromechanical relay sockets for use with a DIO block. The
RLY block comes populated with eight DPDT electromechanical
relays. Output channels can switch voltages up to 240 VAC
and maximum load currents up to 10.0 amperes. Relays are
plug-in replaceable.
Table 2-12. RLY-100 Specifications (Electromechanical Relays)
Characteristic/Value1
Property
Outputs
24 VDC, 48 VDC, 125 VDC
120 VAC, 240 VAC
Channels
8 (relay contacts)
Relay Type
Systems control output EM relay
(MSD type 283 with blowout magnets)
Coil nominal voltage
WBPEEUI240751C0
24 VDC
2 - 17
RLY-200
Table 2-12. RLY-100 Specifications (Electromechanical Relays) (continued)
Characteristic/Value1
Property
Relay Coil nominal current
75 mA
(cont)
Contact configuration
Contact material
Contact resistance
DPDT (2 form C)
Silver cadmium oxide, gold flashed
50 mΩ
Cycle rate
Minimum switching
load
Switching speed
Bounce time
30 operations per minute at rated load
24 VDC at 10 mA
No. of operations
100,000
Currents
15 msecs
15 msecs (average)
24 VDC
48 VDC
Make
Property
30 A
30 A
125 VDC 120 VAC
30 A
30 A
240 VAC
30 A
Carry
10 A
10 A
10 A
10 A
10 A
Resistive break
10 A
7A
3A
10 A
10 A
Inductive break
10 A
5A
1A
3A
1A
NOTE: L/R = 20 msecs; pf = 80%
Field power (IFP/LFP)
voltage2
24.0 VDC nominal
Weight (with relays)
2.3 kg (5.2 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. 24 VDC from DIO block to power relay coils.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
RLY-200
Solid State Relay Assembly
The RLY-200 block is an auxiliary block that connects eight
solid state relay sockets for use with a DIO block. The RLY
block can be populated with 24 VDC, 125 VDC, 120 VAC, and
240 VAC solid state relays in any combination. Relay outputs
are fused. Relays are plug-in replaceable and are supplied separately (refer to Table 11-12).
2 - 18
WBPEEUI240751C0
RLY-200
Table 2-13. RLY-200 Specifications (Solid State Relays)
Characteristic/Value1
Property
Outputs
24 VDC, 125 VDC
120 VAC, 240 VAC
Channels
8
Relays
Property
Output range (VDC/VAC)
Output current (A)2:
0° to 30°C (32° to 86°F)
15 ° to 25°C (59° to 77°F)
at 70°C (158°F)
Load frequency (Hz)
Relay fusing
24 VDC
125 VDC
120/240 VAC
5 to 60
10 to 200
12 to 280
—
3.0
1.2
—
1.0
0.4
—
3.0
1.2
—
—
47 to 63
Leakage current (mA)2
0.01
0.01
0.75
One cycle surge (A)3
5.0
1.5
85.0
Relay
Fuse
Description
24 VDC
3.15 A, 250 V
5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
125 VDC
1.0 A, 250 V
5 x 20 mm, fast-acting, low break capacity
(IEC 127-2/II)
120 VAC
3.15 A, 250 V
5 x 20 mm, time-lag, high break capacity
(IEC 127-2/V)
240 VAC
Field power (IFP/LFP)
voltage4
24.0 VDC nominal
Weight (with relays)
1.8 kg (4.0 lb)
NOTES:
1. All specification values are maximums unless stated otherwise.
2. ACRMS current.
3. ACPEAK current.
4. 24 VDC from DIO block to power relay coils.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE
WBPEEUI240751C0
2 - 19
WBPEEUI240751C0
Description and Operation
Section 3
Introduction
This section describes the following capabilities and components of the Harmony I/O system:
•
•
•
•
Inputs and outputs.
I/O blocks.
Auxiliary blocks.
I/O system configuration.
Inputs and Outputs
The Harmony I/O system supports a variety of input and output types, both analog and digital. Analog signals, for example,
include pressure and flow transmitter signals, and thermocouple (TC) and RTD temperature inputs. Digital signals are
two-state signals that have discrete on and off voltage levels
such as relay contacts, switches, and solenoids. Inputs and
outputs can be either internally I/O system powered or externally powered.
Analog Input
The following analog inputs are supported (Fig. 3-1):
WBPEEUI240751C0
•
4 to 20 milliampere high level.
•
–10 to +10 VDC high level.
•
–100 to +100 millivolt (DC) low level.
•
Thermocouple:
B, E, J, K, L, N (14 AWG), N (28 AWG), R, S, T, U.
Chinese E, S.
•
RTD:
10 Ω copper.
100 Ω platinum (U.S. Lab. Standard, U.S. Industry Standard, European Standard).
120 Ω nickel.
Chinese 53 Ω copper.
3-1
Inputs and Outputs
T R A N S M ITT E R
+
4-2 0 m A
–
IN T E R N A L FIE L D
POW ERED
T R A N S M IT TE R
+24 V D C
+
4 -2 0 m A
–
E X T ER N AL F IE LD
POW ERED
COMMON
+
± 10 V O R
± 10 0 m V
VSOURCE
–
R LE A D 1
S IN G LE -EN D E D
OR
D IFF E R E N TIA L
VO LTAG E
+
THERMO COUPLE
–
R LE A D 2
–
+
C
3 -W IR E RT D
T0 0554C
Figure 3-1. Analog Input
Data Conversion
An I/O block that supports analog inputs reads currents or
voltages at its input channels, scales and converts the inputs
to real values in engineering units, then reports the input values to the Harmony controller. The block provides channel status information along with each reported input.
High and low level inputs are converted to the proper engineering units based on input type and engineering unit high and
low value specifications. Thermocouple and RTD inputs are
converted to the proper engineering units (degrees C or degrees
F) using predefined conversion tables for each type of thermocouple and RTD supported.
3-2
WBPEEUI240751C0
Inputs and Outputs
Calibrations
No field calibrations for analog inputs are required. The electronics automatically perform the following adjustments to the
raw analog inputs depending on input type:
•
Drift correction using onboard zero and span reference
voltages.
•
Lead wire resistance adjustment for low level, thermocouple, and RTD inputs.
•
Cold junction temperature compensation for thermocouple
inputs using either an internal or external cold junction
reference.
Analog Output
The following analog outputs are supported (Fig. 3-2):
•
•
4 to 20 milliampere high level.
1 to 5 VDC high level.
+
1 -5 V O R
4 -2 0 m A
LOA D
IN T ER N AL F IE LD
PO W ER E D
–
T 00 55 5 A
Figure 3-2. Analog Output
Data Conversion
An I/O block that supports analog outputs receives output
demand values in engineering units from the Harmony controller, scales the demand values to percentages of output, and
converts them to analog voltages or currents at the output
channels. User selectable default states of zero percent, 100
percent, or hold output are provided.
Calibrations
The electronics automatically adjust analog outputs to compensate for supply voltage variations. Field calibration of analog outputs is not required.
WBPEEUI240751C0
3-3
Inputs and Outputs
Readback
Each analog output channel is monitored on the block. This
readback function serves two purposes:
•
Provides high accuracy by using a software compensation
algorithm in combination with the analog output readback
value.
•
The integrity of the hardware and field wiring is constantly
monitored by way of checking the readback value.
The block also reports the readback values to the controller. It
automatically scales the values to their proper engineering
units before reporting them. The readback values are converted to the proper engineering units based on engineering
unit high and low value specifications.
Digital Input
Digital input channels can be used to read the states of
switches, relay contacts, and solenoids (Fig. 3-3). The following
digital inputs are supported:
•
•
24, 48, and 125 VDC.
120 and 240 VAC.
+
–
IN T ER N AL F IE LD
PO W ER E D
VSOURCE
+
–
EX T ER N A L F IEL D
PO W ER E D
(SW IT C H H OT )
COMMON
VSOURCE
+
–
COMMON
EX T ER N A L F IEL D
PO W ER E D
(SW IT C H C O M M O N )
T 00 55 6 A
Figure 3-3. Digital Input
3-4
WBPEEUI240751C0
Inputs and Outputs
An I/O block that supports digital inputs reads voltage levels
at its input channels, converts the voltages to boolean logic
states (0 or 1), then reports the input states to the Harmony
controller. The block provides channel status information
along with each reported input.
Digital Output
Digital output channels can be used to drive annunciators
such as buzzers and lamps and to drive two-state final control
elements such as actuators, relays, and solenoids (Fig. 3-4).
The following digital output voltages are supported:
•
•
24, 48, and 125 VDC.
120 and 240 VAC.
+
LOAD
IN T ER N AL F IE LD
PO W ER E D
–
O PE N
C O LLE C TO R
O U T PU T S
VSOURCE
+
EX T ER N A L F IE LD
POW ER E D
–
LOAD
CO MM O N
NC
LOAD
CO MM O N
EL EC T R O M E C H AN IC AL
R E LAY O U T PU T
V SOURCE
C
EX T ER N A L F IE LD
POW ER E D
NO
LOAD
CO MM O N
T 00 5 57 A
Figure 3-4. Digital Output
The system can support current loads up to 10 amperes with
auxiliary relay assemblies used with DIO blocks.
WBPEEUI240751C0
3-5
I/O Block
An I/O block that supports digital outputs receives boolean
logic states (0 or 1) from the Harmony controller and converts
them to digital voltages to switch the output channels.
The DOT-120 output channels are fused and monitored
through readback circuitry on the block. The block constantly
monitors readback from the output contacts to verify and
insure hardware and field wiring integrity. The block also
reports the readback values to the controller.
I/O Block
An I/O block interfaces and processes field device input and
output signals. An I/O module mounted on a termination base
forms an I/O block (Fig. 3-5). The I/O module contains the
electronics. It handles the Hnet communication and stores
and executes a portion of the process configuration. In general,
a base is a passive device that connects and distributes signals
between the I/O module and field wiring terminals and
between redundant I/O modules.
There are several different I/O block types available (refer to
Table 1-1). The three basic types being analog (A), digital (D),
and control (C). All share the same housing layout and connection, configuration, and mounting methods. Refer to Table 1-2
for a summary of I/O block capabilities.
The front panel of an I/O block communicates a considerable
amount of information including block type, operating mode,
and operating status. Front panel features include:
•
Text-based front panel mode and status indicators.
•
Front accessed power fuses with status indicators.
•
Front accessed stop/reset button.
•
Front mounted device ID and user label area protected by a
clear plastic cover.
Refer to I/O Block in Section 7 for further explanation of front
panel items.
3-6
WBPEEUI240751C0
I/O Block
T E R M IN AT IO N B A S E
I/O M O D U L E
I/O B L O C K
T 006 05 B
Figure 3-5. I/O Block
I/O Module
The I/O module (Fig. 3-5) contains the I/O processing circuitry. The circuitry consists of multiple printed circuit boards
that perform signal conditioning and processing dependent on
I/O type. An onboard processor performs engineering units
conversion, online diagnostics, and Hnet communications
interface. Power conversion functions are also provided. Front
panel LEDs provide power and digital I/O status indications.
The block packaging provides access to configuration jumpers
on the circuit boards as required by removing the side of the
I/O module (Fig. 3-6). A retractable handle facilitates the
installation and removal of the I/O module.
WARNING
WBPEEUI240751C0
An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous.
3-7
I/O Block
I/O BO AR D
R E TR AC TA BLE
H A N D LE
AC C ES S
C OV ER
T 01 60 3 A
Figure 3-6. Configuration Jumper Access
I/O modules can be removed and installed while system power
is applied. With the I/O module removed, current mode analog
input channels are maintained if configured to use local field
power (refer to Block Power in this section). Voltage mode analog input channels, however, and analog output, digital input,
and digital output channels are in an open circuit state in a
nonredundant configuration. I/O channels will continue to
operate normally when one of the modules in a redundant configuration is removed.
Figure 3-7 is a block diagram of the I/O circuitry. The block
diagram generally reflects the operation of all I/O blocks. The
I/O section varies from block to block.
Block Power
Each block provides onboard regulation for any operating voltages it requires. The I/O module accepts redundant 24 VDC
inputs which it filters, auctioneers, and regulates to produce
3-8
WBPEEUI240751C0
I/O Block
HNET
INT E R FAC E
M E M O RY
CPU
DATA BU S
SP EC IA L
O PE R AT ION S
SW IT CH (S W 2)
I/O S EC T IO N
A
M AC H INE
FAU LT T IM E R
A
+5 VDC
I/O
C H A N N EL N
I/O C HA N NE L BU S
+15 VDC
I/O
CH A NN E L 1
BL O C K
PO W E R
B
+24 V D C BL P
-1 5 V D C
A
I/O CH A N N E L
IN T ER FA C E
HN E T
B
SE RIA L LIN K
INT E R FAC E
B
RE DU N DA N C Y
LINK
OR
STAT IO N LIN K
LE D
D R IV ER S
S TATU S
LE D S
IF P
LF P
F IEL D PO W ER
SE LE C T
T 00 5 59 A
Figure 3-7. Block Diagram - I/O Module
its operating voltages. Each 24 VDC input is fused and monitored. Figure 3-8 details the block power section.
Logic Power
Redundant 24 VDC block logic power (BLP) is bussed through
the mounting column to the I/O module. The redundant BLP
power is auctioneered through summing diodes into a single
24 VDC. Onboard DC-to-DC converters develop +5 VDC,
+15 VDC, and –15 VDC operating voltages from the integrated
24 VDC.
The I/O module tests itself for a +5 VDC out-of-range condition. When this voltage is outside its normal operating range, a
hardware fault (i.e., power on reset) will occur and the block
operation will halt.
Power Monitor
WBPEEUI240751C0
The power monitor circuits test and report the status of the
redundant 24 VDC BLP inputs. The inputs are only tested for
3-9
I/O Block
SOA
A LA R M
POW ER
S TAT U S
P OW E R
M O N ITO R
F IE LD P O W E R
S E LE C T
IFP
IF P /LFP
LFP
B LP A
+ 24 V D C
P OW E R
AU C TIO N E E R
+24 V D C
B LP B
FR O M
M O U N TIN G
C O LU M N
P OW E R
FILTE R
+24 V D C
5 VDC
POW ER
R E G U LATO R
15 V D C
POW ER
R E G U LATO R
F IE LD
POW ER
+5 V D C
+15 V D C
B LO C K
POW ER
– 15 V D C
T 0056 0B
Figure 3-8. Block Power
their presence or absence. The circuits do not test the inputs
for voltage range.
The power monitor circuits also test and report status for the
internal field power (IFP) or external local field power (LFP)
input depending on the field power select jumper setting.
Again, the circuits only test for the presence or absence of the
field power input.
The I/O block will generate an SOA alarm if the fuse for any of
these inputs is bad or if the input voltage is absent.
Refer to the Block Power and Mounting Hardware instruction
for a complete explanation of BLP, IFP, and LFP power, and the
SOA alarm signal for power status monitoring.
Central Processing Unit
The central processing unit (CPU) contains a microprocessor
and its supporting circuitry. The CPU interprets and executes
instructions to control the I/O block functions. Its responsibilities include executing the I/O block portion of the control configuration and controlling:
•
•
•
•
3 - 10
Hnet communication.
Analog and digital I/O processing.
Redundancy or station link communication.
Block diagnostics.
WBPEEUI240751C0
I/O Block
•
Status reporting.
Memory
The I/O block utilizes static-RAM memory and flash-ROM
memory. The static-RAM memory provides temporary storage
for the CPU to perform calculations and data manipulation.
The Hnet interface also uses a portion of the RAM memory to
store received messages and messages to be transmitted. The
flash-ROM memory stores the I/O block operating firmware
and the block’s portion of the control configuration. This type
of memory allows firmware upgrades to be downloaded from
the controller. The electronic ID of the block is stored in ROM
memory.
Hnet Interface
Hnet is the redundant, serial communication protocol over
which the Harmony controller communicates with I/O blocks.
Figure 3-9 details the Hnet interface section of the I/O module
circuitry. The Hnet interface encodes and transmits Hnet messages, receives and decodes Hnet messages, and monitors
Hnet status.
DATA A N D
CONTROL
T R A N S C E IV E R
A
R E L AY
A
HN ET A
T R A N S C E IV E R
B
R E L AY
B
HN ET B
HNET
C O N T RO L
T00 561B
Figure 3-9. Hnet Interface
The Hnet control portion of the interface is a custom, application-specific integrated circuit (ASIC). This circuit manages the
serial communication protocol between the I/O block and Harmony controller. It also performs data integrity checks. The
interface checks for the following message errors: Data transmission error using cyclic redundancy check (CRC) method,
maximum message reply time expired, and reply message
overrun.
WBPEEUI240751C0
3 - 11
I/O Block
The Hnet control section also provides a means for the CPU to
interrogate the Hnet to determine its condition. If a bus failure
or stall is detected on either of the Hnet channels, the channel
will be shut down locally until the problem is corrected. The
capability to detect a bus failure allows the I/O module to set
the appropriate output channel default states if communication with the Harmony controller is completely lost.
The signal relays (A and B) allow the I/O module to isolate itself
from the Hnet in the event of a component failure or to perform
diagnostics. This important feature assures that a fault in one
block cannot affect the communications of other blocks. The
Hnet interface circuitry includes the logic that controls the
relays.
Machine Fault Timer
The machine fault timer (MFT) is a security feature built into
the I/O module. The timer is a one-shot timer that must be
periodically reset by the CPU to prevent it from timing out. If an
error condition exists that causes the I/O module to fail or
operate incorrectly, the timer will not be reset and will cause a
time-out condition. A time-out condition triggers a reset signal
to shut down the I/O module.
The I/O module performs a series of online diagnostics to verify circuit integrity. A detected hardware failure may cause a
time-out condition. If the cause of the problem is not a hardware failure such as a configuration error, the I/O module and
timer can be reset by the manual reset switch accessed
through the block front panel. A hardware failure will most
likely require an I/O module replacement.
Serial Link Interface
Besides the Hnet interface, an I/O module supports an additional external serial link used for either redundancy or manual/auto station communication. The CIO-100 block uses the
serial channel for station link. All other blocks use the serial
channel for redundancy link.
Figure 3-10 details the serial link interface. The I/O module
uses a dual universal asynchronous receiver/transmitter
(DUART) circuit to direct data transfer over the serial links.
The DUART receives parallel data from the CPU and converts it
to serial data that it sends to one of the serial link interfaces. It
3 - 12
WBPEEUI240751C0
I/O Block
DATA AN D
C O N T RO L
D UAR T
R E D U N DAN C Y
LIN K
IN T ER FAC E
A
B
R E D U N DAN C Y
LIN K
OR
DATA AN D
C O N T RO L
D UAR T
STAT IO N LIN K
IN T ER FAC E
STAT IO N LIN K
(C I0-100 O N LY)
T 00 5 62 A
Figure 3-10. Serial Link Interface
also performs serial to parallel data conversion on data
received serially from the interface circuits.
Redundancy Link
The redundancy link allows redundant I/O modules to communicate. The backplane on the base makes the redundancy
link hardware connection between redundant I/O modules.
The link operates at a one-megabaud rate and is itself redundant. Redundant I/O modules exchange the following information:
•
•
•
•
Station Link
I/O channel configuration.
Status and availability of all I/O channels.
Electronic ID.
Device label.
The station link interfaces the RS-485 serial link to communicate with an analog control station (IISAC01). This interface
acts as a communications gateway between the Harmony controller and the station. The station link operates at a 40-kilobaud rate and supports up to eight analog control stations.
The base makes the station link hardware connection between
the I/O module and stations.
NOTE: Only the CIO-100 block supports the station link.
WBPEEUI240751C0
3 - 13
I/O Block
LED Drivers and Status LEDs
The LED drivers control the front panel status indicators as
directed by the CPU. The indicators show I/O module operating status, error codes, digital I/O states, and power status.
I/O Channel Interface
The I/O channel interface allows the CPU to select an I/O
channel. For an output channel, the CPU can write control
information to the channel and can acquire readback data and
status. For an input channel, the CPU can read input data and
status from the channel.
NOTE: The block diagram (Fig. 3-7) shows the interface in schematic fashion.
The actual implementation may vary depending on block type; however, the
interface function still applies.
I/O Section
The I/O section varies based on the I/O block capabilities.
Each I/O block is populated with varying numbers and types
of I/O channels. The I/O channel types include:
AI - analog input.
AO - analog output.
DI - digital input.
DO - digital output.
In general, the I/O section circuitry provides:
3 - 14
•
Range and mode selection for analog I/O.
•
Voltage threshold selection for universal digital inputs.
•
Signal buffering.
•
Signal conditioning.
•
Signal isolation.
•
Noise rejection.
•
Analog-to-digital and digital-to-analog conversion; one A/D
per channel on AIN-200, AIN-220, and AIN-300.
•
Readback of outputs.
•
Open and short detection.
WBPEEUI240751C0
I/O Block
•
Circuit protection (surges, shorts, overvoltages, etc.).
Special Operations Switch (SW2)
The special operations switch (SW2) is used to enable normal
operation, to initialize the I/O module, and to select offline
diagnostics. Refer to Table 7-4 for normal operation and initialize switch settings. Refer to Diagnostics in Section 8 for a
description of the diagnostics.
Base
There are two types of I/O block bases (Fig. 3-5): screw terminal and clamp terminal. There is a nonredundant and redundant version of each base. In general, a block supports four
different base versions. The base has several purposes:
•
•
•
•
•
Field wiring termination.
I/O channel signal routing.
I/O module mounting.
Hardware keying of base to I/O module.
Shield (i.e., chassis ground) connection.
NOTE: The terminal strip can be removed from the clamp termination base for
cable connection applications. Refer to Cable Connection in this section.
The base attaches directly to a block mounting column. Alignment posts help locate the base on the mounting column. The
assembly is physically mounted using two captive screws (four
screws for a redundant base). Tabs on the base insert into slots
in the mounting column to help further secure the base in
place. I/O signals connect to the base and are routed internally
to I/O module connectors. Field connections remain undisturbed if the module is removed or replaced.
A nonredundant base provides mounting and connection for a
single I/O module. A redundant base is available to provide
mounting and connection for two I/O modules that operate
redundantly. The redundant base is wider than the nonredundant base by the width of an I/O module and requires a redundant block mounting column.
Screw and Clamp Termination Bases
A termination base supports either screw terminals (S type) or
clamp terminals (C type) for direct field wire connection. The
WBPEEUI240751C0
3 - 15
I/O Block
screw terminals accommodate wire lugs and the clamp terminals accommodate stripped wires. Figure 3-11 shows the
screw terminal base and Figure 3-12 shows the clamp terminal base.
NOTE: A DIO block uses an R type base to connect its digital outputs to an
RLY block. When an RLY block is connected, the DIO block outputs drive either
electromechanical or solid state relays. The R type base has screw or clamp
terminals for digital input wiring, and a connector to cable the digital outputs to
the RLY block.
T 01 46 1 A
Figure 3-11. Screw Terminal Base (S Type)
The terminals accept wiring with a cross-sectional area of up to
3.3 square millimeters stranded (12 AWG stranded). The number of terminals depends on the number and types of I/O
channels.
To simplify the installation process, the terminals are clearly
marked to identify positive (+) and negative (–) polarity, and
three-wire RTD, normally open relay contact, and normally
3 - 16
WBPEEUI240751C0
I/O Block
T 01 4 62 A
Figure 3-12. Clamp Terminal Base (C Type)
closed relay contact wiring connections (Fig. 3-13). Additionally, input and output channel terminals are color coded for
easier recognition. The markings and color coding allow wiring
of input and output channels without requiring any additional
documentation:
•
Black letter on blue background - analog input channel.
•
Blue letter on black background - analog output channel.
•
Black letter on orange background - digital input channel.
•
Orange letter on black background - digital output
channel.
The base has a front panel door to conceal the terminal strips
and connectors, and to prevent accidental contact. A label is
affixed to the inside of the door for identifying field wires.
WBPEEUI240751C0
3 - 17
I/O Block
C H A N N EL
AS SIG N M EN T S
I/O TE R M IN A LS
01 02
03 04
05 06
C H A SS IS
G RO U N D
07 08
09 10
11 12
13 14
15 16
L FP
LO C AL
F IEL D PO W ER
T 00 9 63 A
Figure 3-13. Terminal Markings (Door Removed)
Cable Connection
The clamp terminals can be removed from the C type base to
provide cable connection of field wiring. A cable with a plug-in
cable connector is used instead. This supports applications
that require a cable connection to external devices or terminations that are part of a remote termination system (RTS).
Figure 3-14 shows the C type base with the clamp terminals
removed.
3 - 18
WBPEEUI240751C0
I/O Block
T 01 4 63 A
Figure 3-14. C Type Base for Cable Connection
One or more HRM-RTS cables, which are terminated at both
ends with connectors, are used to connect the I/O block to the
remote termination system.
Shield Terminations (Chassis Ground)
The back panel of the base is a ground plate that connects to
chassis ground (Fig. 3-13). The ground plate has screw terminals to connect shield wires requiring termination to chassis
ground. Attaching the assembly to the mounting column
makes the connection between the ground plate and chassis
ground.
I/O Module Mounting
The I/O module attaches to the base. This attachment connects the I/O channels, Hnet communications, and power to
the module. For redundant I/O modules, the attachment also
WBPEEUI240751C0
3 - 19
I/O Block
connects the redundancy link. For the CIO block, it also connects the station link to the module.
I/O modules can be inserted or removed without having to
power down the system. A captive mounting screw on the I/O
module secures it in place.
Hardware Keying
Each type of I/O module requires its own type of termination
base. Hardware keying using posts on the base and holes in
the back of the I/O module prevents an accidental mismatch of
I/O module and base. The block type and model number
shown on the front panel of an I/O module and base are the
same to easily identify that they are compatible.
I/O Redundancy
Redundancy allows backup electronics to read inputs and to
drive outputs in the event of a primary failure. As a background diagnostic task, the backup is continuously monitoring
its ability to read field inputs and to drive field outputs.
I/O redundancy is accomplished by using two I/O modules of
the same type, a wider base to mount and connect the two
modules, and a wider mounting column to attach the
redundant base (Fig. 3-15). In this arrangement, the field wiring connects once at the base and is internally routed to both
modules. The redundancy feature allows a failed I/O module to
be replaced without affecting the operating module in the
redundant pair. Refer to Section 4 for further explanation of
redundancy.
Failure Mode (Outputs)
To insure known output conditions in the event of an I/O block
failure, output channels have two failure modes: default state
output and failure state output. The failure mode an output
channel enters depends on the type of failure. If Hnet communication or communication with the Harmony controller is lost,
block outputs enter their default states. This assumes, however, the I/O block is 100 percent operational. If critical I/O
block circuitry fails, block outputs will enter their failure
states.
3 - 20
WBPEEUI240751C0
I/O Block
TE R M IN ATIO N BA S E FO R
R E DU NDAN T I/O M O D ULE S
TW O ID E N TIC AL
I/O M O D U LE S
R E D U N DAN T
I/O BLO CK
T 00816C
Figure 3-15. Redundant I/O Block
WBPEEUI240751C0
Default States
Default states for outputs are selected during function code
configuration. The outputs will automatically return to normal
operation after communication has been restored. For an analog output, the default state is either zero percent output, 100
percent output, or hold the current output. For a digital output, the default state is either zero state output, one state output, or hold the current output. Refer to Function Codes in
Section 6 for information about default state specifications.
Failure States
Failure states for outputs are by default their unpowered or off
states. A nonredundant output channel will enter its failure
state when:
•
All power to the I/O module is lost.
•
Machine fault timer error occurs (refer to Machine Fault
Timer in this section).
3 - 21
I/O Block
•
Stop or reset occurs.
In some cases, a reset may be enough to return the outputs to
normal operation. If a reset does not, then an I/O module
replacement will most likely be required. Table 3-1 summarizes the I/O block output channel conditions based on type of
event.
Table 3-1. I/O Block Failure Mode Output Conditions
Event
Output Condition
Loss of all power
Failure state
MFT time-out
Failure state
Redundant I/O module failure
Primary
Backup assumes output control
Backup
No effect; outputs under primary control
Loss of communication:
Hnet (primary)
Backup assumes output control
Hnet (backup)
No effect; outputs under primary control
Hnet (both redundant I/O modules)
Default state
Default state
Harmony controller
Reset
Failure state
Channel error
Error dependent
Short Circuit Protection
Most I/O blocks incorporate some type of current limiting
where appropriate to protect against short circuits in the field
wiring. This current limiting often makes I/O fusing unnecessary. The current limiting prevents excessive current levels at
faulted terminals which could cause circuit damage. Specifically, I/O block channels are protected against shorts across
the transmitter or load, across positive and negative terminals,
from the positive terminal to ground, and from the negative
3 - 22
WBPEEUI240751C0
I/O Block
terminal to ground. A channel will recover to full function after
correcting the fault condition.
NOTES:
1. In the case of external remote field powered I/O, some type of external
protection such as fusing should be incorporated where appropriate. Refer to
the Block Power and Mounting Hardware instruction for an explanation of
the various field power options available.
2. The DOT-100 block has no fusing or current limiting. The DOT-120 block
provides fusing for the contact outputs. The fusing is present for only one set of
contacts per output.
3.
The RLY-200 block has fusing for the solid state outputs.
Table 3-2 lists the fault currents present as a result of a short
condition. For blocks that are not listed, the channels are in a
no current condition or operate within their normal operating
range. In these cases, the I/O block sees a zero volt input or a
zero ohm load which are both valid. Refer to Figures 3-1, 3-2,
3-3, and 3-4 for examples of I/O connections.
Table 3-2. Channel Fault Currents (Nominal) Under Short Conditions
Short Condition
Block
I/O
Mode
Power
AIN-120
AI
Current
IFP/LFP
60 mA
160 mA
Note 1
RFP
100 mA2
Note 1
—
IFP/LFP
60 mA
160 mA
Note 1
RFP
100 mA2
Note 1
—
70 mA
186 mA
Note 1
AIN-220
CIO-100
CIO-100,
DIO-4003
AI
Current
+/–
+/Gnd
AI
Current
IFP/LFP
AO
Current
IFP/LFP
Voltage
IFP/LFP
24 VDC
IFP/LFP
31 mA
48 VDC
LFP
8.1 mA
125 VDC LFP
14 mA
120 VAC
LFP
15 mA
240 VAC
LFP
15 mA
DI
–/Gnd
50 mA
50 mA
—
NOTES:
1. The current is limited by the transmitter. Some type of external protection may be necessary.
2. Transmitter shorted.
3. Open collector outputs are not current limited.
WBPEEUI240751C0
3 - 23
Auxiliary Block
Auxiliary Block
An auxiliary block extends I/O block capabilities (Fig. 3-16).
There are different types of auxiliary blocks available (refer to
Table 1-1).
T 00 96 0 A
Figure 3-16. Auxiliary Block
An auxiliary block shares a similar housing layout with I/O
blocks. Its mounting method is slightly different, however. The
block occupies one block position on the mounting column,
but does not connect to either power or Hnet. A front panel
door conceals the terminal strips and various circuitry to prevent accidental contact.
I/O System Configuration
Harmony I/O system configuration requirements are minimal:
•
3 - 24
Auxiliary blocks - either require no configuration or
require minimal configuration (i.e., jumper setting) depending on type.
WBPEEUI240751C0
I/O System Configuration
•
I/O blocks - most require some minimal hardware configuration; all require function code configuration (Fig. 3-17).
•
Repeater mounting units - Hnet repeaters in repeater
mounting units require no configuration.
FU N C T IO N C O D ES
IO C /A IN
S9
S18
S25
SHPG
SIM
SPARE
AI
(222)
IO D /D E F
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
S18
S19
S20
S21
S22
S23
S24
S25
S26
S29
S31
S33
(221)
CH01
CH02
CH03
CH04
CH05
CH06
CH07
CH08
CH09
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH17
CH18
CH19
CH20
CH21
CH22
CH23
CH24
PERMIT
CJR
SPARE
SPARE
PRIMARY
STATUS
BACKU P
STATUS
OVR /SIM
SPARE
RES ERVE D
HARMONY
C O N T RO LLE R
JU M PE R S ETT IN G S
HNET
FIEL D PO W ER S ELE C T
AIN -2 20
-
+
4 - 20m A
IF P
J1
J2
+ 24 V
+
CH 1
–
I/O C H A N N EL C ON F IG U R AT IO N
4-20m A
IF P/LFP
1-J1
1-J2
T 00 9 96 A
Figure 3-17. Example I/O Connection, Setup, and Configuration
I/O Block Hardware
Generally, I/O block hardware configuration consists of setting
the special operations switch (SW2), field power select jumpers, and various I/O channel jumpers. Some blocks do not
require any I/O channel configuration.
I/O Block Function Codes
I/O block function code configuration includes defining a
device label and adding function codes to the control
WBPEEUI240751C0
3 - 25
I/O System Configuration
configuration in the Harmony controller. A device label is normally defined during installation. I/O block function codes are
normally added to the control configuration during its creation; however, they can be added at any time to existing configurations. Refer to Section 6 for detailed information about
using configuration tools.
3 - 26
WBPEEUI240751C0
Redundancy
Section 4
Introduction
This section provides a general description of block redundancy, and details redundancy for specific block types. Redundancy allows backup electronics to read inputs and to drive
outputs in the event of a primary failure. The backup is continuously monitoring its ability to read field inputs and to drive
field outputs as a background diagnostic task.
NOTE: A CIO block cannot be redundant. However, the analog control station
(IISAC01) can be used with the CIO block to provide automatic or manual
backup. Refer to the IISAC01 Analog Control Station instruction for further
explanation.
Description
Redundancy in I/O blocks protects against most common
power, communications, and block hardware and software failures and some I/O channel failures. A failover from primary
I/O module to backup I/O module is not instantaneous. Typically, failover should occur in less than 100 milliseconds.
Online diagnostics and readback checks are used to determine
the operating status of an I/O module. Both the primary and
the backup module perform the same diagnostics and readback tests. In all cases, the Harmony controller handles the
data management.
The redundant I/O modules utilize the serial redundancy link
to verify redundant hardware connection, monitor and verify
operation, resolve primary/backup modes, and to exchange
status information. Connectors and signal lines on the backplane of the base establish the redundancy link. The redundancy link is also redundant.
For all redundant capable I/O blocks, both I/O modules are
active and both report data to and receive data from the controller. Both modules contain the same device label and function code configuration. The input and output channels are
internally routed on the base to both I/O modules. If the
WBPEEUI240751C0
4-1
Description
primary and backup I/O modules report different values for
the same channel to the controller, the controller will mark the
value as suspect. Refer to Suspect Condition in Section 6 for
further explanation.
Redundancy Arbitration
Primary and backup responsibilities are determined by an
arbitration process performed during startup. The redundancy
link between the I/O modules allows them to communicate
directly with each other. Basically, the first module up and
running assumes the primary role. A feature built into the I/O
block, however, ensures that the left module always assumes
the primary role and the right module assumes the backup role
as long as both I/O modules are mounted on the base when
the block starts up. The front panel status LEDs indicate
which I/O module is the primary and which is the backup.
Refer to Table 7-2 for the LED indications.
The arbitration process also insures that a labeled I/O module
becomes the primary when there is an unlabeled I/O module
in the redundant pair. After the labeled module starts up and
assumes the primary role, it will then automatically configure
the unlabeled backup module with its label so both share identical device labels.
Failover
The backup I/O module automatically assumes the primary
module’s responsibilities if the primary fails. Catastrophic failures that will cause a failover from primary to backup include:
•
•
Primary halts completely.
Primary loses block logic power (both BLP A and BLP B).
If a catastrophic failure of the primary module occurs, the
backup module will become the primary even if it has some
type of non catastrophic failure. Non catastrophic failures
include:
•
•
•
Primary’s Hnet communications fail (both channels).
One of the primary’s I/O channels fail.
Primary loses IFP or LFP field power.
If a non catastropic failure of the primary module occurs, the
failover will only occur if the backup I/O module is 100 percent
4-2
WBPEEUI240751C0
Analog Input
operational. If the backup I/O module has detected a problem
such as an Hnet communication failure, I/O channel failure,
and IFP or LFP field power failure, then no failover will occur.
When a failover occurs due to a non catastrophic failure of the
primary module, the primary will halt with LEDs one and two
on. When a failover occurs due to a catastrophic failure (i.e.,
FAULT lit), an error code will display on LEDs one through
eight of the primary module. Refer to Table 8-3 for a description of the LED status codes.
Analog Input
For analog input capable blocks, channels are directly wired in
parallel to both I/O modules (Figs. 4-1 through 4-7). A short
across an input of one I/O module due to an I/O block fault
will not allow either I/O module to read the input. An open in
an input channel circuit of the base will not allow either I/O
module to read the input.
AIN-120
Failures detectable by an AIN-120 module that cause a failover
to the backup module include:
•
•
•
•
•
AIN-200/220
Failures detectable by an AIN-200/220 module that cause a
failover to the backup module include:
•
•
•
•
•
•
AIN-300
Amplifier failure.
A-to-D converter failure (one per channel).
Opto-coupler failure.
Bad voltage reference.
Bad TC cold junction reference (A-to-D and RTD).
Channel failure or out of range.
The AIN-300 block has special circuitry to disconnect the RTD
current source on the backup I/O module during normal operation. This prevents two current sources from being connected
to the RTD at one time. Failures detectable by an AIN-300
module that cause a failover to the backup module include:
•
WBPEEUI240751C0
Multiplexer failure.
Amplifier failure.
A-to-D converter failure.
Bad voltage reference.
Channel failure or out of range.
Amplifier failure.
4-3
Analog Output
REDUNDANT
A IN -120 B A S E
HNET
A
B
A IN -120 M O D U LE
+24 V
+
V IN
+
+
–
–
CH 1
–
+
•
•
•
MUX
IFC
AM P
A /D
C H 16
–
CPU
AN D
HNET
IN TE R FAC E
REF1
REF2
A
B
R E D U N DA N C Y LIN K
B
A
R E D U N DA N C Y LIN K
A IN -120 M O D U LE
+
CH 1
–
+
•
•
•
MUX
AM P
C H 16
–
A /D
CPU
AN D
HNET
IN TE R FAC E
REF1
REF2
T 0323 1A
Figure 4-1. AIN-120 Block - Voltage Mode (Differential or Single -Ended)
•
•
•
•
A-to-D converter failure (one per channel).
Opto-coupler failure.
Bad voltage reference.
Channel failure or out of range.
Analog Output
The AOT-150 block has special circuitry that switches the
channels between the primary I/O module and the backup I/O
4-4
WBPEEUI240751C0
Analog Output
R E D U N DA N T
A IN -1 2 0 B A S E
4 -2 0 m A
LOO P
A IN -1 2 0 M O D U L E
H NET
A
B
IFP /LF P
+24 V
15 0 τ
+
+
2 50 τ
–
CH 1
–
+
•
•
•
MUX
IF C /L FC
AM P
A /D
C H 16
–
CPU
AND
HNET
IN T E R FAC E
REF1
REF2
A
B
R E D U N DA N C Y LIN K
A IN -1 2 0 M O D U L E
R E D U N DA N C Y LIN K
B
A
+
CH 1
–
+
•
•
•
MUX
C H 16
–
AM P
A /D
CPU
AND
HNET
IN T E R FAC E
REF1
REF2
T 0323 2A
Figure 4-2. AIN-120 Block - Current Mode (IFP or LFP Powered)
module so that only one I/O module is driving the outputs at a
time (Fig. 4-8). A short across an output of one I/O module
due to an I/O block fault will not affect the output of the other
I/O module. An open in the output channel circuit of the base
will not allow either I/O module to control the output.
NOTE: Normal failover time for the AOT-150 block is less than 100 milliseconds. Under rare conditions, the output channels could be affected by a failover
for up to 200 milliseconds.
WBPEEUI240751C0
4-5
Analog Output
REDUNDANT
A IN -120 B A S E
+24 V
+
4-20 m A
LO O P
A IN -120 M O D U LE
HN ET
A
B
+24 V
+
250τ
–
CH 1
–
+
•
•
•
MUX
AM P
A /D
C H 16
–
CPU
AND
HNET
IN T E R FAC E
REF1
REF2
A
B
R E D U N DA N C Y LIN K
A IN -120 M O D U LE
R E D U N DA N C Y LIN K
B
A
+
CH 1
–
+
•
•
•
MUX
AM P
A /D
C H 16
–
CPU
AND
HNET
IN T E R FAC E
REF1
REF2
T 0324 0A
Figure 4-3. AIN-120 Block - Current Mode (RFP Powered)
Analog output channel failures detectable by the primary I/O
module that cause a failover to the backup I/O module
include:
•
•
•
•
4-6
Failed output driver.
Failed output amplifier.
Failed output sample and hold circuit.
Failed readback circuit.
- Amplifier failure.
WBPEEUI240751C0
Digital Input
R E D U N DA N T
A IN -200/220 B A S E
HNET
A
B
A IN -2 00/220 M O D U LE
+ 24 V
+
V IN
R EF1
+
+
–
–
CH 1
+
•
•
•
–
C H 16
–
AMP
A /D
O P TO C O U P LE R
1
O P TO C O U P LE R
16
R E F 16
AMP
A /D
•
•
•
C PU
AND
HNET
IN T E R FAC E
17
C JC R E F
R E F 17
A /D
RTD 1
A
B
R E D U N DA N C Y L IN K
A IN -2 00/220 M O D U LE
B
A
R E D U N DA N C Y L IN K
R EF1
+
–
CH 1
+
•
•
•
–
C H 16
AMP
A /D
O P TO C O U P LE R
R E F 16
AMP
A /D
O P TO C O U P LE R
1
•
•
•
16
C PU
AND
HNET
IN T E R FAC E
17
C JC R E F
R E F 17
A /D
RTD 2
T 0 3 23 4 A
Figure 4-4. AIN-200/220 Block - Voltage and Thermocouple Mode
•
- A-to-D converter failure.
- Bad voltage reference.
Failed D-to-A converter (one for all channels).
Digital Input
For digital input capable blocks, channels are directly wired in
parallel to both I/O modules (Figs. 4-9 and 4-10). A short
WBPEEUI240751C0
4-7
Digital Input
R E D U N DA N T
A IN -220 B A S E
4-2 0 m A
LO O P
HNET
A
B
A IN -22 0 M O D U LE
IF P /L FP
+2 4 V
15 0τ
+
REF1
+
250 τ
–
IF C /LF C
–
CH 1
+
•
•
•
–
C H 16
AM P
A /D
O P TO C O U P LE R
1
O P TO C O U P LE R
16
R E F 16
AM P
A /D
A
B
R E D U N DA N C Y LIN K
B
A
R E D U N DA N C Y LIN K
•
•
•
CPU
AN D
HNET
IN T E R FAC E
A IN -22 0 M O D U LE
REF1
+
–
CH 1
+
•
•
•
–
C H 16
AM P
A /D
O P TO C O U P LE R
1
O P TO C O U P LE R
16
R E F 16
AM P
A /D
•
•
•
CPU
AN D
HNET
IN T E R FAC E
T 0 32 4 1 A
Figure 4-5. AIN-220 Block - Current Mode (IFP or LFP Powered)
across an input of one I/O module due to an I/O block fault
will result in a false, unchanging zero state input. An open in
an input channel circuit of the base will not allow either I/O
module to read the input.
An input state change error for a digital input will cause a failover to the backup I/O module. This error occurs when one of
the digital inputs is changing state faster than the module can
handle. It is typically caused by a problem with the input
source. All digital channel LEDs will flash steadily and at the
same rate to indicate this type of error.
4-8
WBPEEUI240751C0
Digital Output
R E D U N DA N T
A IN -2 20 B A S E
+ 24 V
4-20 m A
LO O P
HNET
A
B
A IN -22 0 M O D U LE
+ 24 V
R EF1
+
+
–
–
CH 1
+
•
•
•
–
C H 16
AMP
A /D
O P TO C O U P LE R
1
O P TO C O U P LE R
16
R E F 16
AMP
A /D
A
B
R E D U N DA N C Y L IN K
B
A
R E D U N DA N C Y L IN K
•
•
•
C PU
AND
HNET
IN T E R FAC E
A IN -22 0 M O D U LE
R EF1
+
–
CH 1
+
•
•
•
–
C H 16
AMP
A /D
O P TO C O U P LE R
1
O P TO C O U P LE R
16
R E F 16
AMP
A /D
•
•
•
C PU
AND
HNET
IN T E R FAC E
T 0 3 24 2 A
Figure 4-6. AIN-220 Block - Current Mode (RFP Powered)
Digital Output
For digital output capable blocks, channels are directly wired
in parallel to both I/O modules (Figs. 4-9 through 4-12). A
short across an output of one I/O module due to an I/O block
fault will not allow the output to switch off. There are no
detectable channel failures for the digital outputs of DIO-400
and DOT-100 blocks.
The DOT-120 block has readback circuitry to monitor actual
outputs. If there is a difference between the actual output and
the read back output, the channel will be marked as suspect.
For the DOT-120 block, failover will occur if the primary I/O
module has an output stuck closed, but the backup will be
unable to correct this condition.
WBPEEUI240751C0
4-9
Digital Output
R E D U N DA N T
A IN -3 00 B A S E
HNET
B
A
A IN -300 M O D U LE (P R IM A RY )
REF1
–
RT D
AMP
CH 1
+
A /D
O P TO CO U PLER
C
1
•
•
•
16
O P TO C O U P LE R
IS O LAT E D
GND
– 15 V
C H 16
1
•
•
•
16
M AT C H E D
CURRENT
SO U RCES
C PU
AND
HNET
IN T E R FAC E
R EF16
AMP
A /D
O P TO CO U PLER
O P TO C O U P LE R
– 15 V
A
B
R E D U N DA N C Y LIN K
A IN -300 M O D U LE (B A C K U P )
B
A
R E D U N DA N C Y LIN K
REF1
AMP
CH 1
A /D
O P TO CO U PLER
1
•
•
•
16
O P TO C O U P LE R
IS O LAT E D
GND
– 15 V
C H 16
1
•
•
•
16
M AT C H E D
CURRENT
SO U RCES
C PU
AND
HNET
IN T E R FAC E
R EF16
AMP
A /D
O P TO CO U PLER
O P TO C O U P LE R
– 15 V
T 0 3 23 3 A
Figure 4-7. AIN-300 Block
4 - 10
WBPEEUI240751C0
Digital Output
HNET
A
B
R E D U N DA N T
AO T-1 5 0 B A S E
AO T-1 5 0 M O D U L E (P R IM A RY )
IF P /L FP
1
D /A
CPU
AND
H NET
IN TE R FAC E
•
•
•
S A M P LE
AND
HO LD 1
+
0 -7 5 τ
LOAD
+
–
–
16
+
A /D
–
IF C /LF C
B Y PA S S
S W IT C H
CH 1
OPEN
A
B
R E D U N D A N C Y L IN K
AO T-1 50 M O D U L E (B AC K U P )
B
A
R E D U N D A N C Y L IN K
IF P /L FP
1
D /A
CPU
AND
H NET
IN TE R FAC E
•
•
•
A /D
S A M P LE
AND
HO LD 1
+
–
16
+
–
B Y PA S S
S W IT C H
CH 1
CLO SED
T 03235 A
Figure 4-8. AOT-150 Block
WBPEEUI240751C0
4 - 11
Digital Output
R E D U N DA N T
D IO -400 B A SE
HNET
A
B
D IO -40 0 M O D U LE
IFP /LF P
+5 V
+
DI
CH 1
–
•
•
•
DI 1
+5 V
1
•
•
•
16
C H 16
D I 16
IF P /L F P
C H 17
1
•
•
•
8
C PU
AND
HNET
IN T ER FAC E
DO 1
+
•
•
•
DO
–
C H 24
DO 8
A
B
R E D U N DAN C Y LIN K
B
A
R E D U N DAN C Y LIN K
D IO -40 0 M O D U LE
+5 V
CH 1
•
•
•
DI 1
+5 V
1
•
•
•
16
C H 16
D I 16
C H 17
1
•
•
•
8
C PU
AND
HNET
IN T ER FAC E
DO 1
•
•
•
C H 24
DO 8
T 0 3 23 6 A
Figure 4-9. DIO-400 Block (IFP or LFP Powered)
4 - 12
WBPEEUI240751C0
Digital Output
R ED U N DA N T
D IO -400 B AS E
HNET
A
B
D IO -400 M O D U LE
VSOURCE
DI
+5 V
+
CH 1
–
•
•
•
DI 1
+5 V
C H 16
VSOURCE
DI 16
+
DO
1
•
•
•
16
C H 17
1
•
•
•
8
C PU
AND
HNET
IN T ER FAC E
DO 1
–
•
•
•
C H 24
DO 8
A
B
R ED U N DAN C Y L IN K
B
A
R ED U N DAN C Y L IN K
D IO -400 M O D U LE
+5 V
CH 1
•
•
•
DI 1
+5 V
1
•
•
•
16
C H 16
DI 16
C H 17
1
•
•
•
8
C PU
AND
HNET
IN T ER FAC E
DO 1
•
•
•
C H 24
DO 8
T 0 3 24 3 A
Figure 4-10. DIO-400 Block (RFP Powered)
WBPEEUI240751C0
4 - 13
Digital Output
HNET
B
A
R E D U N DA N T
D O T-1 0 0 B A S E
D O T-1 0 0 M O D U L E
NC
CPU
AND
HNET
IN TE R FAC E
LOAD
CH 1
L AT C H /
D R IV E R
1
•
•
•
O P TO CO UPLER
C
R E L AY
NO
16
R E D U N DA N C Y LIN K
A
B
D O T-1 0 0 M O D U L E
R E D U N DA N C Y LIN K
CPU
AND
HNET
IN TE R FAC E
B
A
CH 1
L AT C H /
D R IV E R
1
•
•
•
O P TO CO UPLER
R E L AY
16
T 03237 A
Figure 4-11. DOT-100 Block
4 - 14
WBPEEUI240751C0
Digital Output
R E D U N DA N T
D OT-1 20 B A S E
D OT-120 M O D U LE
HN ET
A
B
NC
R E A D B AC K
JU M P E R
CPU
AND
HN ET
IN T E R FA C E
LO A D
CH 1
LAT C H /
D R IV E R
1
•
•
•
O P TO COU PLER
R EADBACK
C
R E LAY
NO
16
R E A D B AC K
O P TO COU PLER
R E D U N DA N C Y LIN K
A
B
D OT-120 M O D U LE
R E D U N DA N C Y LIN K
B
A
R E A D B AC K
JU M P E R
CPU
AND
HN ET
IN T E R FA C E
CH 1
LAT C H /
D R IV E R
R E A D B AC K
1
•
•
•
O P TO COU PLER
R EADBACK
R E LAY
16
O P TO COU PLER
T 03 2 38 A
Figure 4-12. DOT-120 Block
WBPEEUI240751C0
4 - 15
WBPEEUI240751C0
Installation
Section 5
Introduction
This section describes I/O and auxiliary block installation and
connection for the Harmony I/O system. This instruction discusses only I/O system installation requirements. The instruction does not provide any I/O system planning information
and assumes all components have already been purchased
and are ready to be installed.
Special Handling
Observe these steps when handling electronic circuitry:
1. Use Static Shielding Bag. Keep an assembly in its static
shielding bag until ready to install it in the system. Save the
bag for future use.
2. Ground Bags before Opening. Before opening a bag containing an assembly with static sensitive devices, touch it to
the equipment housing or ground to equalize charges.
3. Avoid Touching Circuitry.
Circuitry Handle assemblies by the plastic outer packaging; avoid touching the circuitry.
4. Ground Test Equipment.
Equipment
5. Use an Antistatic Field Service Vacuum.
Vacuum Remove dust
from assemblies if necessary.
6. Use a Grounded Wrist Strap.
p. Use the ABB Automation
field static kit (part number 1948385A1 - consisting of two
wrist straps, ground cord assembly, alligator clip, and static
dissipative work surface) when working with modules. The kit
grounds a technician and the static dissipative work surface to
the same ground point to prevent damage to the circuitry by
electrostatic discharge. Connect the wrist strap to the appropriate grounding plug on the power supply or to an unpainted
portion of the enclosure with the alligator clip. The wrist strap
must be effectively connected to the earth grounding electrode
system through the AC safety ground.
WBPEEUI240751C0
5-1
Unpacking and Inspection
7. Do Not Use Lead Pencils to Set Switches.
Switches To avoid contamination of switch contacts that can result in unnecessary
circuit board malfunction, do not use a lead pencil to set a
switch.
Unpacking and Inspection
1. Examine the hardware immediately to verify that it has not
been damaged in transit.
2. Notify the nearest ABB sales office of any damage.
3. File a claim for any damage with the transportation company that handled the shipment.
4. Use the original packing material and container to store
the hardware.
5. Store the hardware in an environment of good air quality,
free from temperature and moisture extremes and corrosives.
Installation Procedures
Table 5-1 lists all of the I/O and auxiliary block installation
procedures. Refer to Installation and Connection Sequence in
this section for an explanation of how to use the procedure
sections.
Table 5-1. Installation Procedures
Procedure
5-2
Description
PR1
Installation preparation
PR2
I/O block base installation
PR3
I/O module installation
PR4
Auxiliary block installation
PR5
BLK-100 installation
PR6
AIN-120 setup
PR7
AIN-200 setup
PR8
AIN-220 setup
PR9
AIN-300 setup
PR10
AOT-150 setup
PR11
CIO-100 setup
WBPEEUI240751C0
Installation and Connection Sequence
Table 5-1. Installation Procedures (continued)
Procedure
Description
PR12
DIO-400 setup
PR13
DOT-100 setup
PR14
DOT-120 setup
PR15
CIO-110 setup
PR16
RLY-200 setup
PR17
CIO-100/110 cable connection
PR18
RLY-100/200 cable connection
PR19
Field wiring (S type base)
PR20
Field wiring (C type base)
PR21
Field wiring (cable connection)
PR22
CIO-110 wiring
PR23
RLY-100/200 wiring
PR24
Offline diagnostics
PR25
Device label definition
PR26
I/O system configuration
Installation and Connection Sequence
NOTE: Always follow the instructions given in Special Handling in this section
when handling an I/O module.
Figures 5-1 through 5-6 comprise the I/O and auxiliary block
installation and connection flowchart. This flowchart applies
whether installing blocks in a new system or in an existing
system.
In the flowchart, each flowchart block represents a single task.
The PR code in the flowchart block identifies the procedure
section that describes the steps to complete the indicated task.
For example, turn to section PR4 to read about auxiliary block
installation. Some steps are self-explanatory and have no
related procedure section. Complete all steps given in a procedure section before continuing to the next flowchart block. The
procedure sections are located towards the back of the
instruction.
WBPEEUI240751C0
5-3
Installation and Connection Sequence
A IN B L O C K
A
AOT B L O C K
S TA R T
P R E PA R E
FOR
IN S TA L L AT IO N
PR1
C IO B LO C K
D IO B LO C K
D
D OT B L O C K
F
E M P TY
BLO CK
P O S ITIO N S ?
B
C
E
IN S TA LL
BLANK
BLO CK
YE S
PR5
NO
D E F IN E
D E V IC E
LABELS
PR25
RU N O FF -LIN E
D IAG N O S TIC S
(O P TIO N A L
C H E C KO U T ) P R 24
DONE
TR 1 977B
Figure 5-1. I/O and Auxiliary Block Installation and Connection Flowchart
A
A IN B LO C K
S E PA R AT E T H E
I/O M O D U LE
FR O M IT S B A S E
IN S TA LL
A IN B LO C K
BASE
PR2
C O N N E C T F IE LD
W IR IN G TO B A S E
S E T U P A IN B LO C K
S C R E W TE R M IN A L
P R 19
A IN -120
PR6
C LA M P T E R M IN A L
P R 20
A IN -200
PR7
C A B LE
P R 21
A IN -220
A IN -300
PR8
PR9
IN S TA LL
I/O M O D U LE
A N OTH E R
I/O B LO C K ?
NO
F
PR3
YES
A IN B LO C K
AOT B LO C K
C IO B LO C K
D IO B LO C K
D OT B LO C K
A
B
C
D
E
T R 19 78 B
Figure 5-2. AIN Block Flowchart
5-4
WBPEEUI240751C0
Installation and Connection Sequence
B
AOT B LO C K
S E PA R AT E T H E
I/O M O D U LE
FR O M IT S B A S E
IN S TA LL
AOT B LO C K
BASE
PR2
C O N N E C T F IE LD
W IR IN G TO B A S E
S C R E W TE R M IN A L
P R 19
C LA M P T E R M IN A L
P R 20
C A B LE
P R 21
IN S TA LL
I/O M O D U LE
SET UP
AOT-150
B LO C K
P R 10
A N OTH E R
I/O B LO C K ?
NO
F
PR3
YES
A IN B LO C K
AOT B LO C K
C IO B LO C K
D IO B LO C K
D OT B LO C K
A
B
C
D
E
T R 19 79 B
Figure 5-3. AOT Block Flowchart
WBPEEUI240751C0
5-5
Installation and Connection Sequence
C
C IO B LO C K
S E PA R ATE TH E
I/O M O D U LE
F R O M IT S B A S E
IN S TA LL
C IO B LO C K
BASE
PR2
YES
IIS AC 01
S TAT IO N S ?
E LE C T R IC
D R IV E /P U LS E
P O S IT IO N E R ?
YES
SET UP
C IO -110
B LO C K
P R 15
NO
NO
IN S TA LL
C IO -110
B LO C K
PR 4
CONNECT
C A B LE S
P R 17
C O N N E C T FIE LD
W IR IN G TO
C IO -110 B LO C K
(N O TE 1)
P R 22
C O N N E C T F IE LD
W IR IN G TO B A S E (N O T E 1 )
S C R E W TE R M IN A L
C LA M P T E R M IN A L
P R 19
C A B LE
P R 21
P R 20
SET UP
C IO -100
B LO C K
IN S TA L L
I/O M O D U LE
P R 11
A N O TH E R
I/O B LO C K ?
NO
F
PR3
YES
A IN B LO C K
AO T B LO C K
C IO B L O C K
D IO B L O C K
NOTE:
1. 24 V D C LF P C O N N E C TIO N IS R E Q U IR E D AT T H E B A S E ,
O R AT TH E C IO -110 B LO C K IF IN S TA LLE D, F O R S TATIO N O P E R ATIO N .
D O T B LO C K
A
B
C
D
E
T R 19 80 B
Figure 5-4. CIO Block Flowchart
5-6
WBPEEUI240751C0
Installation and Connection Sequence
D
S E PA R AT E TH E
I/O M O D U LE
FR O M IT S B A S E
D IO B LO C K
IN S TA LL D IO
B LO C K B A S E
(N OT E 1)
PR2
EL E C T RO M E C H A N IC A L
YE S
R E LAY
A S S E M B LY ?
R LY-100
B LO C K
IN S TA LL
R LY
B LO C K
R E LAY
TY P E
PR4
NO
SO LID S TAT E
C O N N E C T FIE LD
W IR IN G TO
R LY B L O C K
P R 23
SET UP
R LY-200
B LO C K
P R 16
CONNECT
C A B LE S
P R 18
C O N N E C T FIE LD
W IR IN G TO B A S E
S C R E W T E R M IN A L
C LA M P TE R M IN A L
P R 19
C A B LE
P R 21
P R 20
SET UP
D IO -400
B LO C K
IN S TA LL
I/O M O D U LE
P R 12
A N OT H E R
I/O B LO C K ?
NO
F
PR3
YE S
A IN B LO C K
AO T B LO C K
C IO B LO C K
D IO B LO C K
NOTE:
1. A R E LAY C O N N E C TO R B A S E IS R E Q U IR E D TO C O N N E C T
D IO O U TP U TS TO A R E LAY A S S E M B LY.
D O T B LO C K
A
B
C
D
E
T R 19 81 B
Figure 5-5. DIO and RLY Blocks Flowchart
WBPEEUI240751C0
5-7
Installation and Connection Sequence
E
D OT B LO C K
S E PA R AT E T H E
I/O M O D U LE
FR O M IT S B A S E
IN S TA LL
D OT B LO C K
BASE
PR2
C O N N E C T F IE LD
W IR IN G TO B A S E
S E T U P D OT B LO C K
S C R E W TE R M IN A L
P R 19
D OT-100
P R 13
C LA M P T E R M IN A L
P R 20
D OT-120
P R 14
C A B LE
P R 21
A N OTH E R
I/O B LO C K ?
NO
IN S TA LL
I/O M O D U LE
F
PR3
YES
A IN B LO C K
AOT B LO C K
C IO B LO C K
D IO B LO C K
D OT B LO C K
A
B
C
D
E
T R 19 82 B
Figure 5-6. DOT Block Flowchart
5-8
WBPEEUI240751C0
Configuration
Section 6
Introduction
This section details I/O block configuration. All configuration
is performed through a Harmony controller.
NOTE: The Function Code Application Manual contains I/O block configuration examples.
Configuration Tools
The Harmony I/O system can be configured and tuned using
any configuration tools that support the I/O block function
codes. This includes, for example:
•
•
•
Composer (1.0 and later).
Conductor NT (2.0 and later).
Conductor VMS (1.0 and later).
NOTE: Only Composer has utilities to define device labels.
Harmony Controller
The Harmony controller is responsible for downloading and
verifying the process configuration executed by an I/O block.
An I/O block performs its input and output processing based
on this process configuration.
Download
When an I/O block is first installed, it contains only a base
configuration. This base configuration allows the block to participate in the device labeling process. During the actual labeling process, an I/O device definition function code (FC 221)
with a device label is added to the base configuration. Once the
label has been established, the Harmony controller can then
communicate with and download the appropriate configuration to the block. Refer to Labels in this section for more
information.
WBPEEUI240751C0
6-1
Harmony Controller
The complete control configuration resides and is retained in
the Harmony controller at all times. The controller only off
loads a portion of the configuration to be executed by the I/O
blocks.
The controller automatically downloads the configuration during startup or after any configuration changes. For this to
automatically occur, however, a device label must already have
been established in each I/O block. Also, the device label in
the block must match a device label in the control configuration of the Harmony controller (i.e., I/O device definition function code).
Verification
The Harmony controller is responsible for verifying I/O block
configuration. After losing then regaining communication with
an I/O block, the controller will issue commands to read, compare, then download if necessary the configuration. A download will occur if the controller detects any of the following
conditions:
•
Excluded function code.
•
Extra function code.
•
Difference in Harmony controller and I/O block
specifications.
Changes
All control configuration changes made by the process engineer, technician, or operator affect the control configuration
that resides in the Harmony controller. The changes can
include adding new or deleting existing function codes, and
modifying and tuning specifications of existing function codes.
When a change is made to the control configuration that
affects I/O blocks, the controller automatically downloads the
changes to the appropriate blocks.
For a nonredundant controller, all changes except tuning
require the controller to be placed in configure mode. The
controller and I/O blocks do not execute the control configuration while in configure mode. For redundant controllers, online
configuration enables making configuration changes without
affecting the primary controller or interrupting the control
6-2
WBPEEUI240751C0
Labels
process. Refer to the Primary Interface instruction for an
explanation of online configuration.
Tuning is the process of making changes to function code
specifications while the controller and I/O blocks are executing. Not all specifications can be tuned. Only those specifically
designated as tunable can be tuned. Refer to the Function
Code Application Manual to identify tunable function code
specifications.
Time Synchronization
All I/O blocks are time synchronized to insure accurate time
stamping of process data. The Harmony controller maintains
the time synchronization. The I/O block time-stamps data
(input and output values) to a resolution of one millisecond. It
applies the time-stamp to a value at the time the value is
acquired.
Firmware Download
The I/O block firmware includes a real-time operating system,
Hnet support, redundancy link support, and the function code
environment. The I/O system supports firmware downloads,
which allows I/O block firmware to be updated without having
to replace physical components. All firmware downloads are
performed using Composer tools and are managed by the Harmony controller. Refer to the Primary Interface instruction for
firmware download procedures.
The controller takes an I/O block offline to download new firmware. The block’s status LEDs will indicate a 0x19 (25 decimal)
code when a firmware download is in process (refer to
Table 8-3).
Labels
A label is simply a name assigned to a device or an I/O point.
In this case, device refers to an I/O block. The Harmony I/O
system uses two types of labels: device and channel. The
device and channel labels are character strings saved in memory. Labels can be up to 32 characters.
NOTE: A device label is required. Channel labels are optional.
WBPEEUI240751C0
6-3
Labels
Device Label
All I/O blocks must have a device label assigned to communicate on Hnet. The Harmony controller uses the device labels to
direct messages to specific I/O blocks and to identify the
source of any received messages. In the control configuration,
device labels map function codes to specific I/O blocks.
Electronic ID
Each I/O block has a unique electronic ID. This ID is fixed in
memory and cannot be modified. This method of identification:
•
Eliminates the need for a physical address switch that
must be uniquely set and subsequently recorded for identification and configuration purposes.
•
Removes any hardware address management requirements
necessary to insure each I/O block has a unique identifier.
•
Simplifies configuration.
The identification label, which is physically adhered to the
front panel of the I/O module, gives the electronic ID of the
I/O block; refer to I/O Module Front Panel in Section 7 for further description. The electronic ID does not need to be remembered or recorded for use in configuration. User-defined device
labels are used instead. The Harmony controller automatically
associates device labels with electronic IDs during the device
labeling process.
Establishing a Device Label
When an I/O block is first removed from its packaging or after
it has been initialized, it does not contain a device label. The
device labeling procedure explained in the Primary Interface
instruction must be performed to establish the label. Once
established, the label is retained by the block. The block can
be removed and reinstalled without requiring a new label to be
assigned.
NOTES:
1. An I/O block needs to be relabeled after performing a firmware download.
After copying firmware from one block to another, both the source block and
the destination block must be relabeled.
6-4
WBPEEUI240751C0
Labels
2. Redundant I/O modules share the same device label. The primary I/O
module will define or update the backup I/O module’s device label automatically. This occurs even if the backup I/O module does not currently have a
device label defined or if it has a device label that is different than the primary
I/O module’s.
The device label for an I/O block can be any unique, meaningful label desired. Labels can be assigned using any labeling
scheme desired. The labels should include enough detail, however, to easily identify and differentiate between devices and
should be defined consistently from block to block.
The Harmony controller performs all device label management, meaning that any changes, updates, and additions are
directed to the controller which then communicates the
changes, updates, and additions to the appropriate, individual
I/O blocks.
NOTE: For compatibility reasons, the label for a Harmony controller is derived
from its hardware address. This label cannot be modified.
Predefining a Device Label
Typically the device label is defined for an I/O block as the last
step of block installation or I/O module replacement as
described in Section 5 and Section 10 respectively. This is not
a requirement however. In some cases, it may be easier and
less time consuming to have the label assigned before beginning installation or replacement. Refer to procedure section
PR25 for the steps to predefine a device label.
Online Configuration
Specification one of FC 221 contains the device label. This
specification is not tunable, which means it normally cannot
be changed while the controller is operating in execute mode.
The specification can be changed, however, using online configuration. If the device label is changed using online configuration, then the controller will automatically change the
block's label to match this new label. Refer to the Primary
Interface instruction for an explanation of online configuration.
WBPEEUI240751C0
6-5
Labels
Channel Label
A channel label identifies an I/O channel of an I/O block. A
channel label can be any unique, meaningful label desired.
The label assignment is optional and is not required for proper
operation. It is strictly for ease of recognition during configuration and maintenance.
A human system interface such as a Conductor work station
and other system nodes use a tag to acquire information from
an exception reporting block and to perform process control. If
desired, the channel label can be defined the same as a tag
name in the system tag database. This allows easily identifying
the relationship between an I/O block point and a tag in the
system tag database.
NOTE: Currently, tag names are limited to 14 characters whereas channel
labels can be up to 32 characters.
Duplicate Labels
Duplicate device labels on the same Hnet are not permitted.
The Harmony controller checks for any duplicate device labels
and will identify any occurrence as a configuration error. It
does not check for duplicate channel labels however. The following paragraphs provide more detail about what occurs
when a duplicate label is detected during configuration, startup, and normal operation.
NOTE: Both I/O modules of a redundant block share the same device label.
These are not seen by the controller as duplicate labels.
Configuration
If the controller configuration contains two or more device definition function codes (FC 221) with identical device labels
assigned, the controller will enter error mode and display a
duplicate label error on its LEDs.
Initial I/O System
Startup
The following occurs when duplicate device labels are detected
on initial I/O system startup:
1. The offending I/O blocks will display a duplicate label error
code (status LEDs 2, 4, and 5 on).
2. A status report indicating bad status is issued for each I/O
block that has a duplicate label. This status indication can be
seen in the controller status bytes.
6-6
WBPEEUI240751C0
Function Codes
3. A device problem report indicating duplicate device labels
is issued for the I/O blocks that have the duplicate labels. This
report can be seen on a human system interface.
This does not affect control configuration execution and the
controller will continue to operate and communicate as normal
with other I/O blocks.
Normal Operation
If an I/O block that has a duplicate label is inserted into a system that has already established communication with another
I/O block:
1. The controller automatically relabels the offending block
with the device label “Duplicate Label Detected”. The text
string appears in the device label specification (S1) in FC 221.
2. The offending I/O block will display a duplicate label error
code (status LEDs 2, 4, and 5 on).
This does not affect control configuration execution and the
controller will continue to operate and communicate as normal
with other I/O blocks.
Function Codes
The Harmony controller and I/O blocks execute a control configuration made up of function codes linked together and
loaded in nonvolatile memory to perform the actual process
control and process management. Function codes are predefined, fixed function algorithms. The controller supports
numerous function codes for building the control configuration. The functions they perform range from computing (function generator, square root, etc.) to control (PID, pulse
positioner, etc.) to I/O interface (analog input, digital output,
etc.). Refer to the Automation Architect instruction for information on how to build a control configuration.
I/O blocks are configured using a series of I/O block specific
function codes:
•
•
•
•
•
•
WBPEEUI240751C0
I/O device definition (FC 221).
Analog in/channel (FC 222).
Analog out/channel (FC 223).
Digital in/channel (FC 224).
Digital out/channel (FC 225).
Test status (FC 226).
6-7
Function Codes
The Harmony controller allows using both I/O block and rack
I/O function codes concurrently to communicate with both
Harmony I/O blocks and Harmony rack I/O devices simultaneously.
I/O Device Definition (FC 221)
The I/O device definition function code (FC 221) is mainly
used to group the various I/O channel function codes of an
I/O block. The function code supports up to 24 input or output channels (i.e., I/O channel function codes). Besides grouping the I/O channels, the function code is also responsible for:
•
•
•
•
•
•
I/O block and channel summary status reporting.
Duplicate device label checking.
Configuration verification.
Redundancy checking and failover.
Generating problem reports.
Override, simulation, and status error inhibit permit.
Refer to Section 8 for I/O block status reporting details.
Function code specifications:
•
Contain an I/O block device label. This associates the
function code with a specific I/O block.
•
Link I/O channel function codes. These function codes
interface the I/O block inputs and outputs.
•
Permit override, simulation, and status error inhibit modes
for all linked I/O channels (i.e., master switch).
•
Control I/O block status reporting. A status error inhibit
condition prevents I/O channel errors from being included
in the I/O block device status report made to the controller.
•
Enable redundant I/O module checking.
•
Identify an external cold junction reference for thermocouple inputs.
These are just some of the function code capabilities. Refer to
the Function Code Application Manual for detailed function
code descriptions, specifications, outputs, and capabilities.
6-8
WBPEEUI240751C0
Function Codes
I/O Channel (FC 222, 223, 224, 225)
The I/O channel function codes allow for single channel modularity. In other words, one I/O channel function code reads
the input value or drives the output of one channel. Specifications are set on a per channel basis rather than on an I/O
group basis. The function codes provide addressing, startup,
execute (i.e., run time), override, simulation, and failure mode
operation specifications. The I/O channel function codes are
exception reporting function codes.
Tables 6-1 and 6-2 summarize some of the I/O channel function code capabilities. Refer to the Function Code Application Manual for detailed function code descriptions,
specifications, outputs, and capabilities.
Table 6-1. I/O Channel Function Code Summary
FC
I/O
Purpose
Reads analog input
channel data.
Normal Mode Output
222
Analog input
Analog input value in
engineering units and the
channel status.
223
Analog output Sets analog output
demand value and
acquires output channel
readback data.
Readback analog output
value in engineering units
and the channel status.
224
Digital input
Reads digital input
channel data.
Digital input state (0 or 1)
and the channel status.
225
Digital output
Readback digital output
Sets digital output state
state (0 or 1) and the
and acquires output
channel readback data (if channel status.
1
applicable).
NOTE:
1. Not all digital output channels support readback. This depends on the I/O block type (e.g.,
DOT-100 block does not support readback).
Table 6-2. I/O Channel Specifications Summary
Function Code
Specification Description
Alarming
WBPEEUI240751C0
222
(AI)
223
(AO)
High alarm (EU)
•
•
Low alarm (EU)
•
•
Alarm state
224
(DI)
225
(DO)
•
•
6-9
Function Codes
Table 6-2. I/O Channel Specifications Summary (continued)
Function Code
Specification Description
222
(AI)
223
(AO)
224
(DI)
225
(DO)
•
•
•
Identification
Channel label
•
I/O
characteristics
Custom range high limit
•
Custom range low limit
•
Deviation limit1
•
•
EU Identifier
•
•
High value (EU)
•
•
Input type
•
Low value (EU)
•
•
Significant change (EU)
•
•
Value to output
I/O conditioning
A/D conversion accuracy
•
•
Debounce period
I/O source
Operation
•
•2
•
EU conversion or shaping
algorithm precedence
•
Lead wire resistance
•
Shaping algorithm
•
Normal input or undefined
•
•
•
•
Override enable
•
•
•
•
Override value
•
•
•
•
Simulation enable
•
•
•
•
Simulation value
•
•
•
•
Default state on stall
•
•
Readback enable
Status error inhibit
•
•
•
•
•
NOTES:
1. In normal mode this is redundant I/O deviation limit. In override mode this is override deviation
limit. In simulation mode this is simulation deviation limit.
2. Readback A/D conversion accuracy for analog outputs.
An I/O block prevents the use of any I/O channel function
codes it does not support. For example, a DOT-100 block supports 16 digital output channels, and therefore will only allow
using digital out/channel function codes (FC 225) and additionally only channels one through 16.
6 - 10
WBPEEUI240751C0
Function Codes
I/O Channel Data
An I/O channel function code reports channel data in automatically generated exception reports. Channel data includes
quality, alarm status, channel status, analog value or digital
state, and a time-stamp. The data can be read by an external
device such as a human system interface. The information is
also available at the I/O channel function code outputs, which
can be accessed by other local function codes.
Quality
The quality reported by an I/O channel function code is either
good or bad as determined by the function code.
Alarm Status
For an analog channel, the alarm status indicates that the
value being reported is within normal limits or has reached or
passed either a high alarm or low alarm limit. The alarm limits
are defined in I/O channel function code specifications.
For a digital channel, one of its two digital states can be
selected as an alarm state. The alarm state is selected with an
I/O channel function code specification. When the channel
toggles to the selected alarm state, an alarm is reported.
Channel Status
Channel status is reported in the form of problem reports
which appear on a human system interface. Refer to Section 8
for channel problem report details.
Value or State
The analog value is reported in IEEE real-4 format. The digital
state is reported as either a boolean logic one or zero.
Time-Stamp
The time-stamp is the system time at which a value was read.
The time is in milliseconds.
Suspect Condition
The function code tests redundant inputs and outputs to
determine suspect condition, and it also tests actual value
against an override or simulated value. Actual value refers to
an input value for analog or digital inputs and a demanded
output value for analog or digital outputs. For analog inputs
and outputs, the suspect indication is controlled by the deviation limit specification set in the I/O channel function codes
(refer to Table 6-2).
NOTE: Only readback capable digital outputs can indicate suspect while in normal mode. The DOT-100 block does not support readback.
WBPEEUI240751C0
6 - 11
Function Codes
For redundant inputs and outputs, the function code reports a
suspect condition when:
•
Redundant digital input states are good quality but do not
match.
•
Redundant digital output states (readback) are good quality but do not match.
•
Redundant analog input values are good quality but there
is a difference between the redundant analog inputs and
the difference is greater than the deviation limit specified
in the function code.
•
Redundant analog output values (readback) are good quality but there is a difference between the readback values
for the redundant analog outputs and the difference is
greater than the deviation limit specified in the function
code.
In this case, suspect warns that if a failover from primary to
backup should occur, the difference in redundant values may
be significant enough to cause a process upset.
For override and simulation inputs and outputs, the function
code reports a suspect condition when:
6 - 12
•
While in override or simulation mode, the override or simulation digital input state does not match the actual digital
input state.
•
While in override mode, the override digital output state
does not match the readback output demand state.
•
While in override mode, there is a difference between the
override analog input value and the actual input value and
the difference is greater than the deviation limit specified
in the function code.
•
While in simulation mode, there is a difference between the
simulation analog input value and the actual input value
and the difference is greater than the deviation limit specified in the function code.
•
While in override mode, there is a difference between the
override analog output value and the readback output
demand value and the difference is greater than the deviation limit specified in the function code.
WBPEEUI240751C0
Function Codes
•
While in simulation mode, there is a difference between the
simulation analog output value and the readback output
demand value and the difference is greater than the deviation limit specified in the function code.
In this case, the suspect warns that if the mode is changed
from either override to normal or simulation to normal, the difference between actual value and override value or between
actual value and simulation value may be significant enough
to cause a process upset.
NOTE: When an IISAC01 Analog Control Station is in manual/override/auto-bypass mode and is bypassing the analog output of the CIO block,
the suspect status is not set while in override or simulation mode. The station
itself is responsible for preventing the process upset. It accomplishes this by
maintaining bypass control over the analog output until the control output of its
station function block (FC 80) matches the demand output of the station.
Exception Reporting
Each I/O channel function code is an exception reporting
function code. Exception reported data can appear as dynamic
values, alarms, and state changes on displays and in reports
generated by operator interfaces and other system nodes.
Exception reporting is automatic. An I/O channel function
code will generate an exception report periodically to update
data, after a process point reaches a defined alarm limit or
changes state, or after a significant change in value occurs.
The segment control (FC 82) and analog I/O channel function
codes (FC 222 and 224) have specifications that control exception reporting. Specifically, the segment control function code
contains minimum and maximum exception reporting times
and the I/O channel function codes contain a significant
change specification used to trigger exception reporting.
Engineering Units (EU)
Analog I/O channel function codes automatically perform
engineering unit conversions on analog input, output demand,
and output readback values. Analog inputs and readback values are converted based on the engineering unit low value,
high value, and EU identifier specifications. Also, input type
and range selection for analog inputs factors into the engineering units conversion.
WBPEEUI240751C0
6 - 13
Function Codes
Example:
A high level analog input signal has a range of 0 to 10 VDC. The actual input
signal is at 5 VDC. The engineering unit associated with the input is percent
(%); therefore, the high limit is 100 and the low limit is zero. For this signal, the
I/O block will report the input value as 50 percent.
Alarm limits and significant change are expressed in engineering units.
I/O Source
There are three input or output source selections for each I/O
channel: normal, override, and simulated. The source is
selected by setting certain I/O channel function code specifications (refer to Table 6-2). A value or state is identified as either
normal, simulated, or overridden when reported. Additionally,
an I/O channel can be undefined. An undefined channel is
ignored during control configuration execution.
NOTE: The override, simulation, and status error inhibit permit specification
(S26) in the I/O device definition function code acts as the master switch for
enabling or disabling the override and simulation I/O source options for individual channels.
Normal
The I/O source is normal as long as the override, simulation,
or undefined options are not selected. Normal is the default.
Override
The override option allows the I/O channel value or state to be
manually overridden (locally substituted) to support system
checkout or field testing. An override enable specification controls the override function and an override value specification
sets the substitute value. The value specification is tunable
and can be changed from a human system interface or by
another function code.
Simulation
The simulation option allows the I/O channel value or state to
be simulated by some other function code. A simulation enable
specification controls the simulation function and a simulation
value specification selects the simulation value source.
NOTES:
1. An override value takes precedence over a simulated value, and both
override and simulated values take precedence over a normal input value.
2. Override and simulation modes do not function when the I/O channel is
set to undefined input.
6 - 14
WBPEEUI240751C0
Function Codes
3. The auto-bypass/manual override operation of the IISAC01 Analog Control Station takes precedence over the CIO block’s simulation, override, normal,
and undefined source modes.
Hnet Stall Mode (Default State)
A default state on stall specification in output channel function codes selects a failure mode output. An output channel
will go to the configured default state when Hnet communication or communication with the Harmony controller is lost. For
an analog output, the options are zero percent output, 100
percent output, and hold current output. For a digital output,
the options are zero state output, one state output, and hold
current output. An output will automatically return to normal
(i.e., controlled output) after communication is reestablished.
Refer to Failure Mode (Outputs) in Section 3 for further
explanation.
Status Reporting
A status error inhibit specification in I/O channel function
codes controls error status reporting. If status reporting is disabled, any channel errors will not be reflected in I/O block
device status reports. Block device status reports are integrated into Harmony controller status reports. This permits
disabling status reporting during testing and for an out of service point. It does not disable input or output value and alarm
status reporting, however.
NOTE: The override, simulation, and status error inhibit permit specification
(S26) in the I/O device definition function code acts as the master switch for
enabling or disabling status error inhibiting for individual channels.
Alarming
Alarm status reports are used to trigger alarming features
such as display changes (e.g., colors and dynamic symbols),
alarm tones, external annunciators, and automatic logging
features. System alarming starts at the controller and I/O
block level. When an I/O channel function code reports an
analog value or digital state, it also includes alarm status
information.
Low and high alarm limit specifications in analog I/O channel
function codes are used to set up alarming. A low alarm condition will be reported when an input value or output readback
WBPEEUI240751C0
6 - 15
Function Codes
value is at or below the low alarm limit. Likewise, a high alarm
condition will be reported when the value is at or above the
high alarm limit.
An alarm state specification in digital I/O channel function
codes is used to set up alarming. One of the two digital channel states can be selected as an alarm state. When the input or
output readback toggles to the designated alarm state, an
alarm condition will be reported.
Shaping Algorithms
The following shaping algorithms (i.e., computing functions)
can be used with the analog input channel function code:
•
•
•
Function generator (FC 1).
Square root (FC 7).
Polynomial (FC 167).
An engineering unit conversion/shaping algorithm precedence
specification in the analog input channel function code determines when the shaping will be applied, either before or after
engineering unit conversion.
Test Status (FC 226)
The test status function code (FC 226) provides access to Harmony I/O status information. Any I/O block specific function
code can be tested for status (i.e., I/O device definition and
I/O channel function codes). Refer to the Function Code Application Manual for the statuses that can be accessed with this
function code.
The test status function code checks the status of up to four
status conditions from the same function code. It is a four
input logical OR function that sets the output to a logic zero if
all tested status conditions are false, and to a logic one if one
or more tested status conditions are true.
6 - 16
WBPEEUI240751C0
Operating Procedures
Section 7
Introduction
This section provides operating information for I/O blocks and
auxiliary blocks, and describes termination base markings and
color coding.
I/O Block
All I/O blocks share similar front and rear panel layouts.
Figure 7-1 shows an example front panel.
I/O Module Front Panel
The front panel of an I/O block communicates a considerable
amount of information including block type, operating mode,
and operating status. At a glance the following information can
easily be discerned:
•
•
•
•
•
Block type and model.
Operating mode.
Operating status.
Power status.
I/O channel status (digital I/O only).
Block Type and Model
A block type identifier enables quickly and easily identifying
general block type. I/O blocks are grouped into three major
categories: analog (A), digital (D), and control (C). These categories further divide into subcategories of input only (IN), output
only (OT), and both input and output (IO). A CIO block, for
example, is a control block that has both input and output
capabilities.
A model number distinguishes between the different I/O block
versions within a given block category. Each I/O block model
has different I/O capabilities.
WBPEEUI240751C0
7-1
I/O Block
FAU LT
NORMAL
S TAT U S
1
TYPE
2
3
4
5
MODEL
6
1 00
7
1 00
8
S TO P /R E S E T
B LO C K
P OW E R
A
1.6 A
FU S E
HOLDER
B
1.6 A
F IE LD
P OW E R
C
3.15 A
D IG ITA L
C H A N N E LS
I
07
09
10
O
11
12
13
14
08
R E TR A C TA B L E
H A N D LE
AC C E S S
DOOR
1ST FLOO R CA BINET
Control Loop IN/OUT
LA B E LS
T 00912B
Figure 7-1. I/O Block Front Panel
Operating Mode - Normal and Fault
The NORMAL and FAULT indicate I/O block operating mode.
Table 7-1 summarizes the indications.
Status
The eight status indicators show normal and error status
codes. The status appears as an eight-bit binary status code,
which can be deciphered using look-up tables provided. LED
eight is the most significant bit. Refer to Table 7-2 for normal
7-2
WBPEEUI240751C0
I/O Block
Table 7-1. Operating Mode - Normal and Fault LEDs
Indicator
Normal
State
Description
On
Operational and online.
Flashing
Established communication but not initialized or
configured.
Configured and operational but lost communication with the controller.
Off
No power. If this condition exists, no front panel
LEDs will be on.
Communication not established with controller for
the first time.
Fault condition exists (with FAULT indicator on).
Fault
On
CPU halted (with status code given in eight status
LEDs).
Machine fault timer expired. Refer to Machine
Fault Timer in Section 3 for a description.
Stop/reset button activated.
Off
No fault condition.
Table 7-2. Normal Operating Mode Status Codes
LED Status
Condition
–
–
–
–
–
–
–
– Initializing
1
2
3
4
5
6
–
– Normal stop
–
–
–
–
–
–
7
– Configuration downloaded
–
–
–
–
–
–
–
8 Normal operation (backup I/O module)
–
–
–
–
–
–
7
8 Normal operation (primary I/O module)
NOTE: – = LED off.
operating mode status codes. Refer to Table 8-3 for additional
status codes, both normal and error.
Block Power
The block power indicators (A and B) give a good or bad status
indication for the redundant 24 VDC block logic power inputs
to the block.
The status indicator on indicates a good power input. The
inputs are tested after their front panel fuses, which means a
bad input indication could be a blown fuse, bad connection, or
WBPEEUI240751C0
7-3
I/O Block
it could be a problem with the actual power source. A problem
with the power source, however, will cause a bad status indication on other blocks.
Field Power
The field power indicator gives a good or bad status indication
for the internal field power (IFP) or external local field power
(LFP) input to the block. The indicator appears as C for all
blocks except DIO blocks. A DIO block has two separate field
power indicators to show digital input field power status (DI)
and digital output field power status (DO). The type of power
associated with the indicator depends on the field power option
chosen for the block, either IFP or LFP.
The status indicator on indicates a good power input. The
input is tested after its front panel fuse, which means a bad
input indication could be a blown fuse, a bad connection, or it
could be a problem with the actual power source. A problem
with the power source, however, will cause a bad status indication on other blocks. This assumes there are other blocks
using the same power source however.
Digital Channels
The channel status indicators show digital input and output
channel states and status. Only digital I/O capable blocks
have channel status indicators. The indicator is the channel
number (e.g., 05, 10, 15, etc.). Refer to Table 7-3 for a description of possible indicator states.
Table 7-3. Digital Channel Status
Indicator
Channel Status
On
On state.
Single channel flashing at a steady
rate
1. Readback open or short.
2. Configuration error.
All channels flashing at a steady and Input state change error. One of the
same rate
digital inputs is changing state faster
than the module can handle. Typically caused by a problem with the
input source.
Off
7-4
Off state.
WBPEEUI240751C0
I/O Block
When the I/O block has both digital input and output capabilities, the channel indicators are segregated into input (I) and
output (O) groups on the front panel.
ID Labels
The front panel contains two labels at the bottom of the I/O
module: inner label and outer label. The labels are located in a
small recess covered by a removable clear plastic lens.
Inner Label
Permanently adhered to the block. It gives device identification
information which includes the device ID number and a device
description. The device ID is both a serial number and the
unique electronic ID assigned at the factory. The following is
an example inner label:
Device ID: 123456789ABC
High Level Voltage, Current IN
Outer Label
For customer use. Provides an area for customer identification
of the particular block. It also contains a brief I/O block application description. The following is an example outer label:
1ST STAGE - ACID DRUM
High Level Voltage, Current IN
I/O Module Rear Panel
Figure 7-2 shows the typical rear panel of an I/O module. The
switches, jumpers, and connectors are recessed to allow resting the assembly face up on a table.
For a CIO-100 block, P4 is a station link connector rather than
redundancy link and is labeled as such. For DIO blocks, the
field power select jumpers are for digital output field power
and are labeled as such.
Table 7-4 summarizes the SW2 special operations switch
settings.
WBPEEUI240751C0
7-5
I/O Block
SW 2 : SP EC IA L O PE R AT IO N S
P-HB-AIN-12010000
P 4: R E D U N DAN C Y L IN K
P1 : P OW E R
P5 : C O M M U N IC AT IO N
F IE LD PO W E R S EL EC T
+24VDC ,32 0m A
O PEN
J1
J2
Elsag B ailey
W illiam sp ort, PA .
U.S .A .
POW ER CO NSUM PTION
C L O S ED
ATTENTIO N
8 7 6 5 4 3 2 1
EL E CT RO STATIC
S EN SITIVE
DE VICE S
LOCAL (LFP)
INTE RNAL (IFP )
E S D ( Se e Instru ctio ns)
T 00913B
Figure 7-2. I/O Module Rear Panel
Table 7-4. Special Operations Switch (SW2) Settings
Switch Position (SW2)
Condition
8
7
6
5
4
3
2
1
1
1
1
1
1
1
1
1
Normal operation
1
0
1
1
1
1
1
0
Initialize
0
x
x
x
x
x
x
x
Diagnostic mode (refer to Diagnostics in Section 8)
NOTE: 0 = off or open; 1 = on or closed. The on position is the switch up position when looking at
the I/O module as shown in Figure 7-2.
Termination Base Color Coding and Markings
Field wiring attaches to the terminal strips located behind the
front access door on a termination base (Fig. 7-1). To simplify
installation, field wiring terminals are clearly marked to identify positive (+) and negative (–) polarity; and three-wire RTD,
normally open relay contact, and normally closed relay contact
wiring connections. Additionally, input and output channel
terminals are color coded for easier recognition. The markings
and color coding together allow wiring the input and output
channels without requiring any additional documentation.
Table 7-5 summarizes the markings and color code meanings.
Table 7-5. Terminal Strip Markings and Color Coding
Marking/Color
+24 V
+
–
7-6
Description
Current loop power
Positive terminal
Negative terminal
WBPEEUI240751C0
I/O Block
Table 7-5. Terminal Strip Markings and Color Coding (continued)
Marking/Color
Description
Normally closed relay contact
Normally open relay contact
Three-wire RTD
Black letter on blue background
Analog input channel
Blue letter on black background
Analog output channel
Black letter on orange background Digital input channel
Orange letter on black background Digital output channel
Channels are numbered consecutively whether they are input
or output channels. For example, the input channels of a
DIO-400 block are numbered 01 to 16, and the output channels are numbered 17 to 24.
Operation
This section details the I/O block startup sequence, stop/reset
pushbutton operation, and initialization.
Startup
A startup sequence occurs after a power on or manual reset of
an I/O block. Plugging an I/O module into its base connects
power and begins the start up. Table 7-6 describes a successful startup sequence.
The I/O block performs a series of online diagnostics tests during startup. Refer to Diagnostics in Section 8 for a description.
Stop/Reset Button
The stop/reset button (Fig. 7-1) is used to interrupt configuration execution and to initiate a hardware reset. The button is
accessed through the small opening on the front panel. Some
type of thin rod, preferably nonmetallic, is required to press the
button.
WBPEEUI240751C0
7-7
I/O Block
Table 7-6. Startup Sequence
LEDs
Sequence
Normal
Fault
Status
1 to 8
Block and Field
Power
Digital
Channel
All On
1
Off
On
All On
On
2
On
Off
All On
On
All Off
3
On
Off
All Off
On
All Off
4
On
Off
On/Off1
On
On/Off2
NOTE:
1. Refer to Table 7-2.
2. Refer to Table 7-3.
First Press
Stop
Press the button once to halt operation. The electronics conducts an orderly shutdown after stop is initiated to prevent any
inadvertent process upsets:
1. Save process configuration.
2. Complete any nonvolatile memory write operations.
3. Deactivate all communication links.
4. Transfer control from the primary electronics assembly to
the secondary assembly in redundant configurations.
5. Force any output channels to their powered off states.
6. Illuminate FAULT.
Second Press
Reset
Press the button a second time to initiate a hardware reset. A
hardware reset is required to recover from a module time-out
or a manual stop (single press). After the hardware reset completes, the block then begins its startup sequence. Refer to
Startup in this section.
NOTE: If the module has already stopped due to an error (i.e., FAULT lit), a single press resets the module.
Initialization
Initialization clears block memory and restores a known
default configuration. An initialization first clears nonvolatile
memory, then restores a base set of function codes. An I/O
block can be initialized in two ways: software command or
hardware switch. The Harmony controller will automatically
generate an initialize command when necessary. The special
7-8
WBPEEUI240751C0
Auxiliary Block
operations switch (SW2) on the back of the I/O module allows
manually initializing a block:
1. Halt operation by depressing the stop/reset button once.
2. Remove the I/O module.
3. Set switch SW2 to initialize (refer to Fig. 7-2 for its location).
8 7 6 5 4 3 2 1
ON
O FF
T00 9 02 A
4. Insert the I/O module. The block is initialized after the
front panel status indicators appear as follows and FAULT
turns on.
Status Indicators (On)
1
2
3
4
5
6
–
–
NOTE: – = LED off.
5. Remove the I/O module.
6. Set switch SW2 for normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
7. Insert the I/O module.
8. Redefine the device label or insert the I/O module as a
backup module. If inserted as a backup, the primary will automatically define the device label.
Auxiliary Block
There are no startup or initialization procedures for auxiliary
blocks. The front panel of an auxiliary block contains a block
type and model number, and a label covered by a removable
clear plastic lens for customer use (Fig. 7-3).
WBPEEUI240751C0
7-9
Auxiliary Block
T YP E
MODEL
110
110
AC C ES S
DO OR
1ST FLO OR CABINET
Electric Drive
LA BE LS
T 01 50 0 A
Figure 7-3. Auxiliary Block Front Panel
7 - 10
WBPEEUI240751C0
Troubleshooting
Section 8
Introduction
This section provides troubleshooting information necessary to
isolate Harmony I/O system errors. It is not meant to be all
inclusive. If a problem exists that cannot be corrected using
the information provided in this instruction, contact a local
ABB service office for assistance.
Troubleshooting Procedures
Troubleshooting of the Harmony I/O system is performed
mainly by observing the block front panel LEDs. Problems are
also identified in problem reports made to the system, which
are viewable on a human system interface such as a work station running Conductor software. If the initial indication of a
problem was from a problem report, observe block front panel
indications to help further isolate the problem.
NOTE: All tables in this section give corrective actions for single block indications. If the same indication is given for more than one block, consider a power
system or communications system problem.
The operation of the front panel LEDs is described in Section 7
and in tables that follow in this section. Refer to I/O Block
Problem Reports and I/O Block Status in this section for a
description of the reports made to the system.
Refer to Diagnostics in this section for a description of both
online and offline diagnostics. The offline diagnostics can be
run to verify operation of a suspect I/O block.
Operating Mode - Normal and Fault LEDs
Table 8-1 summarizes the normal and fault LED indications
and gives corrective actions.
WBPEEUI240751C0
8-1
Power LEDs
Table 8-1. Operating Mode - Normal and Fault LEDs
Indicator
Normal
State
Corrective Action
On
Operational and online.
No action required.
Flashing
Established communication but not
initialized or configured.
Normal indication until the controller
downloads and verifies the I/O block
configuration. If the problem persists,
check the controller.
Configured and operational but lost
communications with the controller.
1. Check the controller status.
2. Reset the I/O module.
No power. If this condition exists, no
front panel LEDs will be on.
Refer to Table 8-2 for power problem
corrective actions.
Communication not established with
controller for the first time.
Normal condition while waiting for
controller to establish communication. Check the controller status.
Fault condition exists (with FAULT
indicator on).
Refer to FAULT LED description.
CPU halted (with status code given
in eight status LEDs).
Refer to Table 8-3 in this section for
status code descriptions and corrective actions.
Off
Fault
Description
On
Machine fault timer expired. Refer to Reset the I/O module. If problem perMachine Fault Timer in Section 3
sists, replace the I/O module.
for a description.
Off
Stop/reset button activated.
Normal indication after manual hardware stop and during a reset.
No fault condition.
No action required.
Power LEDs
Table 8-2 summarizes the block power and field power LED
indications and gives corrective actions.
Status Code LEDs
The eight status indicators on the front of the I/O module
show both normal and error status codes. The status codes
appear in binary format. LED eight is the most significant bit.
Refer to Table 8-3 to decipher status codes and determine possible corrective actions if necessary.
8-2
WBPEEUI240751C0
Status Code LEDs
Table 8-2. Block and Field Power LEDs
Indicator
Block
power
A or B
State
Description
Corrective Action
On
Good power input.
Off
BLP power problem for the indicated 1. Verify front panel block power A or
B fuse on the I/O module is present
power input.
and good. If not, replace the fuse.
BLP power problem for the indicated
power input.
2. Check the condition of the power
connector (P1) on the I/O module. If
bad, replace the I/O module.
No action required.
3. Check the condition of the mounting column connector. If bad, replace
the mounting column.
4. If problem persists, replace the I/O
module.
Field power
C, DI, or
DO
On
Good power input.
No action required.
Off
IFP power problem (if jumper
selected).
1. Verify front panel field power fuse
on I/O module is present and good. If
not, replace the fuse.
2. Verify the field power select jumpers are set to IFP power.
3. Check the condition of the power
connector (P1) on the I/O module. If
bad, replace the I/O module.
4. Check the condition of the mounting column connector. If bad, replace
the mounting column.
5. If problem persists, replace the I/O
module.
LFP power problem (if jumper
selected).
1. Verify front panel field power fuse
on I/O module is present and good. If
not, replace the fuse.
2. Verify the field power select jumpers are set to LFP power.
3. Check the LFP power connection.
4. If problem persists, replace the I/O
module.
WBPEEUI240751C0
8-3
Status Code LEDs
Table 8-3. Status Codes
Code
LED On
Condition
Corrective Action
0
0x00 – – – – – – – – Initializing
1
0x01 1 – – – – – – – Nonvolatile memory
checksum error
Normal operation. No action required.
3
0x03 1 2 – – – – – – Block halt due to failover Controlled failover occurred (backup 100
percent operational). Either the I/O module lost Hnet communication (Hnet stall)
or the following problem occurred:
Initialize I/O block using special operations switch (SW2). Refer to Initialization in Section 7 for procedures. If error
persists, replace the I/O module.
- Channel error.
- Field power failure (IFP).
- Auxiliary field power failure (LFP).
- Halt error.
Replace I/O module and troubleshoot
offline as a nonredundant I/O module.
- or Stop new primary, reset this I/O module,
and troubleshoot according to error and
status reports.
5
0x05 1 – 3 – – – – – Configuration error:
undefined block
Check the controller status. Verify the
following in the controller configuration:
1. Function block inputs reference valid
function block outputs.
2. Function block inputs restricted to
specific function code types are connected properly to function block
outputs.
6
0x06 – 2 3 – – – – – Configuration error: data Check the controller status. Verify the
type conflict
following in the controller configuration:
1. No data type mismatches for function
block inputs.
2. Constant specifications are within
valid range limits.
10
8-4
0x0A – 2 – 4 – – – – Software error
Contact ABB
WBPEEUI240751C0
Status Code LEDs
Table 8-3. Status Codes (continued)
Code
13
LED On
Condition
0x0D 1 – 3 4 – – – – Redundancy link
communications error
Corrective Action
Problem in redundancy link connection
between primary and backup, or redundancy link hardware failure.
1. Reset the I/O modules.
2. Check redundancy link connector pins
(P4) on primary and backup I/O modules. If bad, replace the I/O module.
3. Replace the backup I/O module.
4. Stop primary by pressing the
stop/reset button once. Backup should
take over. Replace the primary I/O module.
5. Replace the base.
NOTE: The controller should be online
with a valid configuration while replacing
the I/O modules to manage the failover.
14
0x0E – 2 3 4 – – – – Redundancy IDs same
Redundant I/O modules unable to determine whether primary or backup. Same
corrective actions as error code 13.
17
0x11 1 – – – 5 – – – Nonvolatile memory
write error
Same corrective actions as error code 1.
19
0x13 1 2 – – 5 – – – Read-only memory
checksum error
Program image in read-only memory is
corrupt.
1. Perform a firmware download.
2. If error persists, replace the I/O
module.
22
0x16 – 2 3 – 5 – – – Block type code mismatch between primary
and backup
Redundant I/O modules are of different
types. Hardware keying is not correct.
Front panel label on base and I/O module should match. Replace incompatible
I/O module with compatible type.
23
0x17 1 2 3 – 5 – – – Duplicate Hnet address
Each I/O block is manufactured with its
own unique device ID (serial number).
Should not occur. Replace I/O module.
24
0x18 – – – 4 5 – – – Invalid block type
Internal error. Replace the I/O module.
25
0x19 1 – – 4 5 – – – Firmware download in
progress
No action required.
WBPEEUI240751C0
8-5
I/O Block Problem Reports
Table 8-3. Status Codes (continued)
Code
LED On
Condition
Corrective Action
26
0x1A – 2 – 4 5 – – – Duplicate device label
detected
Device label assigned to the block is
already in use by another I/O block.
Define a unique device label.
27
0x1B 1 2 – 4 5 – – – Incorrect Hnet
connection
I/O block is connected to a peer-to-peer
network instead of Hnet.
35
0x23 1 2 – – – 6 – – Write violation
49
0x31 1 – – – 5 6 – – Memory or CPU fault
Reset the I/O module. If error persists,
replace the I/O module.
50
0x32 – 2 – – 5 6 – – Bus error
51
0x33 1 2 – – 5 6 – – Illegal instruction
52
0x34 – – 3 – 5 6 – – Internal error - trace or
privilege error
53
0x35 1 – 3 – 5 6 – – Internal error - spurious
or unassigned exception
54
0x36 – 2 3 – 5 6 – – Internal error - divide by
0 or CHK instruction
55
0x37 1 2 3 – 5 6 – – Internal error - undefined TRAP instruction
56
0x38 – – – 4 5 6 – – Board level hardware
error
63
0x3F 1 2 3 4 5 6 – – Normal stop
Reset the I/O module.
64
0x40 – – – – – – 7 – Configuration
downloaded
Normal operation. No action required.
128
0x80 – – – – – – – 8 Normal operation
(backup I/O module)
192
0xC0 – – – – – – 7 8 Normal operation
(primary I/O module)
Replace the I/O module.
NOTE: – = off.
I/O Block Problem Reports
Problem reports are used to identify device and I/O channel
problems (Table 8-4). These reports can be seen on a human
system interface. The I/O device definition function code is
responsible for problem reporting. The Harmony controller
performs the actual reporting.
8-6
WBPEEUI240751C0
I/O Block Problem Reports
Table 8-4. I/O Block Problem Reports
Error
Backup I/O
module error
Type
Device
Description
Corrective Action
Problem with the backup I/O mod- 1. Reset the backup I/O module.
ule. Backup will not be able to take
2. Check the condition of the comover if there is a problem with the
munications connector (P5) on the
primary.
I/O module. If bad, replace the I/O
module.
3. Check redundancy link connector pins (P4) on the backup I/O
module. If bad, replace the I/O
module.
4. Replace the backup I/O module.
5. Replace the base.
Bad field power Device
status
IFP or LFP power problem.
Refer to Table 8-2 for power problem corrective actions.
Bad Hnet
Device
channel A or B
No communication on the indicated Hnet channel.
1. Reset the I/O module.
2. Check the condition of the communications connector (P5) on the
I/O module. If bad, replace the I/O
module.
3. Check the condition of the
mounting column connector. If
bad, replace the mounting column.
4. If problem persists, replace the
I/O module.
Bad power
input A or B
Device
BLP power problem for the indicated power input.
Refer to Table 8-2 for power problem corrective actions.
Bad readback
status
Channel Expected output and actual output 1. Check DOT-120 block readback
are different.
fuses.
2. Failure in the readback circuitry.
Replace the I/O module.
3. Failure in the I/O channel circuitry. Replace the I/O module.
Bad redunDevice
dancy link
channel A or B
WBPEEUI240751C0
Problem in redundancy link connection between primary and
backup I/O modules or redundancy link hardware failure.
1. Reset the I/O modules.
2. Check redundancy link connector pins (P4) on primary and
backup I/O modules. If bad,
replace the I/O module.
8-7
I/O Block Problem Reports
Table 8-4. I/O Block Problem Reports (continued)
Error
Type
Bad redunDevice
dancy link
channel A or B
(continued)
Description
Problem in redundancy link connection between primary and
backup I/O modules or redundancy link hardware failure.
Corrective Action
3. Replace the backup I/O module.
4. Stop primary by pressing the
stop/reset button once. Backup
should take over. Replace the primary I/O module.
5. Replace the base.
NOTE: The controller should be
online with a valid configuration
while replacing the I/O modules to
manage the failover.
Bad reference
status
Device
Input from onboard reference circuitry used for drift correction is
invalid.
Replace the I/O module.
Block nonvola- Device
tile memory
failure
Nonvolatile memory checksum or
write error.
Initialize I/O block using special
operations switch (SW2). Refer to
Initialization in Section 7 for procedures. If error persists, replace
the I/O module.
Calibration
Channel I/O block is out of calibration. I/O
blocks are factory calibrated.
Replace the I/O module.
Channel
failure/out of
range
Channel Overvoltage or undervoltage condition exits for the indicated
channel.
1. Check configuration to verify
proper range selection.
Cold junction
reference
Device
2. Check channel jumpers to verify
proper configuration.
3. Check field wiring connections.
Input from internal or external cold 1. Cold junction reference input
junction reference used for temfrom RTD onboard I/O block failed.
perature compensation is invalid. Replace the I/O module.
2. External cold junction reference
input failed. Check external CJR,
field wiring, and connections.
Configuration
mismatch
8-8
Device
Some type of error exists in the I/O Check the controller status. Corblock configuration in the
rect any invalid input references,
controller.
data type conflicts, range errors,
etc.
WBPEEUI240751C0
Station Problem Reports
Table 8-4. I/O Block Problem Reports (continued)
Error
Type
Description
Corrective Action
Duplicate label Device
Controller detected a device label
defined the same on more than
one I/O block; duplicate device
labels are not permitted.
Redefine the device label for one
of the blocks. Refer to Duplicate
Labels in Section 6 for further
explanation.
Hnet channel A Device
or B relay fault
One of the relays that isolates the
I/O block from Hnet has failed.
Replace the I/O module.
No response
(offline)
I/O module missing, not inserted
properly, or no power.
1. Verify I/O module is present and
inserted properly.
Device
2. Verify the I/O block is powered
up. If not, refer to Table 8-2 for
power problem corrective actions.
3. Reset the I/O module.
Suspect
condition
Channel Refer to Suspect Condition in Section 6 for an explanation.
System output
alarm
Device
Refer to Block Power in Section 3 for an explanation.
To allow tracing I/O block related problems, the device problem report includes:
•
•
•
I/O device definition function block number (FC 221).
Device label.
Error type (Table 8-4).
The I/O channel problem report includes:
•
Channel function block number (FC 222, 223, 224, or
225).
•
Channel label.
•
I/O device definition function block number (FC 221).
•
Device label.
•
Error type (Table 8-4).
Station Problem Reports
An IISAC01 Analog Control Station connected through a
CIO-100 block is considered a remote station. To allow tracing
WBPEEUI240751C0
8-9
Station Problem Reports
remote station problems, FC 80 (control station) will generate
problem reports that include:
•
•
•
•
•
Station function block number (FC 80).
Station address.
I/O device definition function block number.
Device label.
Error type (Table 8-5).
Table 8-5. Station Problem Reports
Error
Description
Corrective Action
Invalid block type
Controller is trying to communicate sta- Verify FC 221 (I/O device definition)
tion information to an I/O block that
matches device label of CIO-100
does not support station link communi- block.
cation.
Missing device
definition
Controller cannot communicate with
IISAC01 station because FC 221 (I/O
device definition) does not exist.
1. Add FC 221 function block.
2. Redefine S28 of FC 80 to point to
a referenced, valid FC 223 function
Occurs when S28 in FC 80 (control sta- block.
tion) references a FC 223 (analog output/channel) that is not referenced by a
FC 221.
Missing or miscon- Controller cannot communicate wit the 1. Verify the CIO-100 block is propfigured CIO
CIO-100 block that is addressed by FC erly configured on Hnet.
221 (I/O device definition).
2. Verify the CIO-100 block is properly labeled.
3. Verify the device label in function
code 221 matches the device label of
the CIO-100 block.
4. Verify Hnet cabling between the
controller and CIO-100 block.
5. Replace the CIO-100 module.
6. Replace the controller.
8 - 10
WBPEEUI240751C0
I/O Block Status
Table 8-5. Station Problem Reports (continued)
Error
Missing or
misconfigured
IISAC01
Description
Corrective Action
1. Insure IISAC01 station is configController is communicating with the
CIO-100 block, but the CIO-100 block ured for 40 kilobaud.
is not communicating with the IISAC01
2. Insure IISAC01 station address
station.
matches S16 in FC 80 (control station).
3. Check station link connectors and
cabling between CIO-100 block and
IISAC01 station (or between
CIO-100, CIO-110, and IISCA01 station).
4. Check LFP power to the IISAC01
station. Verify a minimum of 3.3
square millimeters stranded (12
AWG stranded wire is used to connect power.
5. Replace IISAC01 station.
6. Replace CIO-100 module.
Null device
definition label
Controller cannot communicate with
IISAC01 station because FC 221 (I/O
device definition) device label is undefined.
Too many
IISAC01s
configured for this
CIO
There are too many FC 80 (control sta- 1. Configure some of the IISAC01
tion) function blocks for a single
stations to operate from a different
CIO-100 block. The maximum is eight CIO-100 station link.
(two bypass and six indicating).
2. Verify multiple controllers are not
attempting to utilize the same
CIO-100 block station
communications.
Set S1 of FC 221 to correspond to
the CIO-100 block device label.
I/O Block Status
I/O block status information is reported to the Harmony controller where it is integrated into the controller’s status report.
Refer to the Harmony Area Controller or Harmony Bridge
Controller instruction for module status report details. The
I/O block includes the following types of status information in
its report to the controller:
•
•
WBPEEUI240751C0
Hnet communications (channel A and B).
Configuration.
8 - 11
Diagnostics
•
•
•
•
Power.
Redundancy.
Local I/O.
Station.
Also, status information can be acquired directly from the I/O
device definition function code and the I/O channel function
codes using FC 226 (test status). Refer to Test Status (FC 226)
in Section 6 for further description.
Diagnostics
The I/O block firmware contains various diagnostic routines
used to verify proper operation of components and circuitry.
Some are run automatically during startup (online) and others
can be invoked manually (offline).
Online
An I/O block runs the following online diagnostic checks during startup:
•
•
•
•
•
•
Hnet.
Data converters (D-to-A and A-to-D).
I/O channel bus.
Memory.
Power status.
Voltage references.
If any of these checks detect a hardware problem, the I/O
block will provide error status code indications (if possible) and
the block will halt. Refer to Table 8-3 to decipher the status
codes.
Offline
The offline tests can be run to verify operation of a suspect I/O
block or to check block integrity after installation. The offline
diagnostics should only be run during installation or when the
system is down. Refer to procedure section PR24 for the steps
to run offline diagnostics.
8 - 12
WBPEEUI240751C0
I/O Block Connectors
I/O Block Connectors
The following sections provide the pin assignments for I/O
block connectors.
I/O Module (P1, P4, P5)
An I/O module has three connection points for external signals and power: P1 power, P4 redundancy link, and P5 communication. Tables 8-6, 8-7, and 8-8 list the pin assignments
for P1, P4, and P5.
Table 8-6. P1 Power Pins
Pin
A
B
Connection
1
BLP A (+)
2
BLP B (+)
3
IFP (+)
1
BLC A (–)
2
BLC B (–)
3
IFC (–)
Table 8-7. P4 Redundancy Link Pins
Pin
WBPEEUI240751C0
Connection
Pin
Connection
1
Transmit data A (+)
2
Receive data A (+)
3
Ground
4
Transmit data A (–)
5
Receive data A (–)
6
Handshake OUT
7
Primary/backup
8
Ground
9
Handshake IN
10
Transmit data B (+)
11
Receive data B (+)
12
Ground
13
Transmit data B (–)
14
Receive data B (–)
8 - 13
I/O Block Connectors
Table 8-8. P5 Communication Pins
Pin
Connection
Pin
Connection
1
Ground
2
3
Ground
4
Clock A
Data A
5
Ground
6
SOA 1
7
+V1
8
+V2
9
SOA 2
10
Ground
11
Data B
12
Ground
13
Clock B
14
Ground
CIO-100 (P7, P8)
Table 8-9 lists the pin assignments for the P7 station one connector and the P8 station two connector of the CIO-100 block.
Table 8-9. CIO-100 P7 and P8 Connector Pins
Pin
P7
P8
1
LFP (–)
LFP (–)
2
Serial link (–)
Serial link (–)
3
Not connected
Not connected
4
Analog output 1 (–)
Analog output 2 (–)
5
Analog input 2 (–)
Analog input 4 (–)
6
Analog input 1 (–)
Analog input 3 (–)
7
Ground
Ground
8
LFP1 (+)
LFP1 (+)
Serial link (+)
9
Serial link (+)
10
Not connected
Not connected
11
Analog output 1 (+)
Analog output 2 (+)
12
Analog output 1 (bypass) Analog output 2 (bypass)
13
Analog input 2 (+)
Analog input 4 (+)
14
Analog input 1 (+)
Analog input 3 (+)
NOTE:
1. Fused +24 VDC; one fuse for both connectors P7 and P8.
8 - 14
WBPEEUI240751C0
I/O Block Connectors
DIO (P17)
Table 8-10 lists the pin assignments for the P17 connector of
the DIO blocks.
Table 8-10. DIO P17 Connector Pins
Pin
WBPEEUI240751C0
Connection
Pin
Connection
1
Common
2
DO 22 (+)
3
DO 21 (+)
4
DO 20 (+)
5
DO 19 (+)
6
DO 18 (+)
7
DO 17 (+)
8
DO 23/24 (–)
9
DO 24 (+)
10
DO 23 (+)
11
DO 21/22 (–)
12
Not connected
13
DO 19/20 (–)
14
DO 17/18 (–)
8 - 15
WBPEEUI240751C0
Maintenance
Section 9
Introduction
The reliability of any stand-alone product or control system is
affected by the maintenance of the equipment. ABB Automation recommends that all equipment users practice a preventive maintenance program that will keep the equipment
operating at an optimum level.
This section presents procedures that can be performed
on-site. These preventive maintenance procedures should be
used as guidelines to assist in establishing good preventive
maintenance practices. Select the minimum steps required to
meet the cleaning needs of your system.
Personnel responsible for maintenance should be familiar with
the Harmony I/O system, have experience working with process control systems, and know what precautions to take
when working on live AC systems.
Preventive Maintenance Schedule
Table 9-1 is the preventive maintenance schedule for the Harmony I/O system. The table lists the preventive maintenance
tasks in groups according to their specified maintenance interval. Some tasks in Table 9-1 are intuitive or self explanatory.
Instructions for tasks that require further explanation are covered in the indicated procedure section.
NOTE: The preventive maintenance schedule is for general purposes only.
Your application may require special attention.
WBPEEUI240751C0
9-1
Preventive Maintenance Schedule
Table 9-1. Preventive Maintenance Schedule
Task
Procedure
Frequency
General cleaning. Use a lint-free cloth and mild, all-purpose, nonflammable, commercial spray cleaner to remove dirt, fingerprints,
and grease from the equipment (e.g., LCD screen, keypad, housing assembly). Spray the cleaner on the cloth and not directly on
the equipment.
N/A
As required
Check cabinet air filters. Clean or replace them as necessary.
Check the air filter more frequently in excessively dirty environments.
N/A
3 months
Check block faceplate and housing and the cooling fan assembly
for dust. Clean as necessary using an antistatic vacuum. Insure air
vents are free of dust and lint.
N/A
Check all signal, power, ground, and cable connections associated
with the I/O system; verify they are secure.
PR27
Complete all tasks in this table.
9-2
N/A
Shutdown
WBPEEUI240751C0
Repair and Replacement
Section 10
Introduction
This section explains repair and replacement procedures for
I/O and auxiliary blocks.
Repair
Harmony I/O system repair is limited to assembly replacement. If a block component such as an I/O module fails,
remove and replace it with another. Do not attempt to replace
discrete components in any I/O system assembly.
Replacement
NOTE: Always follow the instructions given in Special Handling in Section 5
when handling an I/O module.
The replacement procedures for most parts and assemblies are
intuitive. Figures 10-1 through 10-4 comprise the replacement
flowchart, which contains replacement procedures for those
parts and assemblies that need explanation.
In the flowchart, each flowchart block represents a single task.
The PR code in the flowchart block identifies the procedure
section that describes the steps to complete the indicated task.
Some steps are self-explanatory and have no related procedure
section. Complete all steps given in a procedure section before
continuing to the next flowchart block. The procedure sections
are located towards the back of the instruction.
WBPEEUI240751C0
10 - 1
Replacement
S TA RT
I/O M O D U LE
A
I/O B L O C K B A S E
B
AU X IL IA RY B L O C K
C
D OT-1 0 0 /1 20 R E LAY
D
R LY B L O C K R E L AY
R E P LAC E M E N T
R LY-1 0 0 /20 0 R E L AY
R LY-1 00
PR33
R LY-2 00
PR34
DONE
E
TR 1 983B
Figure 10-1. Replacement Flowchart (1 of 4)
A
I/O M O D U LE
R E M OV E
I/O M O D U LE
P R 28
S E T U P S W 2, JU M P E R S ,
A N D FU S E S O N
R E P LAC E M E N T S A M E
A S M O D U LE B E IN G
R E P LAC E D
IN S TA LL
R E P LAC E M E N T
I/O M O D U LE
PR3
D E F IN E
D E V IC E
LA B E L
E
P R 25
T R 19 84 B
Figure 10-2. I/O Module Replacement Flowchart (2 of 4)
10 - 2
WBPEEUI240751C0
Replacement
TU R N O FF P O W E R
TO F IE LD D E V IC E S
CO NNECTED
TO B A S E
I/O B LO C K B A S E
B
SET UP ANY JUM PERS
AND FUSES ON
R E P LAC E M E N T TH E
SAME AS BASE
B E IN G R E P LAC E D
TU R N O FF P O W E R
AU X ILIA RY B LO C K TO F IE LD D E V IC E S
CO NNECTED
TO B LO C K
C
IN S TA LL
R E P LAC E M E N T
AU X ILIA RY
B LO C K
PR4
R E M OV E
I/O M O D U LE
P R 28
D IS C O N N E C T
W IR IN G A N D
C A B LIN G
P R 31
IN S TA LL
R E P LAC E M E N T
BASE
PR 2
CO NNECT
W IR IN G A N D
C A B LIN G
D IS C O N N E C T
W IR IN G A N D
C A B LIN G
P R 31
R E M OV E
AU X ILIA RY
B LO C K
P R 30
REM OVE
BASE
P R 29
IN S TA LL
I/O M O D U LE
PR3
S E T U P A N Y JU M P E R S,
F U S E S, A N D R E LAY S
O N R E P LAC E M E N T
T H E S A M E A S B LO C K
B E IN G R E P LAC E D
CO NNECT
W IR IN G A N D
C A B LIN G
TURN ON
P O W E R TO
FIE LD D E V IC E S
E
T R 19 85 B
Figure 10-3. I/O Block and Auxiliary Block Replacement Flowchart (3 of 4)
D
D OT-100/120
R E LAY
R E M OV E
I/O M O D U LE
P R 28
R E P LAC E
D OT-100/120
B LO C K R E LAY
P R 32
IN S TA LL
I/O M O D U LE
E
PR3
TR 1 986B
Figure 10-4. Relay Replacement Flowchart (4 of 4)
WBPEEUI240751C0
10 - 3
WBPEEUI240751C0
Replacement and Spare Parts
Section 11
Introduction
This section provides installation, replacement, and spare part
nomenclature and part numbers. Contact ABB for help determining the quantity of spare parts to keep on hand for your
particular system.
I/O and Auxiliary Block Nomenclature
Tables 11-1 through 11-7 list I/O and auxiliary block
nomenclature.
Table 11-1. Analog Input Nomenclature
1
P
2
-
3
4
H
B
WBPEEUI240751C0
5
-
6
A
7
I
8
N
9
-
10 11 12 13 14 15 16 17
_
_
_
_
_
_
_
_
Block Nomenclature
1
2
2
0
0
0
_
_
_
_
_
_
_
_
_
_
2
2
0
_
_
_
_
_
3
0
0
_
_
_
_
_
Block Type
Current, high level voltage in
Isolated high level voltage, low level
voltage, TC in
Isolated current, high level voltage, low
level voltage, TC in
Isolated RTD in
0
0
0
0
1
C
C
S
S
0
1
2
1
2
0
_
_
_
_
_
_
_
_
_
_
Module/Base Option
Nonredundant cable/clamp terminal base
Redundant cable/clamp terminal base
Nonredundant screw terminal base
Redundant screw terminal base
I/O module
0
0
Reserved for Future Use
Must be zeros
11 - 1
I/O and Auxiliary Block Nomenclature
Table 11-2. Analog Output Nomenclature
1
P
2
-
3
4
H
B
5
-
6
7
8
A
O
T
9
-
10 11 12 13 14 15 16 17
1
5
0
_
_
_
_
_
Block Nomenclature - Current Out
0
0
0
0
1
C
C
S
S
0
1
2
1
2
0
_
_
_
_
_
_
_
_
_
_
Module/Base Option
Nonredundant cable/clamp terminal base
Redundant cable/clamp terminal base
Nonredundant screw terminal base
Redundant screw terminal base
I/O module
0
0
Reserved for Future Use
Must be zeros
Table 11-3. Control Input/Output Nomenclature
1
P
P
2
-
-
3
4
H
B
H
B
5
-
-
6
C
C
7
I
I
8
O
O
9
-
-
10 11 12 13 14 15 16 17
1
1
0
1
0
0
_
_
_
_
_
0
0
1
C
S
0
1
1
0
_
_
_
_
_
_
Module/Base Option1
Nonredundant cable/clamp terminal base
Nonredundant screw terminal base
I/O module
0
0
Reserved for Future Use
Must be zeros
0
0
0
0
0
Block Nomenclature - Control Loop
In/Out
Electric Drive/Pulse Positioner
Termination2
NOTES:
1. Available in nonredundant configuration only. (AO bypass provided by optional manual/auto station (IISAC01).
2. Supports control stations that operate as electric drive/pulse positioner bypass stations. Ribbon cable NKCS04 is required to
connect CIO-110 to CIO-100.
11 - 2
WBPEEUI240751C0
I/O and Auxiliary Block Nomenclature
Table 11-4. Digital Input/Output Nomenclature
1
P
2
-
3
4
H
B
5
-
6
D
7
I
8
O
9
-
10 11 12 13 14 15 16 17
4
0
0
_
_
_
_
_
Block Nomenclature - Universal Digital
In, 24/48 VDC Digital Out
0
0
0
C
C
R
1
2
1
_
_
_
_
_
_
0
R
2
_
_
0
R
3
_
_
0
R
4
_
_
0
0
1
S
S
0
1
2
0
_
_
_
_
_
_
Module/Base Option
Nonredundant cable/clamp terminal base
Redundant cable/clamp terminal base
Nonredundant relay connector base DI screw terminals, DO cable1
Redundant relay connector base DI screw terminals, DO cable1
Nonredundant relay connector base DI cable/clamp terminals, DO cable1
Redundant relay connector base DI cable/clamp terminals, DO cable1
Nonredundant screw terminal base
Redundant screw terminal base
I/O module
0
0
Reserved for Future Use
Must be zeros
NOTE:
1. Used in combination with RLY-100 and RLY-200. Provides screw/clamp terminals for DI and cable connection to the DO located on RLY block.
Table 11-5. Digital Output Nomenclature
1
P
2
-
3
4
H
B
WBPEEUI240751C0
5
-
6
7
8
D
O
T
9
-
10 11 12 13 14 15 16 17
_
_
_
_
_
_
_
_
Block Nomenclature
1
1
0
2
0
0
_
_
_
_
_
_
_
_
_
_
Block Type
Onboard electromechanical relay out
Onboard monitored electromechanical
relay out (with fusing)
0
0
0
0
1
C
C
S
S
0
1
2
1
2
0
_
_
_
_
_
_
_
_
_
_
Module/Base Option
Nonredundant cable/clamp terminal base
Redundant cable/clamp terminal base
Nonredundant screw terminal base
Redundant screw terminal base
I/O module
0
0
Reserved for Future Use
Must be zeros
11 - 3
Cable Nomenclature
Table 11-6. Auxiliary Relay Assembly Nomenclature
1
P
2
-
3
4
H
B
5
-
6
7
8
R
L
Y
9
-
10 11 12 13 14 15 16 17
_
_
_
_
_
_
_
_
Block Nomenclature
1
2
0
0
0
0
_
_
_
_
_
_
_
_
_
_
Block Type
Electromechanical relay assembly1,2
Solid state relay assembly1,3
0
0
0
0
0
Reserved for Future Use
Must be zeros
NOTES:
1. Available in screw termination base style only.
2. RLY-100 is packaged with eight DPDT (form C) electromechanical relays.
3. RLY-200 is packaged unpopulated. Solid state relays are ordered separately. Refer to Table 11-12 for part numbers.
Table 11-7. Blank Block Nomenclature
1
P
2
-
3
4
H
B
5
-
6
7
8
B
L
K
9
-
10 11 12 13 14 15 16 17
1
0
0
_
_
_
_
_
0
0
1
0
0
0
1
2
0
_
_
_
_
_
_
0
0
Block Nomenclature1
Module/Base Option
Nonredundant base
Redundant base
Blank module
Reserved for Future Use
Must be zeros
NOTES:
1. Blank blocks maintain column air flow. They are only required in the middle of a column where air flow would be disrupted
with an empty column position. They are not required at the bottom of a column of blocks.
Cable Nomenclature
Tables 11-8 through 11-10 list cable nomenclature.
Table 11-8. DIO to RLY Cable Nomenclature
1
P
2
-
11 - 4
3
4
M K
5
-
6
7
H
R
8
9
M -
10 11 12 13 14 15 16 17
R
L
Y
1
2
_
_
_
Cable Nomenclature
H
S
_
_
_
_
Cable Type
PLTC rated for use in hazardous areas
For use in nonhazardous areas
0
B
x
x
Cable Length
0.6 m (2 ft) - connects side-by-side DIO
and RLY
01 to 60 for 1.0 to 60 m (3.3 to 200 ft)
WBPEEUI240751C0
Cable Nomenclature
Table 11-9. I/O Block to Remote Termination Cable Nomenclature
1
P
2
-
3
4
M K
5
-
6
7
H
R
8
9
M -
10 11 12 13 14 15 16 17
R
T
S
_
_
1
1
2
2
6
4
_
_
_
Cable Nomenclature
Conductors1
12 conductors
16 conductors
24 conductors
H
S
_
_
_
_
Cable Type
PLTC rated for use in hazardous areas
For use in nonhazardous areas
x
x
Cable Length
01 to 60 for 1.0 to 60 m (3.3 to 200 ft)
NOTE:
1. Used with cable/clamp terminal base (C type) with the clamp terminals removed. Refer to Table PR21-1 to determine cable
usage.
Table 11-10. CIO Cable Nomenclature
1
2
3
4
5
6
N
K
C
S
0
3
N
N
K
K
C
C
S
S
0
0
4
5
7
-
8
9
10
0
0
_
3
5
Cable Length
0.9 m (3 ft)
1.5 m (5 ft)
_
_
_
_
CIO-100 to CIO-110 Cable - 0.6 m (2 ft)
_
_
_
_
Not Used
Leave blank
-
0
0
_
3
5
WBPEEUI240751C0
CIO-100 to NKCS01/11/02/12 Adapter
Cable
CIO-110 to NKCS01/11/02/12 Adapter
Cable
Cable Length
0.9 m (3 ft)
1.5 m (5 ft)
11 - 5
Miscellaneous Parts
Miscellaneous Parts
Tables 11-11 through 11-13 list related, miscellaneous parts
and their part numbers.
1.0 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
1949438A1601
1.6 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
1949438A4001
4.0 A, 250 V, 5 x 20 mm, fast-acting, low break capacity
1949532A3151
3.15 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
1949532A6301
6.3 A, 250 V, 5 x 20 mm, time-lag, medium break capacity
1949697A3151
3.15 A, 250 V, 5 x 20 mm, time-lag, high break capacity
1949697A6301
6.3 A, 250 V, 5 x 20 mm, time-lag, high break capacity
•
•
•
•
•
•
RLY-200
CIO-110
1949438A1001
DOT-120
Part
Note 1
Number
CIO-100
Table 11-11. Fuses
•
•
•
•
•
•
NOTES:
1. Used in all I/O blocks.
2. Refer to the individual block specification tables in Section 2 for fuse usage.
RLY-200
RLY-100
Part
DOT-120
Number
DOT-100
Table 11-12. Relays
1947684A32
Solid state relay 120/240 VAC
•
1947685A31
Solid state relay 24 VDC
•
1947685A32
Solid state relay 125 VDC
1949002A3
Magnacraft miniature epoxy sealed PC board EM relay (SPDT)
1949562A1
Systems control output EM relay (DPDT)
•
•
•
•
NOTE: Refer to the individual block specification tables in Section 2 for relay specifications.
11 - 6
WBPEEUI240751C0
Miscellaneous Parts
Table 11-13. Miscellaneous
Number
WBPEEUI240751C0
Part
1946984A4
1 × 2 jumper block (0.1 mm center-to-center)
1946984A6
1 × 2 jumper
1946984A7
2 × 2 jumper block (0.2 mm center-to-center)
1946984A8
2 × 3 jumper block (0.2 mm center-to-center)
1948616A12
12-position terminal block (clamp terminal base)
1948616A16
16-position terminal block (clamp terminal base)
1949459A2
2-position terminal block (base)
200021A040S080
M4 × 8-mm screw
200021A040S100
M4 × 10-mm screw (with captive star washer)
6642146A1
Plastic lens - I/O block label cover
6642153A1
Plastic lens - auxiliary block label cover
6643676A1
Wire guide
P-HA-MSC-SCREW100
100 M4 × 10-mm screws for terminating field wiring shields (200021A040S100)
11 - 7
WBPEEUI240751C0
CIO-100 Setup
PR11
Purpose/Scope
15 min.
This procedure gives the steps required to set up the CIO-100
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS6.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Safety Considerations
1. For analog input channels, if the fused AI IFP/LFP option is
selected to power a 4 to 20 milliampere input, removing the I/O
module from the base in nonredundant applications will result
in a loss of power to all input current loops.
CAUTION
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module as appropriate (Table PR11-1).
NOTE: J1 and J2 affect the I/O channels only. The fused LFP power to operate
the stations is routed directly from the LFP terminals to the station connectors.
WBPEEUI240751C0
PR11 - 1
Procedure
Table PR11-1. Field Power Select Jumpers
□
C1
Field Power
J1
J2
Description
IFP
1 2 3
1 2 3
Field power from mounting
column bus
LFP
1 2 3
1 2 3
Field power from LFP
terminals on base
4. Set the analog input field power select jumpers J15 and
J16 located on the CIO-100 base (Table PR11-2). These jumpers affect channels configured as IFP or LFP powered 4 to 20
milliampere analog inputs. Refer to Figure PR11-1 for jumper
locations.
Table PR11-2. Analog Input Field Power Select Jumpers (Base)
Field Power
Fused AI
IFP/LFP1
(no station)
Unfused AI
LFP2,3
(station)
J15
J16
Description
1
2
3
1
2
3
Routes IFP/LFP field power
through the fuse in the I/O
module.
1
2
3
1
2
3
Routes LFP power directly to
the base terminals. Use this
setting if stations are
connected.
NOTES:
1. This option can be selected to provide fused IFP or LFP power to the analog input channels;
however, removing the I/O module from the base will result in a loss of power to all input current
loops.
2. Use this setting if current loop power must be maintained when the I/O module is removed from
the base.
3. Use this setting if analog inputs are RFP powered.
Figure PR11-2 shows the field power connections made with
jumpers J15 and J16.
PR11 - 2
□
5. Set the analog input channel jumpers located on the
CIO-100 base as appropriate (Table PR11-3).
□
6. Remove the access cover from the left side of the I/O module (Fig. PR11-3).
□
7. Set the analog output channel jumpers as appropriate
(Table PR11-4). Refer to Figure PR11-4 for jumper locations.
WBPEEUI240751C0
Procedure
Table PR11-3. Analog Input Channel Jumpers
Input
4 to 20 mA
Field
Power
IFP/LFP
RFP
Differential
1 to 5 VDC
RFP
Single-ended
1 to 5 VDC
RFP
n1-J1
n1-J2
n1-J3
n1-J4
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
NOTE:
1. n corresponds to the channel number from 1 to 4. For example, 1-J1, 1-J2, 1-J3, and 1-J4 configure channel one.
Table PR11-4. Analog Output Channel Jumpers
Output
Field
Power
4 to 20 mA2
IFP/LFP
1 to 5 VDC
IFP/LFP
n1-J1
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
NOTE:
1. n corresponds to the channel number, either 5 or 6. For
example, 5-J1 configures channel five.
2. A current output is required to support the IISAC01 output bypass feature.
□
WBPEEUI240751C0
8. Set the digital input channel jumpers as appropriate
(Table PR11-5). All digital inputs must be RFP powered.
PR11 - 3
Procedure
Table PR11-5. Digital Input Channel Jumpers
Input
Field
Power
24 VDC
RFP
48 VDC
RFP
125 VDC
RFP
120 VAC
RFP
240 VAC
RFP
n1-J1
n1-J2
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
NOTE:
1. n corresponds to the channel number from 7 to 10. For example, 7-J1 and 7-J2
configure channel seven.
□
9. Set the digital output channel jumpers as appropriate
(Table PR11-6).
Table PR11-6. Digital Output Channel Jumpers
Output
24 VDC
Field
Power
IFP/LFP
RFP
n1-J1
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
NOTE:
1. n corresponds to the channel number from 11 to 14.
For example, 11-J1 configures channel 11.
PR11 - 4
□
10. Replace the access cover.
□
11. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
WBPEEUI240751C0
Procedure
□
12. Verify a 3.15 A, 250 V fuse is present in the field power
fuse holder.
□
13. Open the access door of the CIO-100 base and verify a
6.3 A, 250 V fuse is present in fuse holder F1. This fuse is for
the +24 VDC LFP power that operates IISAC01 control stations. The fuse protects the power distributed to both station
connectors.
NOTE: If connecting to a CIO-110 block for electric drive/pulse positioner termination, +24 VDC LFP power to operate the IISAC01 control stations attaches
and is fuse protected at the CIO-110 block instead of at the CIO-100 block.
J 15
J16
1-J1
1-J3
1-J2
1-J4
2-J1
2-J3
2-J2
2-J4
3-J1
3-J3
3-J2
3-J4
4-J1
4-J3
4-J2
4-J4
T 00 9 59 A
Figure PR11-1. User-Configurable Jumpers - Base
WBPEEUI240751C0
PR11 - 5
Procedure
I/O B LO C K
+
A N A LO G
IN P U T
CHANNELS –
J1 5
+
LF P
–
+
1 2 3
J1 6
1 2 3
IFP /LF P
–
+
LF P
–
BASE
I/O M O D U LE
T0322 6A
Figure PR11-2. Analog Input Field Power Selection (J15/J16)
I/O BO AR D
AC C ES S
C OV ER
T 00 91 4 A
Figure PR11-3. Configuration Jumper Access
PR11 - 6
WBPEEUI240751C0
Procedure
5-J1
AO1
6-J1
AO2
7-J1
D I1
7-J 2
8-J1
D I2
8-J2
9-J1
D I3
9-J2
10-J1
D I4
10-J2
11-J1
12-J1
13-J1
14-J1
DO1
DO2
DO3
DO4
T 00 89 4 A
Figure PR11-4. User-Configurable Jumpers - I/O Board
WBPEEUI240751C0
PR11 - 7
Field Device Connection
Field Device Connection
Figures PR11-5, PR11-6, PR11-7, and PR11-8 show the circuit
connections made after attaching field wiring and setting
jumpers.
+24 V
TR A N S M ITTE R
+
IN T ER N AL/L O C A L
F IEL D PO W ER E D
4 -2 0 m A
+
–
M E AS U R E D
IN P U T
1 -5 V
–
CO MM O N
+24 VDC
TR A N S M ITTE R
+
R E M OT E F IELD
PO W ER E D
+
M E AS U R E D
IN P U T
1 -5 V
4 -2 0 m A
–
–
CO MM O N
+
SIN G L E-EN D E D
VO LTAG E
VSOURCE
+
M E AS U R E D
IN P U T
1 -5 V
–
–
CO MM O N
+
D IF F ER E N T IAL
VO LTAG E
VSOURCE
1 -5 V
–
+
M E AS U R E D
IN P U T
T 00 82 8 A
Figure PR11-5. Analog Input (Simplified)
PR11 - 8
WBPEEUI240751C0
Field Device Connection
+24 V
+
1 -5 V
LOAD
IN T ER N AL/L O C A L
F IEL D PO W ER E D
LOAD
IN T ER N AL/L O C A L
FIEL D PO W ER E D
–
CO MM O N
+24 V
+
4 -2 0 m A
–
CO MM O N
T 00 82 9 A
Figure PR11-6. Analog Output (Simplified)
V SOURCE
+
+5 V
R E M OTE FIE L D
P OW E R ED
–
CO MM ON
IN P U T
T 00 83 4 A
Figure PR11-7. Digital Input (Simplified)
WBPEEUI240751C0
PR11 - 9
Field Device Connection
IFP /L FP
+
LOAD
IN T ER N AL/L O C A L
F IEL D PO W ER E D
–
CO MM O N
V SOURCE
+
R E M OT E F IELD
PO W ER E D
–
LOAD
CO MM O N
T 00 83 8 A
Figure PR11-8. Digital Output (Simplified)
PR11 - 10
WBPEEUI240751C0
DIO-400 Setup
PR12
Purpose/Scope
10 min.
This procedure gives the steps required to set up the DIO-400
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS7.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Safety Considerations
1. Insure the setting for the digital input field power monitor
jumper DIFP-J2 matches the actual field power voltage (IFP or
LFP). Circuit damage will occur if the LFP voltage is greater
than the voltage setting of jumper DIFP-J2.
CAUTION
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
WBPEEUI240751C0
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the digital output field power select jumpers J1 and J2
located on the back of the I/O module as appropriate
(Table PR12-1).
PR12 - 1
Procedure
Table PR12-1. Digital Output Field Power Select Jumpers
Field Power1
J1
J2
IFP
1 2 3
1 2 3
Field power from mounting
column bus
LFP
1 2 3
1 2 3
Field power from LFP
terminals on base
Description
NOTE:
1. 24 VDC IFP/LFP required when connecting to an RLY block.
□
4. Remove the access cover from the left side of the I/O module (Fig. PR12-1).
□
5. Set the digital input field power select jumper DIFP-J1 as
appropriate (Table PR12-2). Refer to Figure PR12-2 for the
jumper location.
Table PR12-2. Digital Input Field Power Select Jumper
Field Power
DIFP-J1
IFP
(24 VDC only)
1 2 3
4 5 6
LFP
□
C1
1 2 3
4 5 6
6. Set the digital input field power monitor jumper DIFP-J2 as
appropriate (Table PR12-3). This should correspond to the
IFP/ LFP voltage being used for the digital input channels.
Refer to Figure PR12-2 for the jumper location.
Table PR12-3. Digital Input Field Power Monitor Jumper
Input
24 VDC
48 VDC
125 VDC
PR12 - 2
DIFP-J2
1
7
2
8
3 4 5 6
9 10 11 12
1
7
2
8
3 4 5 6
9 10 11 12
1
7
2
8
3 4 5 6
9 10 11 12
WBPEEUI240751C0
Procedure
Table PR12-3. Digital Input Field Power Monitor Jumper (continued)
Input
120 VAC
240 VAC
□
DIFP-J2
1
7
2
8
3 4 5 6
9 10 11 12
1
7
2
8
3 4 5 6
9 10 11 12
7. Set the input channel jumpers as appropriate
(Table PR12-4).
Table PR12-4. Digital Input Channel Jumpers
Input
Field
Power
24 VDC
IFP/LFP
RFP
48 VDC
LFP
RFP
125 VDC LFP
RFP
120 VAC LFP
WBPEEUI240751C0
n1-J1
n1-J2
n1-J3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
PR12 - 3
Procedure
Table PR12-4. Digital Input Channel Jumpers (continued)
Input
Field
Power
n1-J1
120 VAC RFP
240 VAC LFP
RFP
n1-J2
n1-J3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
1 2 3
4 5 6
7 8 9
1
7
2
8
3 4 5 6
9 10 11 12
1 2 3
NOTE:
1. n corresponds to the channel number from 1 to 16. For example, 1-J1, 1-J2, and 1-J3 configure
channel one.
□
8. Set the output channel jumpers as appropriate
(Table PR12-5).
Table PR12-5. Digital Output Channel Jumpers
Output
24 VDC
Field Power
2
IFP/LFP
RFP
48 VDC
LFP
RFP
n1-J1
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
1 2 3
4 5 6
7 8 9
NOTE:
1. n corresponds to the channel number from 17 to 24.
For example, 17-J1 configures channel 17.
2. 24 VDC IFP/LFP required when connecting to an RLY
block.
□
PR12 - 4
9. Replace the access cover.
WBPEEUI240751C0
Field Device Connection
□
10. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
11. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
□
12. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
I/O BO AR D
AC C ES S
C OV ER
T 00 91 4 A
Figure PR12-1. Configuration Jumper Access
Field Device Connection
Figures PR12-3 and PR12-4 show the circuit connections
made after attaching field wiring and setting jumpers.
Figure PR12-5 shows the circuit connections made when operating the DIO-400 block with an RLY-100 or RLY-200 block.
WBPEEUI240751C0
PR12 - 5
Field Device Connection
1-J2
1-J 3
2-J2
2-J 3
3-J2
3-J 3
4-J2
4-J 3
5-J2
5-J 3
6-J2
6-J 3
7-J2
7-J 3
8-J2
8-J 3
D IG ITA L
IN P U T S
9-J2
9-J 3
10-J 2
10-J 3
11-J 2
11-J 3
12-J 2
12-J 3
13-J 2
13-J 3
14-J 2
14-J3
15-J 2
15-J 3
16-J 2
16-J 3
17-J 1
18-J 1
19-J 1
20-J 1
21-J 1
22-J 1
23-J 1
24-J 1
D IG ITA L
O U T PU T S
D IF P -J 1
D IG ITA L IN P U T
F IE L D P OW ER
S E LE C T
D IF P-J2
D IG ITA L IN P U T
F IEL D PO W E R
M O N ITO R
T 00 88 1 A
Figure PR12-2. User-Configurable Jumpers - I/O Board
PR12 - 6
WBPEEUI240751C0
Field Device Connection
IFP /L FP
+
+5 V
IN TE R N A L /LO C A L
FIE L D PO W ER ED
–
IN P U T
CO MM O N
VSOURCE
+
+5 V
R E M OTE FIE L D
P OW E R ED
–
CO MM ON
IN P U T
T 00 83 3 A
Figure PR12-3. Digital Input (Simplified)
IFP /L FP
+
LOAD
IN T ER N AL/L O C A L
F IEL D PO W ER E D
–
CO MM O N
V SOURCE
+
R E M OT E F IELD
PO W ER E D
–
LOAD
CO MM O N
T 00 83 8 A
Figure PR12-4. Digital Output (Simplified)
WBPEEUI240751C0
PR12 - 7
Field Device Connection
NC
+24 V
V SOURCE
C
NO
LOAD
H R M -R LY
CO MM O N
CO MM O N
E L EC T RO M E C H A N IC A L O R
S O L ID S TATE R EL AY
T 00 8 39 A
Figure PR12-5. DIO with RLY - Digital Output (Simplified)
PR12 - 8
WBPEEUI240751C0
DOT-100 Setup
PR13
Purpose/Scope
5 min.
This procedure gives the steps required to set up the DOT-100
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS8.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Important Notice
Only wire field devices to the normally open relay contacts on a
redundant DOT block. Both the normally open and normally
closed relay contacts can be used on a nonredundant DOT
block.
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
WBPEEUI240751C0
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module as appropriate (Table PR13-1).
PR13 - 1
Field Device Connection
Table PR13-1. Field Power Select Jumpers
Field Power1
J1
J2
IFP
1 2 3
1 2 3
Field power from mounting
column bus
LFP
1 2 3
1 2 3
Field power from LFP
terminals on base
Description
NOTE:
1. 24 VDC to power output relay coils.
□
4. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
5. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
□
6. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
Field Device Connection
Figure PR13-1 shows the circuit connections made after
attaching field wiring.
NC
V SOURCE
C
+24 V
NO
IN TE R N A L /L O C A L
FIE L D PO W ER ED
LOAD
CO MM O N
CO MM O N
T 00 84 0 A
Figure PR13-1. Digital Output (Simplified)
PR13 - 2
WBPEEUI240751C0
DOT-120 Setup
PR14
Purpose/Scope
10 min.
This procedure gives the steps required to set up the DOT-120
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS9.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Important Notice
Only wire field devices to the normally open relay contacts on a
redundant DOT block. Both the normally open and normally
closed relay contacts can be used on a nonredundant DOT
block.
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
WBPEEUI240751C0
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module as appropriate (Table PR14-1).
PR14 - 1
Procedure
Table PR14-1. Field Power Select Jumpers
Field Power1
J1
J2
IFP
1 2 3
1 2 3
Field power from mounting
column bus
LFP
1 2 3
1 2 3
Field power from LFP
terminals on base
Description
NOTE:
1. 24 VDC to power output relay coils.
□
4. Remove the access cover from the left side of the I/O module (Fig. PR14-1).
□
5. Set the readback/fusing select jumpers as appropriate
(Table PR14-2). Refer to Figure PR14-2 for the jumper
locations.
Table PR14-2. Readback/Fusing Select Jumpers
Output
Normally closed
Normally open
n1-J1
n1-J2
1
2
3
1
2
3
1
2
3
1
2
3
NOTE:
1. n corresponds to the channel number from 1 to 16. For example,
1-J1 and 1-J2 configure channel one.
The jumper settings determine which of the contact outputs
are monitored. Both readback jumpers n-J1 and n-J2 must be
set the same. For example, if the output is wired as a normally
closed output, then both jumpers should be in the normally
closed position. If both contact outputs are used, only one is
monitored depending on the jumper settings.
PR14 - 2
□
6. Replace the access cover.
□
7. Verify 6.3 A, 250 V fuses are present in each of the
DOT-120 block fuse holders XF1 through XF16 (Fig. PR14-2).
□
8. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
WBPEEUI240751C0
Procedure
□
9. Verify a 3.15 A, 250 V fuse is present in the field power
fuse holder.
□
10. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
I/O BO AR D
AC C ES S
C OV ER
T 00 91 4 A
Figure PR14-1. Configuration Jumper Access
WBPEEUI240751C0
PR14 - 3
Procedure
F U SE
H O LD E R
1-J1
1-J 2
2-J1
2-J 2
3-J1
3-J 2
4-J1
4-J 2
5-J1
5-J 2
6-J1
6-J 2
7-J1
7-J 2
8-J1
8-J 2
9-J1
9-J 2
XF1
XF2
XF3
XF4
XF5
XF6
XF7
XF8
XF9
10-J1
1 0-J2
11-J1
1 1-J2
12-J1
1 2-J2
X F1 0
X F1 1
X F1 2
13-J1
1 3-J2
X F1 3
14-J1
1 4-J2
15-J1
1 5-J2
16-J1
1 6-J2
X F1 4
X F1 5
X F1 6
T 00 8 95 A
Figure PR14-2. User-Configurable Jumpers - I/O Board
PR14 - 4
WBPEEUI240751C0
Field Device Connection
Field Device Connection
Figure PR14-3 shows the circuit connections made after
attaching field wiring.
NC
V SOURCE
C
+24 V
NO
IN T E R N A L/LO C A L
F IE LD P O W E R E D
LO A D
COMMON
COMMON
T030 13A
Figure PR14-3. Digital Output (Simplified)
WBPEEUI240751C0
PR14 - 5
WBPEEUI240751C0
CIO-110 Setup
PR15
Purpose/Scope
5 min.
This procedure gives the steps required to set up the CIO-110
block for proper operation.
Parts
None.
Tools
•
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
IISAC01 Analog Control Station instruction.
Procedure
□
1. Set the M/A power select jumpers J1 and J2 as appropriate (Table PR15-1).
Table PR15-1. M/A Power Select Jumpers
J1
J2
External M/A power source connected at
terminal block
Power Source
1 2 3
4 5 6
1 2 3
4 5 6
LFP power used for M/A power; no external
M/A power source connected
1 2 3
4 5 6
1 2 3
4 5 6
Refer to Figure PR15-1 for jumper locations. Refer to the
IISAC01 Analog Control Station instruction for an explanation
of the M/A power.
WBPEEUI240751C0
□
2. Verify a 1.6 A, 250 V fuse is present in fuse holder XF3.
This fuse is required when using LFP power for M/A power.
□
3. Verify 4.0 A, 250 V fuses are present in fuse holders XF1
and XF2. These fuses are for the +24 VDC LFP power that
operates IISAC01 control stations connected at P2 and P4
respectively.
PR15 - 1
Procedure
M /A P O W E R (LF P )
F U S E H O LD E R
S TATIO N P O W E R 1
FUSE HOLDER
P1
XF3
XF1
J1
TB1
M /A P O W E R 1
S E LE C T
JUM PER
TB2
M A -P W R
P2
+1M A -S E L
+1R A ISE
+1L OW E R
+1M A -P W R
+2M A -S E L
+2R A IS E
+2L OW E R
+2 -
P3
L FP
+ -
J2
M /A P O W E R 2
S E LE C T
JUM PER
X F2
P4
S TAT IO N PO W E R 2
F U S E H O LD E R
T 01009 B
Figure PR15-1. I/O Board Layout
PR15 - 2
WBPEEUI240751C0
RLY-200 Setup
PR16
Purpose/Scope
15 min.
This procedure gives the steps required to set up the RLY-200
block for proper operation.
NOTE: NC on the terminal label means not connected.
Parts
Number
1947684A32
Qty
Description
1-8
120 VAC solid state relay
240 VAC solid state relay
1947685A31
24 VDC solid state relay
1947685A32
1949438A1001
1949438A3151
1949697A3151
125 VDC solid state relay
1-8
125 VDC relay fuse
24 VDC relay fuse
120 VAC relay fuse
240 VAC relay fuse
Tools
•
Small-tipped, flat-blade screwdriver.
Safety Considerations
CAUTION
1. Use only ABB Automation approved relays on the relay
assembly. Using unapproved relays could improperly route
signals and damage equipment connected to the relay and the
relay itself. CSA certification is voided when unapproved
relays are used.
Procedure
□
C1
1. Install the relays in sockets XK17 through XK24
(Fig. PR16-1). The block can be populated with relays of different ratings. They do not all have to be the same.
a. Verify the relay being installed is an approved relay
(refer to Section 11).
WBPEEUI240751C0
PR16 - 1
Procedure
b. Align and insert the relay into the socket. Insure that it
is seated flush with the socket.
c. Tighten the attachment screw.
□
2. Install the proper fuse in each fuse holder XF17 through
XF24. The fuse is dependent on the type of relay installed
(Table PR16-1).
Table PR16-1. Fuses
Relay
Fuse
Description
24 VDC
3.15 A, 250 V
5 x 20 mm, fast-acting, low break capacity (IEC 127-2/II)
125 VDC
1.0 A, 250 V
5 x 20 mm, fast-acting, low break capacity (IEC 127-2/II)
120 VAC
3.15 A, 250 V
5 x 20 mm, time-lag, high break capacity (IEC 127-2/V)
240 VAC
PR16 - 2
WBPEEUI240751C0
Procedure
XK 18
XK 17
F U SE
H O LD E R
XF1 7
XF 1 8
XK 19
TB1
R E LAY
SO C K ET
XK 20
AT TAC H M E N T
SC R EW
H O LE
T B2
XF 19
XF2 0
XK 21
XF2 1
P1
XK 22
XF2 2
XK 23
XF2 3
XK 24
XF2 4
T 00 8 96 A
Figure PR16-1. I/O Board Layout (Shown Without Relays)
WBPEEUI240751C0
PR16 - 3
WBPEEUI240751C0
CIO-100/110 Cable Connection
PR17
Purpose/Scope
10 min.
This procedure gives the steps required to cable connect an
IISAC01 Analog Control Station to a CIO-100 block. A station
can either connect directly to the CIO-100 block or connect
through a CIO-110 block (Fig. PR17-1).
C IO -100
C IO -100
IIS AC 0 1
C U R R E N T BY PAS S
STAT IO N
C IO -110
IIS AC 0 1
EL EC T R IC D R IVE /
PU LSE PO SITIO N E R
BY PAS S S TAT IO N
T 02 0 43 A
Figure PR17-1. CIO Connection
This procedure only covers CIO-100 and CIO-110 block cable
requirements. Refer to the IISAC01 Analog Control Station
instruction for station setup, installation, and cabling
requirements.
Parts
WBPEEUI240751C0
Number
Qty
Description
NKCS03
1 per station connection CIO-100 to IISAC01 translation cable
NKCS04
1 per station connection CIO-100 to CIO-110 cable
NKCS05
1 per station connection CIO-110 to IISAC01 translation cable
PR17 - 1
Procedure
Tools
•
IISAC01 Analog Control Station instruction.
Procedure
Figure PR17-2 shows the cabling required to connect an
IISAC01 station that supports current mode bypass operation.
Figure PR17-3 shows the cabling required to connect an
IISAC01 station that supports electric drive/pulse positioner
bypass operation.
NOTE: The CIO-110 block must be located either directly above or directly
below the CIO-100 block it is to connect to.
□
Make the necessary cable connections as shown in
Figure PR17-2 or PR17-3.
Table PR17-1. CIO-100 to CIO-110 Connector Relationship
Station
CIO-100
CIO-110
1
P7
P1, P2
2
P8
P3, P4
Table PR17-2. CIO-100 and IISAC01 Analog Input Relationship
Station
1
2
PR17 - 2
CIO-100
Connector
P7
P8
IISAC01
Analog Input
Analog Input
CH1
AI1
AI1
CH2
AI2
AI2
CH3
AI3
AI1
CH4
AI4
AI2
WBPEEUI240751C0
Procedure
C IO -100
N K C S03
P7
P8
N K C S01
N K C S11
N K C S02
N K C S12
TO
IIS AC 0 1
STAT IO N 1
TO
IIS AC 0 1
STAT IO N 2
T 01 01 3 A
Figure PR17-2. Current Mode Bypass Cable Connection
WBPEEUI240751C0
PR17 - 3
Procedure
C IO -100
P7
P8
N K C S04
C IO -110
P1
P2
P3
N K C S05
P4
N K C S01
N K C S11
N K C S02
N K C S12
TO
IIS AC 0 1
STAT IO N 1
TO
IIS AC 0 1
STAT ION 2
T 01 01 4 A
Figure PR17-3. Electric Drive/Pulse Positioner Bypass Cable Connection
PR17 - 4
WBPEEUI240751C0
RLY-100/200 Cable Connection
PR18
Purpose/Scope
5 min.
This procedure gives the steps required to cable connect a
RLY-100 or RLY-200 block to a DIO-400 block (Fig. PR18-1).
NOTE: A DIO block must have a relay connector base (P-HB-DIO-4000R?00)
to connect DIO outputs to an RLY block.
D IO -40 0
R LY-10 0,
R LY-20 0
T 02109B
Figure PR18-1. DIO to RLY Connection
Parts
Number1,2
Qty
P-MK-HRM-RLY12Hxx
1
P-MK-HRM-RLY12Sxx
Description
DIO to RLY cable
DIO to RLY cable
NOTES:
1. H = PLTC rated for use in external enclosure applications; S = for use in internal enclosure applications.
2. Refer to Section 11 for complete nomenclatures.
Tools
WBPEEUI240751C0
None.
PR18 - 1
Procedure
Procedure
□
Make the necessary cable connections as shown in
Figure PR18-2. This figure shows the cabling required to connect an RLY-100 or RLY-200 block to the DIO block.
D IO
H R M -R LY
D IO
H R M -R LY
P1 7
P1 7
R LY-2 00
R LY-1 00
P1
P1
T 01 0 15 A
Figure PR18-2. DIO Block to RLY Block Cable Connection
PR18 - 2
WBPEEUI240751C0
I/O Module Removal
PR28
Purpose/Scope
1 min.
This procedure gives the steps required to remove an I/O module from its base. The removal procedure is the same for all
I/O modules. An I/O module can be removed with power on.
NOTE: Always follow the instructions given in Special Handling in Section 5
when handling an I/O module.
Parts
None.
Tools
•
•
Flat-blade or Phillips screwdriver.
Thin rod for reset button, preferably nonmetallic.
Safety Considerations
WARNING
1. An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous.
CAUTION
1. For analog input channels, if the fused AI IFP/LFP option is
selected to power a 4 to 20 milliampere input, removing the I/O
module from the base in nonredundant applications will result
in a loss of power to all input current loops.
Procedure
□
□
W1
□
WBPEEUI240751C0
1. Depress the stop/reset button once to halt block operation
if not already halted.
2. Loosen the captive front panel fastening screw
(Fig. PR28-1).
3. Grasp the I/O module by its handle and gently pull.
PR28 - 1
Procedure
AL IG N M EN T
PO S TS
FA ST E N IN G
SC R EW
R E TR AC TA BL E
H A N D LE
T 00 9 11 B
Figure PR28-1. I/O Module Removal
PR28 - 2
WBPEEUI240751C0
I/O Block Base Removal
PR29
Purpose/Scope
5 min.
This procedure gives the steps required to remove a terminal
(C, R, and S type) or connector base (K type). The procedure is
the same whether removing a nonredundant or redundant
base.
Parts
None.
Tools
•
Phillips screwdriver.
Procedure
WBPEEUI240751C0
□
1. Loosen the two captive screws that attach the base to the
column (Fig. PR29-1). A redundant base has four captive
screws.
□
2. Slide the base to the right so the tabs on the back of the
base clear the slots in the column as shown in Figure PR29-1,
then remove the base.
PR29 - 1
Procedure
R E A R V IE W
A LIG N M E N T
H O LE S
C A P T IV E
FA S T E N IN G
SCREW S
T 032 46A
Figure PR29-1. Base Removal
PR29 - 2
WBPEEUI240751C0
Auxiliary Block Removal
PR30
Purpose/Scope
10 min.
This procedure gives the steps required to remove an auxiliary
block. The procedure is the same for all auxiliary blocks.
Parts
None.
Tools
•
Phillips screwdriver.
Procedure
WBPEEUI240751C0
□
1. Separate the auxiliary block housing from its mounting
bracket by opening the front panel door and loosening the four
captive screws that attach the housing to the bracket
(Fig. PR30-1).
□
2. Remove the auxiliary housing bracket by removing the
three screws attaching the bracket to the column.
PR30 - 1
Procedure
A LIG N M E N T
HOLES
R E A R V IE W
C A P T IV E
FA S T E N IN G
S C R E W (4)
S C R E W (3)
T 00 9 62 B
Figure PR30-1. Auxiliary Block Removal
PR30 - 2
WBPEEUI240751C0
Wiring and Cabling
Disconnection
PR31
Purpose/Scope
15 min.
This procedure gives the steps to disconnect field wiring, power
wiring, and cables prior to removing an I/O or auxiliary block.
Parts
None.
Tools
•
•
Flat-blade screwdriver.
Phillips screwdriver.
Safety Considerations
1. Verify the main power, field power, and power entry panel
circuit breakers/switches are turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so
could result in severe or fatal shock. Do not turn the power on
until the installation, retrofit, upgrade, or wiring procedures are
complete.
WARNING
Procedure
□
□
W1
□
1. Record any block, wiring, and cabling information necessary so the wiring and cabling can be easily reconnected. This
step may not be required if the front door label contains the
information, or this information is already recorded in some
other form.
2. Verify that power is off to the Harmony I/O system and
field devices being disconnected.
3. Disconnect all field wiring from the block.
Screw Terminals
If the wiring is attached using screw terminals, remove each
wire attached.
Clamp Terminals
If the field wiring is attached using clamp terminals, unplug
the terminal strip from the connector on the base. Individual
wires can remain connected to the terminals.
WBPEEUI240751C0
PR31 - 1
Procedure
Cable Connector
PR31 - 2
If the field wiring is attached using a cable connector, unplug
the cable from the base.
□
4. Disconnect the LFP power wiring from the block.
□
5. Disconnect all cables.
WBPEEUI240751C0
DOT-100/120 Relay
Replacement
PR32
Purpose/Scope
15 min.
This procedure gives the steps to replace a relay on a DOT-100
or DOT-120 block.
Parts
Number
1949002A3
Tools
Qty
1 - 16
Description
Electromechanical relay (SPDT)
None.
Safety Considerations
1. Use only ABB Automation approved relays on the relay
assembly. Using unapproved relays could improperly route
signals and damage equipment connected to the relay and the
relay itself. CSA certification is voided when unapproved
relays are used.
CAUTION
Procedure
□
1. Remove the access cover from the left side of the I/O module (Fig. PR32-1).
□
2. Pull the existing relay from its socket XK1 through XK16
(Fig. PR32-2). Rock the relay from side to side to loosen and
remove it.
□
C1
WBPEEUI240751C0
3. Verify the replacement relay is an approved relay and of the
same type.
□
4. Align and insert the new relay. Insure that it is seated flush
with the socket.
□
5. Replace the access cover.
PR32 - 1
Procedure
I/O BO AR D
AC C ES S
C OV ER
T 00 91 4 A
Figure PR32-1. Configuration Jumper Access
PR32 - 2
WBPEEUI240751C0
Procedure
R E LAY
S O C K ET
XK1
XF1
XK2
XF2
XK3
XK4
XF3
XF4
XK5
XF5
XK6
XF6
XK7
XF7
XK8
XF8
XK9
XF9
X F 10
X K 10
X F 11
X K 11
X F 12
X K 12
X F 13
X K 13
X F 14
X K 14
X F 15
X K 15
X F 16
X K 16
T 01 83 5 A
Figure PR32-2. I/O Board Layout (Shown Without Relays)
WBPEEUI240751C0
PR32 - 3
WBPEEUI240751C0
RLY-100 Relay Replacement
PR33
Purpose/Scope
5 min.
This procedure gives the steps to replace a relay on the
RLY-100 block.
Parts
Number
1949562A1
Tools
Qty
1-8
Description
Electromechanical relay (DPDT)
None.
Safety Considerations
WARNING
1. Verify field power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal
shock. Do not turn the power on until the replacement procedure is complete.
CAUTION
1. Use only ABB Automation approved relays on the relay
assembly. Using unapproved relays could improperly route
signals and damage equipment connected to the relay and the
relay itself. CSA certification is voided when unapproved
relays are used.
Procedure
□
W1
□
□
C1
WBPEEUI240751C0
1. Turn off power to the field device controlled by the relay
being replaced.
2. Open the access door, then pull the existing relay from its
socket XK17 through XK24 (Fig. PR33-1). The sockets are very
tight to insure the relays remain in place. Rock the relay up
and down to loosen and remove it.
3. Verify the replacement relay is an approved relay and of the
same type.
PR33 - 1
Procedure
PR33 - 2
□
4. Align and insert the new relay. Insure that it is seated flush
with the socket.
□
5. Turn on power previously turned off in Step 1.
WBPEEUI240751C0
Procedure
TB1
T B2
X K 18
R E LAY
S O C K ET
XK 17
X K 20
XK 19
P1
XK 22
XK 21
XK 24
XK 23
T 00 89 7 A
Figure PR33-1. RLY-100 Board Layout (Shown Without Relays)
WBPEEUI240751C0
PR33 - 3
WBPEEUI240751C0
RLY-200 Relay Replacement
PR34
Purpose/Scope
5 min.
This procedure gives the steps to replace a relay on the
RLY-200 block.
NOTE: Check for a blown fuse before replacing a relay.
Parts
Number
1947684A32
1947685A31
Tools
Qty
Description
1-8
120 VAC solid state relay
24 VDC solid state relay
1947685A32
125 VDC solid state relay
1947803A1
240 VAC solid state relay
•
Small-tipped, flat-blade screwdriver.
Safety Considerations
WARNING
1. Verify field power is turned off before starting the replacement procedure. Failure to do so could result in severe or fatal
shock. Do not turn the power on until the replacement procedure is complete.
CAUTION
1. Use only ABB Automation approved relays on the relay
assembly. Using unapproved relays could improperly route signals and damage equipment connected to the relay and the
relay itself. CSA certification is voided when unapproved relays
are used.
Procedure
□
W1
□
WBPEEUI240751C0
1. Turn off power to the field device controlled by the relay
being replaced.
2. Open the access door, then loosen the attachment screw of
the relay to be replaced (Fig. PR34-1).
PR34 - 1
Procedure
□
□
C1
PR34 - 2
3. Pull the existing relay from its socket XK17 through XK24.
4. Verify the replacement relay is an approved relay and of
the same type.
□
5. Align and insert the new relay. Insure that it is seated
flush with the socket.
□
6. Tighten the attachment screw.
□
7. Turn on power previously turned off in Step 1.
WBPEEUI240751C0
Procedure
XK 18
XK 17
F U SE
H O LD E R
XF 1 7
XF 18
XK 19
T B1
R E LAY
SO C K ET
XK 20
AT TAC H M E N T
SC R EW
H O LE
TB2
XF1 9
XF 2 0
XK 21
XF 2 1
P1
XK 22
XF 2 2
XK 23
XF 2 3
XK 24
XF 2 4
T 00 896 A
Figure PR34-1. RLY-200 Board Layout (Shown Without Relays)
WBPEEUI240751C0
PR34 - 3
WBPEEUI240751C0
AIN-120
WS1
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
Analog Inputs - FC 222
Input
WBPEEUI240751C0
Range
Current
4 to 20 mA
High Level Voltage
0 to 1 VDC
0 to 5 VDC
0 to 10 VDC
1 to 5 VDC
-10 to +10 VDC
Custom voltage
-10 to +10 VDC
WS1 - 1
Analog Inputs - FC 222
CH1
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH2
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH3
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WS1 - 2
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH4
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH5
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH6
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS1 - 3
Analog Inputs - FC 222
CH7
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH8
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
CH9
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WS1 - 4
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH10 Channel Info:
Channel Label:
Input:
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH11 Channel Info:
Channel Label:
Input:
" Deg F
" Deg C
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH12 Channel Info:
Channel Label:
Input:
" Deg F
" Deg C
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS1 - 5
Analog Inputs - FC 222
CH13 Channel Info:
Channel Label:
Input:
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH14 Channel Info:
Channel Label:
Input:
" Deg F
" Deg C
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH15 Channel Info:
Channel Label:
Input:
" Deg F
" Deg C
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WS1 - 6
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH16 Channel Info:
Channel Label:
Input:
____________________________________________________________
_________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS1 - 7
WBPEEUI240751C0
AIN-200
WS2
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Field Power Selection:
! IFP (only option)
Analog Inputs - FC 222
Input
WBPEEUI240751C0
Range/Type
High level voltage
0 to 1 VDC
0 to 5 VDC
0 to 10 VDC
1 to 5 VDC
-10 to +10 VDC
Low level voltage
0 to 100 mV
-100 to +100 mV
Custom voltage
-10 to +10 VDC
Thermocouple (TC)
B, E, J, K, L, N (14 AWG), N (28 AWG),
R, S, T, U
Chinese E, S
WS2 - 1
Analog Inputs - FC 222
CH1
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH2
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH3
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WS2 - 2
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH4
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH5
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH6
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS2 - 3
Analog Inputs - FC 222
CH7
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH8
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH9
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WS2 - 4
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH10 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH11 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH12 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS2 - 5
Analog Inputs - FC 222
CH13 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH14 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
CH15 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WS2 - 6
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH16 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" _______ to _______ VDC
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω:
_________________________________ (mV or TC input)
Eng. Units:
" _______________
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS2 - 7
WBPEEUI240751C0
AIN-220
WS3
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
Analog Inputs - FC 222
Input
WBPEEUI240751C0
Range/Type
Current
4 to 20 mA
High level voltage
0 to 1 VDC
0 to 5 VDC
0 to 10 VDC
1 to 5 VDC
-10 to +10 VDC
Low level voltage
0 to 100 mV
-100 to +100 mV
Custom voltage
-10 to +10 VDC
Thermocouple (TC)
B, E, J, K, L, N (14 AWG), N (28 AWG),
R, S, T, U
Chinese E, S
WS3 - 1
Analog Inputs - FC 222
CH1
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
CH2
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WS3 - 2
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH3
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
CH4
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS3 - 3
Analog Inputs - FC 222
CH5
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
CH6
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WS3 - 4
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH7
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
CH8
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS3 - 5
Analog Inputs - FC 222
CH9
Channel Info:
__________________________________________________________
Channel Label:
________________________________________ (optional 32 characters max.)
Input:
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH10 Channel Info:
" Deg C
__________________________________________________________
Channel Label:
Input:
" Deg F
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WS3 - 6
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH11 Channel Info:
__________________________________________________________
Channel Label:
Input:
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH12 Channel Info:
" Deg C
__________________________________________________________
Channel Label:
Input:
" Deg F
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS3 - 7
Analog Inputs - FC 222
CH13 Channel Info:
__________________________________________________________
Channel Label:
Input:
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH14 Channel Info:
" Deg C
__________________________________________________________
Channel Label:
Input:
" Deg F
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WS3 - 8
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WBPEEUI240751C0
Analog Inputs - FC 222
CH15 Channel Info:
__________________________________________________________
Channel Label:
Input:
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
CH16 Channel Info:
" Deg C
__________________________________________________________
Channel Label:
Input:
" Deg F
________________________________________ (optional 32 characters max.)
" 4 to 20 mA
" IFP/LFP
" RFP
" _______ to _______ VDC (RFP only)
" Single-ended " Differential (voltage mode)
" Thermocouple
TC Type:
_________________________________
Lead Wire Ω: _________________________________ (mV or TC input)
Eng. Units:
WBPEEUI240751C0
" ____________________
" Percent (%)
" Deg F
Low Value: ___________
High Value: ___________
" Deg C
WS3 - 9
WBPEEUI240751C0
AIN-300
WS4
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Field Power Selection:
! IFP (only option)
Analog Inputs - FC 222
CH1
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WBPEEUI240751C0
High Value: _______________
WS4 - 1
Analog Inputs - FC 222
CH2
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH3
Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WS4 - 2
High Value: _______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH4
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH5
Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WBPEEUI240751C0
High Value: _______________
WS4 - 3
Analog Inputs - FC 222
CH6
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH7
Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WS4 - 4
High Value: _______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH8
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH9
Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WBPEEUI240751C0
High Value: _______________
WS4 - 5
Analog Inputs - FC 222
CH10 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH11 Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WS4 - 6
High Value: _______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH12 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH13 Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WBPEEUI240751C0
High Value: _______________
WS4 - 7
Analog Inputs - FC 222
CH14 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
CH15 Channel Info:
High Value: _______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WS4 - 8
High Value: _______________
WBPEEUI240751C0
Analog Inputs - FC 222
CH16 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Input:
" 10 Ω copper
" 100 Ω platinum
" U.S. Lab. Std. " U.S. Ind. Std. " Euro. Std.
" 120 Ω nickel
" Chinese 53 Ω copper
Lead Wire Ω:
_________________________________
Eng. Units:
" Deg F
" Deg C
Low Value: ________________
WBPEEUI240751C0
High Value: _______________
WS4 - 9
WBPEEUI240751C0
AOT-150
WS5
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
Analog Outputs - FC 223
CH1
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH2
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS5 - 1
Analog Outputs - FC 223
CH3
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH4
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH5
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH6
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WS5 - 2
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Analog Outputs - FC 223
CH7
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH8
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH9
Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH10 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS5 - 3
Analog Outputs - FC 223
CH11 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH12 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH13 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH14 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WS5 - 4
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Analog Outputs - FC 223
CH15 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
CH16 Channel Info:
" Deg F
" Deg C
High Value: ______________
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WBPEEUI240751C0
" Deg F
" Deg C
High Value: ______________
WS5 - 5
WBPEEUI240751C0
CIO-100
WS6
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
Analog Inputs - FC 222
CH1
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
Eng. Units:
CH2
" 4 to 20 mA
" IFP/LFP
" RFP
" 1 to 5 VDC (RFP only)
" Single-ended " Differential (voltage mode)
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
" Deg F
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
Eng. Units:
WBPEEUI240751C0
" 4 to 20 mA
" IFP/LFP
" RFP
" 1 to 5 VDC (RFP only)
" Single-ended " Differential (voltage mode)
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
" Deg F
" Deg C
WS6 - 1
Analog Outputs - FC 223
CH3
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
Eng. Units:
CH4
" 4 to 20 mA
" IFP/LFP
" RFP
" 1 to 5 VDC (RFP only)
" Single-ended " Differential (voltage mode)
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
" Deg F
" Deg C
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
Eng. Units:
" 4 to 20 mA
" IFP/LFP
" RFP
" 1 to 5 VDC (RFP only)
" Single-ended " Differential (voltage mode)
" ____________________
" Percent (%)
Low Value: ___________
High Value: ___________
" Deg F
" Deg C
Analog Outputs - FC 223
CH5
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
" 4 to 20 mA (IFP/LFP only)
" 1 to 5 VDC (IFP/LFP only)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
WS6 - 2
" Deg F
" Deg C
High Value: ______________
WBPEEUI240751C0
Digital Inputs - FC 224
CH6
Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
" 4 to 20 mA (IFP/LFP only)
" 1 to 5 VDC (IFP/LFP only)
Stall State:
" 0%
" 100%
Eng. Units:
" _______________
" Hold Output
" Percent (%)
Low Value: ______________
" Deg F
" Deg C
High Value: ______________
Digital Inputs - FC 224
CH7
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input (RFP only): " 24 VDC
" 48 VDC
" 125 VDC
" 120 VAC
" 240 VAC
CH8
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input (RFP only): " 24 VDC
" 48 VDC
" 125 VDC
" 120 VAC
" 240 VAC
WBPEEUI240751C0
WS6 - 3
Digital Outputs - FC 225
CH9
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input (RFP only): " 24 VDC
" 48 VDC
" 125 VDC
" 120 VAC
" 240 VAC
CH10 Channel Info:
Channel Label:
____________________________________________________________
_________________________________________ (optional 32 characters max.)
Input (RFP only): " 24 VDC
" 48 VDC
" 125 VDC
" 120 VAC
" 240 VAC
Digital Outputs - FC 225
CH11 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
24 VDC:
" IFP/LFP
" RFP
Stall State:
" On (0)
" Off (1)
CH12 Channel Info:
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
WS6 - 4
24 VDC:
" IFP/LFP
" RFP
Stall State:
" On (0)
" Off (1)
" Hold Output
WBPEEUI240751C0
Digital Outputs - FC 225
CH13 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
24 VDC:
" IFP/LFP
" RFP
Stall State:
" On (0)
" Off (1)
CH14 Channel Info:
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
24 VDC:
" IFP/LFP
" RFP
Stall State:
" On (0)
" Off (1)
WBPEEUI240751C0
" Hold Output
WS6 - 5
WBPEEUI240751C0
DIO-400
WS7
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" 48 VDC
" 120 VAC
" 240 VAC
" 125 VDC
" None
Digital Input Field Power:
" IFP
" LFP
Digital Output Field Power:
" IFP
" LFP (24 or 48 VDC only)
NOTES:
1. Digital inputs can be 24 VDC IFP or 24 VDC, 48 VDC, 125 VDC, 120 VAC, or 240 VAC LFP powered.
RFP is also supported.
2.
Digital outputs can be either 24 VDC IFP or 48 VDC LFP powered only. RFP is not supported.
3.
Digital outputs must be configured as 24 VDC IFP/LFP to operate with an RLY block.
WBPEEUI240751C0
WS7 - 1
Digital Inputs - FC 224
Digital Inputs - FC 224
CH1
CH2
CH3
WS7 - 2
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
WBPEEUI240751C0
Digital Inputs - FC 224
CH4
CH5
CH6
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
WBPEEUI240751C0
WS7 - 3
Digital Inputs - FC 224
CH7
CH8
CH9
WS7 - 4
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
WBPEEUI240751C0
Digital Inputs - FC 224
CH10 Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
CH11 Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
CH12 Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
WBPEEUI240751C0
WS7 - 5
Digital Inputs - FC 224
CH13 Channel Info:
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
CH14 Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
CH15 Channel Info:
WS7 - 6
____________________________________________________________
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
WBPEEUI240751C0
Digital Outputs - FC 225
CH16 Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Input:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" 125 VDC " LFP
" RFP
" 120 VAC " LFP
" RFP
" 240 VAC " LFP
" RFP
Digital Outputs - FC 225
CH17 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
CH18 Channel Info:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
CH19 Channel Info:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
WBPEEUI240751C0
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
WS7 - 7
Digital Outputs - FC 225
CH20 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
CH21 Channel Info:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
CH22 Channel Info:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
CH23 Channel Info:
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
WS7 - 8
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
WBPEEUI240751C0
Digital Outputs - FC 225
CH24 Channel Info:
_____________________________________________________________
Channel Label: ___________________________________________ (optional 32 characters max.)
Output:
Stall State:
WBPEEUI240751C0
" 24 VDC
" IFP/LFP
" RFP
" 48 VDC
" LFP
" RFP
" On (0)
" Off (1)
" Hold Output
WS7 - 9
WBPEEUI240751C0
DOT-100
WS8
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
NOTE: 24 VDC IFP or LFP is needed to power the output relay coils.
Digital Outputs - FC 225
CH1
CH2
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
WBPEEUI240751C0
" Hold Output
" Hold Ouput
WS8 - 1
Digital Outputs - FC 225
CH3
CH4
CH5
CH6
CH7
CH8
WS8 - 2
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
WBPEEUI240751C0
Digital Outputs - FC 225
CH9
CH10
CH11
CH12
CH13
CH14
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
WBPEEUI240751C0
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
WS8 - 3
Digital Outputs - FC 225
CH15
CH16
WS8 - 4
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
" Hold Output
" Hold Output
WBPEEUI240751C0
DOT-120
WS9
Block ID:
____________________________________________________________________
Location:
____________________________________
Column: _______
Row: _______
Device Label: _______________________________________________________ (32 characters max.)
Field Power Options
Internal Field Power (IFP):
! 24 VDC (always available)
Local Field Power (LFP):
" 24 VDC
" None
Field Power Selection:
" IFP
" LFP
NOTE: 24 VDC IFP or LFP is required to power the output relay coils.
Digital Outputs - FC 225
CH1
CH2
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
WBPEEUI240751C0
" Hold Output
" Hold Ouput
WS9 - 1
Digital Outputs - FC 225
CH3
CH4
CH5
CH6
CH7
CH8
WS9 - 2
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
WBPEEUI240751C0
Digital Outputs - FC 225
CH9
CH10
CH11
CH12
CH13
CH14
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
WBPEEUI240751C0
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
" Hold Output
WS9 - 3
Digital Outputs - FC 225
CH15
CH16
WS9 - 4
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
Channel Info:
____________________________________________________________
Channel Label:
_________________________________________ (optional 32 characters max.)
Output:
" Normally open
" Normally closed
Stall State:
" On (0)
" Off (1)
" Hold Output
" Hold Output
WBPEEUI240751C0
Hardware Drawings
Appendix A
Introduction
This section provides drawings showing dimensions for I/O
and auxiliary blocks.
I/O Block
Figures A-1 through A-3 are I/O block components: I/O module, nonredundant base, and redundant base.
D IM E N SIO N S
M IL LIM E TE R S
IN C H E S
162
6.38
76.2
3.00
266.0
10.47
T0 1104B
Figure A-1. I/O Module
WBPEEUI240751C0
A-1
I/O Block
D IM EN S IO N S
M ILLIM E TE R S
IN C H E S
137.6
5.42
169.2
6.66
267.1
10.51
T 0110 5B
Figure A-2. Nonredundant Base
A-2
WBPEEUI240751C0
I/O Block
D IM E N S IO N S
M IL LIM E T E R S
IN C H E S
1 6 9 .2
6 .6 6
2 1 6.6
8 .53
2 6 7.1
1 0 .5 1
T 01 45 1 A
Figure A-3. Redundant Base
WBPEEUI240751C0
A-3
Auxiliary Block
Auxiliary Block
Figure A-4 is the auxiliary block.
168.5
6.64
DIMENSIONS
MILLIMETERS
INCHES
143.6
5.65
266.0
10.47
T01440A
Figure A-4. Auxiliary Block
A-4
WBPEEUI240751C0
Installation Preparation
PR1
Purpose/Scope
Variable
This procedure gives steps that should be performed in preparation for I/O and auxiliary blocks installation.
Prerequisites
•
•
•
Block mounting hardware installed.
Block power connected.
Hnet components installed and connected.
Parts
None.
Tools
•
•
Block Power and Mounting Hardware instruction.
Harmony Communications Network (Hnet) instruction.
Procedure
For each Harmony I/O system enclosure, perform the following steps:
□
1. Verify the enclosure is prepared and ready for I/O and auxiliary blocks installation.
•
Cooling fan assembly, column mounting bars, and block
mounting columns installed in the enclosure.
•
24 VDC BLP and IFP power connected from the power system to each block mounting column.
•
Hnet connected from the controller to a mounting column
(primary enclosure only).
•
Hnet properly connected between the block mounting
columns.
•
Hnet terminators properly installed or connected.
•
Repeater mounting units with Hnet repeaters installed and
properly connected if required.
Refer to the Block Power and Mounting Hardware and Harmony Communications Network (Hnet) instructions if any of
WBPEEUI240751C0
PR1 - 1
I/O and Auxiliary Block Considerations
the previously listed items have not been completed before
beginning any I/O and auxiliary blocks installation.
□
2. Verify the internal enclosure locations for I/O and auxiliary
blocks to be installed. Refer to I/O and Auxiliary Block Considerations in this section.
□
3. Fill out the appropriate I/O block worksheets as necessary.
Information recorded on these worksheets is needed in the
installation procedures that follow.
NOTE: The worksheets are only intended to aid in the installation process. In
some cases, the information recorded on the worksheets may already be available or provided in some other form. In these cases, filling out the worksheets
is not necessary.
Table PR1-1 provides a listing of worksheets. The worksheets
are located towards the back of the instruction in the WS sections. Refer to I/O Block Worksheets in this section for more
information.
Table PR1-1. Worksheets
I/O Block
Worksheet
I/O Block
Worksheet
AIN-120
WS1
CIO-100
WS6
AIN-200
WS2
DIO-400
WS7
AIN-220
WS3
DOT-100
WS8
AIN-300
WS4
DOT-120
WS9
AOT-150
WS5
NOTE: Make copies of worksheets and maintain the originals in this instruction.
I/O and Auxiliary Block Considerations
Keep the following considerations in mind when locating I/O
and auxiliary blocks:
1. An enclosure can contain more than one repeater mounting unit. The units are typically located on the first column.
2. Position an auxiliary block directly above or below its I/O
block.
3. Install blank blocks in any empty slots to maintain air flow
through a block column. Blank blocks are not needed, however, to fill positions at the bottom of a column.
PR1 - 2
WBPEEUI240751C0
I/O Block Worksheets
4. When installing any nonredundant I/O blocks or auxiliary
blocks on a redundant column, locate the blocks at the bottom
of the column so that air flow through the redundant I/O modules of blocks is not disrupted in midstream.
I/O Block Worksheets
The number of input and output signals a single Harmony I/O
system will interface can be substantial. Worksheets for each
I/O block type are provided in this instruction to record block
related information to facilitate setup and installation
(Table PR1-1). Table PR1-2 describes the information recorded
in these worksheets and where it is used.
Table PR1-2. Worksheet Information
Information
Description
Where Used
Location
Physical location including
block column and row.
I/O block installation.
Device label
32-character label assigned to
the I/O block.
I/O block installation and controller configuration.
Field power option selected for
the I/O block
IFP or LFP
I/O block wiring and setup (i.e.,
jumper settings).
Field power option selected per IFP/LFP or RFP
channel
I/O block wiring and setup.
Channel label
Optional 32-character label
assigned to each I/O channel.
Controller configuration.
Input and output type
1 to 5 VDC, 4 to 20 mA, 10 Ω
copper RTD, etc.
I/O block wiring and setup.
WBPEEUI240751C0
PR1 - 3
WBPEEUI240751C0
I/O Block Base Installation
PR2
Purpose/Scope
5 min.
This procedure gives the steps required to install a termination
base for an I/O block. The procedure is the same whether
installing a nonredundant or redundant base. A redundant
base, however, requires a redundant mounting column.
Parts
None.
Tools
•
Phillips screwdriver.
Procedure
WBPEEUI240751C0
□
1. Verify the block location. I/O blocks can be located anywhere within an enclosure in any available, empty mounting
position.
□
2. Position the base on the mounting column. Insert the tabs
at the back, left side of the base into the slots in the column as
shown in Figure PR2-1. Tilt the base slightly to properly insert
the tabs. The base is properly positioned when the posts on
the back of the base line up with the alignment holes in the
column. The mounting column connectors should protrude
through the base.
□
3. Tighten the two captive screws to attach the base to the
column. A redundant base has four captive screws.
□
4. Verify the back of the base is flush with the mounting
column.
PR2 - 1
Procedure
R E A R V IE W
IN S E RT TA B S
IN S LO TS
A LIG N M E N T
H O LE S
C A P T IV E
FA S T E N IN G
SCREW S
T 0 091 0B
Figure PR2-1. Base Attachment
PR2 - 2
WBPEEUI240751C0
I/O Module Installation
PR3
Purpose/Scope
1 min.
This procedure gives the steps required to install an I/O module. The installation procedure is the same for all I/O modules.
Also, the procedure is the same whether installing modules on
redundant or nonredundant bases.
NOTE: Always follow the instructions given in Special Handling in Section 5
when handling an I/O module.
Parts
None.
Tools
•
Flat-blade or Phillips screwdriver.
Safety Considerations
1. An I/O module should not be inserted or removed with power
applied when located in a class I, division 2 hazardous location
unless the area is known to be nonhazardous.
WARNING
Procedure
□
1. Verify the block location. I/O modules are keyed to compatible bases to prevent a mismatch.
□
2. Grasp the retractable handle when inserting the I/O module. Insure the handle is extended completely so that the fastening screw does not stick out from the back of the module
(Fig. PR3-1).
□
W1
3. Position the I/O module on the base. The I/O module is
properly positioned when the posts protruding from the base
line up with the alignment holes on the back of the I/O
module.
NOTE: Do not use the fastening screw to align the I/O module.
□
WBPEEUI240751C0
4. Gently push the module in until the front of the base and
the front of the I/O module are flush. This should not require
PR3 - 1
Procedure
much pressure. If the I/O module cannot be pushed in flush
with the base, then either it is not properly aligned or it is not
compatible with the particular base.
□
5. Tighten the captive front panel fastening screw. The fastening screw actually threads into the mounting column and
not into the base. Do not overtighten.
AL IG N M EN T
PO S TS
FA ST E N IN G
SC R EW
R E TR AC TA BL E
H A N D LE
T 00 9 11 B
Figure PR3-1. I/O Module Attachment
PR3 - 2
WBPEEUI240751C0
Auxiliary Block Installation
PR4
Purpose/Scope
10 min.
This procedure gives the steps required to install an auxiliary
block. The installation procedure is the same for all auxiliary
blocks.
Parts
Number
200021A040S080
Tools
•
Qty
3
Description
M4 × 8-mm screw
Phillips screwdriver.
Procedure
□
1. Separate the auxiliary block housing from its mounting
bracket if required. Open the front panel door and loosen the
four captive screws that attach the housing to the bracket
(Fig. PR4-1).
□
2. Verify the block location. An auxiliary block can be located
directly above or below its associated I/O block.
□
3. Install the auxiliary housing bracket.
a. Position the bracket on the column by aligning the
posts on the back of the bracket with the alignment holes
in the column. The backplane connectors should protrude
through the back of the bracket when positioned properly.
b. Attach the bracket to the column using three M4
screws.
□
4. Attach the auxiliary housing.
a. Position the housing on the bracket by aligning the
posts on the back of the housing with the alignment holes
in the bracket.
b. Open the door and tighten the four captive screws to
fasten the housing to the bracket.
WBPEEUI240751C0
PR4 - 1
Procedure
A LIG N M E N T
HOLES
R E A R V IE W
C A P T IV E
FA S T E N IN G
S C R E W (4)
S C R E W (3)
T 00 9 62 B
Figure PR4-1. Auxiliary Block Installation
PR4 - 2
WBPEEUI240751C0
BLK-100 Installation
PR5
Purpose/Scope
5 min.
This procedure gives the steps required to install a blank block
(BLK-100) to fill empty block positions. Any empty positions
within a column of blocks must be filled to maintain airflow.
Blank blocks are not required, however, in empty positions at
the bottom of a column.
The procedure is the same whether installing a nonredundant
or redundant blank block. A redundant blank block, however,
requires a redundant mounting column.
Parts
None.
Tools
•
Flat-blade or Phillips screwdriver.
Procedure
□
1. Install the block base.
a. Position the base on the mounting column. Insert the
tabs at the back, left side of the base into the slots in the
column as shown in Figure PR5-1. The base is properly
positioned when the posts on the back of the base line up
with the alignment holes in the column. The mounting column connectors should protrude through the base.
b. Tighten the two captive screws to attach the base to the
column. A redundant base has four captive screws.
c. Verify the back of the base is flush with the mounting
column.
□
2. Install the blank module.
a. Grasp the retractable handle when inserting the blank
module. Insure the handle is extended completely so that
the fastening screw does not stick out from the back of the
module (Fig. PR5-2).
b. Position the blank module on the base. The module is
properly positioned when the posts protruding from the
WBPEEUI240751C0
PR5 - 1
Procedure
R E A R V IE W
IN S E RT TA B S
IN S LO TS
A LIG N M E N T
H O LE S
C A P T IV E
FA S T E N IN G
SCREW S
T 0 091 0B
Figure PR5-1. Base Attachment
base line up with the alignment holes on the back of the
module.
NOTE: Do not use the fastening screw to align the blank module.
c. Gently push the module in until the front of the base
and the front of the module are flush. This should not
require much pressure. If the module cannot be pushed in
flush with the base, then it is not properly aligned.
PR5 - 2
WBPEEUI240751C0
Procedure
AL IG N M EN T
PO S TS
FA ST E N IN G
SC R EW
R E TR AC TA BL E
H A N D LE
T 01 3 77 B
Figure PR5-2. Blank Module Attachment
d. Tighten the captive front panel fastening screw. The
fastening screw actually threads into the mounting column
and not into the base. Do not overtighten.
e. For a redundant block, repeat steps a through d for the
second blank module.
WBPEEUI240751C0
PR5 - 3
WBPEEUI240751C0
AIN-120 Setup
PR6
Purpose/Scope
15 min.
This procedure gives the steps required to set up the AIN-120
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS1.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Safety Considerations
1. For analog input channels, if the fused AI IFP/LFP option is
selected to power a 4 to 20 milliampere input, removing the I/O
module from the base in nonredundant applications will result
in a loss of power to all input current loops.
CAUTION
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
WBPEEUI240751C0
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module (Table PR6-1).
PR6 - 1
Procedure
Table PR6-1. Field Power Select Jumpers (Module)
Field Power
IFP
1
LFP
J1
J2
Description
1 2 3
1 2 3
Field power from mounting
column bus
1 2 3
1 2 3
Field power from LFP
terminals on base
NOTE:
1. Use this setting if all channels are RFP powered.
□
C1
4. Set the analog input field power select jumpers J17 and
J18 located on the AIN-120 base (Table PR6-2). These jumpers
affect channels configured as IFP or LFP powered 4 to 20 milliampere inputs. Refer to Figure PR6-1 for jumper locations.
Table PR6-2. Analog Input Field Power Select Jumpers (Base)
Field Power
J17
J18
Fused AI
IFP/LFP1
1 2 3
1 2 3
Unfused AI
LFP2,3
1 2 3
1 2 3
Description
Routes IFP/LFP field power
through the fuse in the I/O
module.
Routes LFP power directly to
the base terminals.
NOTES:
1. This option can be selected to provide fused IFP or LFP power to the analog input channels;
however, removing the I/O module from the base in a nonredundant application will result in a loss
of power to all input current loops.
2. Use this setting if current loop power must be maintained when the I/O module is removed from
the base in nonredundant applications.
3. Use this setting if analog inputs are RFP powered. Use this option if stations are connected.
Figure PR6-2 shows the field power connections made with
jumpers J17 and J18.
□
5. Set the input channel jumpers located on the AIN-120 base
(Table PR6-3). Refer to Figure PR6-1 for jumper locations.
Table PR6-3. Input Channel Jumpers
Input
4 to 20 mA
Field
Power
n1-J1
n1-J2
IFP/LFP
3 2 1
3 2 1
RFP
3 2 1
3 2 1
3 2 1
3 2 1
Differential high level RFP
voltage
PR6 - 2
WBPEEUI240751C0
Procedure
Table PR6-3. Input Channel Jumpers (continued)
Input
Single-ended high
level voltage
Field
Power
RFP
n1-J1
n1-J2
3 2 1
3 2 1
NOTE:
1. n corresponds to the channel number from 1 to 16. For example, 1-J1
and 1-J2 configure channel one.
WBPEEUI240751C0
□
6. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
7. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
□
8. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
PR6 - 3
Procedure
1 -J 1
1 -J 2
2 -J 1
2 -J 2
3 -J 1
3 -J 2
4 -J 1
4 -J 2
5 -J 1
5 -J 2
6 -J 1
6 -J 2
7 -J 1
7 -J 2
8 -J 1
8 -J 2
9 -J 1
9 -J 2
1 0 -J 1
1 0 -J 2
1 1 -J 1
1 1 -J 2
1 2 -J 1
1 2 -J 2
1 3 -J 1
1 3 -J 2
1 4 -J 1
1 4 -J 2
1 5 -J 1
1 5 -J 2
1 6 -J 1
1 6 -J 2
J 17
J 18
T 01 41 0 A
Figure PR6-1. User-Configurable Jumpers - Base
PR6 - 4
WBPEEUI240751C0
Field Device Connection
I/O B L O C K
+
ANALOG
IN P U T
CHANN ELS –
J1 7
+
LF P
–
+
1 2 3
J18
1 2 3
IFP /L FP
–
+
L FP
–
BASE
I/O M O D U LE
T 0141 3B
Figure PR6-2. Analog Input Field Power Selection (J17/J18)
Field Device Connection
Figure PR6-4 shows the circuit connections made after attaching field wiring and setting jumpers.
WBPEEUI240751C0
PR6 - 5
Field Device Connection
+24 V
T R AN S M IT T ER
IN T ER N AL/L O C A L
F IEL D PO W ER E D
+24 V
4-20 m A
+
+
M E AS U R ED
IN P U T
1-5 V
_
_
COMMON
+24 V
+24 V D C
T R AN S M IT T ER
+
+
R E M OT E F IELD
PO W ER E D
M E AS U R ED
IN P U T
1-5 V
4-20 m A
_
_
COMMON
+24 V
+
SIN G L E-EN D E D
VO LTAG E
VSOURCE
+
M E AS U R ED
IN P U T
+ 10 V
_
_
COMMON
+24 V
+
D IF F ER E N T IAL
VO LTAG E
VSOURCE
+
M E AS U R ED
IN P U T
+ 10 V
_
_
T 00 82 5 B
Table PR6-4. Analog Input (Simplified)
PR6 - 6
WBPEEUI240751C0
AIN-200 Setup
PR7
Purpose/Scope
10 min.
This procedure gives the steps required to set up the AIN-200
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS2.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Verify the field power select jumpers J1 and J2 located on
the back of the I/O module are set as shown in Table PR7-1.
Table PR7-1. Field Power Select Jumpers
Field Power
IFP
WBPEEUI240751C0
J1
1 2 3
J2
1 2 3
Description
Field power from mounting
column bus
□
4. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
5. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
PR7 - 1
Field Device Connection
□
6. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
Field Device Connection
Figure PR7-1 shows the circuit connections made after attaching field wiring.
+
D IF FE R E N T IA L
VO LTAG E
VSOURCE
+
M EASURED
IN P U T
± 10 V O R
± 1 00 m V
–
–
R L EA D 1
+
+
M EASURED
IN P U T
THERM OCOUPLE
–
R LE AD 2
–
T00 826B
Figure PR7-1. Analog Input (Simplified)
PR7 - 2
WBPEEUI240751C0
AIN-220 Setup
PR8
Purpose/Scope
15 min.
This procedure gives the steps required to set up the AIN-220
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS3.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Safety Considerations
1. For analog input channels, if the fused AI IFP/LFP option is
selected to power a 4 to 20 milliampere input, removing the I/O
module from the base in nonredundant applications will result
in a loss of power to all input current loops.
CAUTION
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
WBPEEUI240751C0
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module (Table PR8-1).
PR8 - 1
Procedure
Table PR8-1. Field Power Select Jumpers (Module)
Field Power
IFP
1
LFP
J1
J2
Description
1 2 3
1 2 3
Field power from mounting
column bus
1 2 3
1 2 3
Field power from LFP
terminals on base
NOTE:
1. Use this setting if all channels are RFP powered.
□
C1
4. Set the analog input field power select jumpers J17 and
J18 located on the AIN-220 base (Table PR8-2). These jumpers
affect channels configured as IFP or LFP powered 4 to 20 milliampere inputs. Refer to Figure PR8-1 for jumper locations.
Table PR8-2. Analog Input Field Power Select Jumpers (Base)
Field Power
J17
J18
Fused AI
IFP/LFP1
1 2 3
1 2 3
Unfused AI
LFP2,3
1 2 3
1 2 3
Description
Routes IFP/LFP field power
through the fuse in the I/O
module.
Routes LFP power directly to
the base terminals.
NOTES:
1. This option can be selected to provide fused IFP or LFP power to the analog input channels;
however, removing the I/O module from the base in a nonredundant application will result in a loss
of power to all input current loops.
2. Use this setting if current loop power must be maintained when the I/O module is removed from
the base in nonredundant applications.
3. Use this setting if analog inputs are RFP powered. Use this option if stations are connected.
Figure PR8-2 shows the field power connections made with
jumpers J17 and J18.
□
5. Set the input channel jumpers located on the AIN-220 base
(Table PR8-3). Refer to Figure PR8-1 for jumper locations.
Table PR8-3. Input Channel Jumpers
Input
4 to 20 mA
Field
Power
n1-J1
n1-J2
IFP/LFP
3 2 1
3 2 1
RFP
3 2 1
3 2 1
3 2 1
3 2 1
Differential high level RFP
voltage
PR8 - 2
WBPEEUI240751C0
Procedure
Table PR8-3. Input Channel Jumpers (continued)
Input
Field
Power
n1-J1
n1-J2
Single-ended high
level voltage
RFP
3 2 1
3 2 1
Thermocouple
RFP
3 2 1
3 2 1
NOTE:
1. n corresponds to the channel number from 1 to 16. For example, 1-J1
and 1-J2 configure channel one.
WBPEEUI240751C0
□
6. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
7. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
□
8. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
PR8 - 3
Procedure
1 -J 1
1 -J 2
2 -J 1
2 -J 2
3 -J 1
3 -J 2
4 -J 1
4 -J 2
5 -J 1
5 -J 2
6 -J 1
6 -J 2
7 -J 1
7 -J 2
8 -J 1
8 -J 2
9 -J 1
9 -J 2
1 0 -J 1
1 0 -J 2
1 1 -J 1
1 1 -J 2
1 2 -J 1
1 2 -J 2
1 3 -J 1
1 3 -J 2
1 4 -J 1
1 4 -J 2
1 5 -J 1
1 5 -J 2
1 6 -J 1
1 6 -J 2
J 17
J 18
T 01 41 0 A
Figure PR8-1. User-Configurable Jumpers - Base
PR8 - 4
WBPEEUI240751C0
Field Device Connection
I/O B LO C K
+
A N A LO G
IN P U T
CHANNELS –
J1 7
+
LF P
–
+
1 2 3
J1 8
1 2 3
IFP /LF P
–
+
LF P
–
BASE
I/O M O D U LE
T0141 3B
Figure PR8-2. Analog Input Field Power Selection (J17/J18)
Field Device Connection
Figure PR8-3 shows the circuit connections made after attaching field wiring and setting jumpers.
WBPEEUI240751C0
PR8 - 5
Field Device Connection
+24 V
T R A N S M IT TE R
+24 V
IN T E R N A L/LO C A L
FIE LD P O W E R E D
4 -2 0 m A
+
+
M EASURED
IN P U T
1-5 V
–
–
COMMON
+24 V
+24 V D C
T R A N S M IT T E R
+
R E M O TE F IE LD
POW ERED
+
M EASURED
IN P U T
1 -5 V
4 -2 0 m A
–
–
COMMON
+24 V
+
S IN G LE -E N D E D
VO LTAG E
VSOURCE
+
± 10 V O R
± 10 0 m V
MEASU RED
IN P U T
–
–
COMMON
+ 24 V
+
D IFF E R E N TIA L
VO LTAG E
VSOURCE
+
MEASUR ED
IN P U T
± 10 V OR
± 1 00 m V
–
–
+ 24 V
R LE AD 1
+
+
MEASUR ED
IN P U T
THERMO COUPLE
–
R LE AD 2
–
T 0082 4C
Figure PR8-3. Analog Input (Simplified)
PR8 - 6
WBPEEUI240751C0
AIN-300 Setup
PR9
Purpose/Scope
5 min.
This procedure gives the steps required to set up the AIN-300
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS4.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Verify the field power select jumpers J1 and J2 located on
the back of the I/O module are set as shown in Table PR9-1.
Table PR9-1. Field Power Select Jumpers
Field Power
IFP
WBPEEUI240751C0
J1
1 2 3
J2
1 2 3
Description
Field power from mounting
column bus
□
4. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
□
5. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
PR9 - 1
Field Device Connection
□
6. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
Field Device Connection
Figure PR9-1 shows the circuit connections made after attaching field wiring.
–
3 -W IR E R TD
+
M E AS U R E D
IN P U T
+
–
C
CO MM O N
T 00 8 27 A
Figure PR9-1. Analog Input (Simplified)
PR9 - 2
WBPEEUI240751C0
AOT-150 Setup
PR10
Purpose/Scope
5 min.
This procedure gives the steps required to set up the AOT-150
block for proper operation. This includes setting jumpers and
switches, and checking for fuses.
Prerequisites
•
Completed worksheet WS5.
Parts
None.
Tools
•
•
Small-tipped, flat-blade screwdriver.
Needlenose pliers (optional).
Procedure
□
1. Set the special operations switch SW2 located on the back
of the I/O module to normal operation.
8 7 6 5 4 3 2 1
ON
O FF
T00 8 84 A
□
2. Determine the block field power and I/O channel requirements. Refer to the appropriate worksheet or any other system
documentation available.
□
3. Set the field power select jumpers J1 and J2 located on the
back of the I/O module as appropriate (Table PR10-1).
Table PR10-1. Field Power Select Jumpers
Field Power
□
WBPEEUI240751C0
J1
J2
Description
IFP
1 2 3
1 2 3
Field power from mounting
column bus
LFP
1 2 3
1 2 3
Field power from LFP
terminals on base
4. Verify 1.6 A, 250 V fuses are present in both the A and B
channel block power fuse holders on the I/O module.
PR10 - 1
Field Device Connection
□
5. Verify a 3.15 A, 250 V fuse is present in the field power fuse
holder.
□
6. If installing redundant I/O modules, insure the settings for
both I/O modules are the same.
Field Device Connection
Figure PR10-1 shows the circuit connections made after
attaching field wiring.
+24 V
+
4 -2 0 m A
LOAD
IN T ER N AL/L O C A L
FIEL D PO W ER E D
–
CO MM O N
T 00 83 0 A
Figure PR10-1. Analog Output (Simplified)
PR10 - 2
WBPEEUI240751C0
Index
A
AIN-120 .................................................... 2-1
Redundancy........................................... 4-3
Setup ................................................ PR6-1
Wiring..................PR19-1, PR20-1, PR21-1
AIN-200 .................................................... 2-2
Redundancy........................................... 4-3
Setup ................................................ PR7-1
Wiring..................PR19-1, PR20-1, PR21-1
AIN-220 .................................................... 2-4
Redundancy........................................... 4-3
Setup ................................................ PR8-1
Wiring..................PR19-1, PR20-1, PR21-1
AIN-300 .................................................... 2-5
Redundancy........................................... 4-3
Setup ................................................ PR9-1
Wiring..................PR19-1, PR20-1, PR21-1
AOT-150 ................................................... 2-6
Redundancy........................................... 4-4
Setup .............................................. PR10-1
Wiring..................PR19-1, PR20-1, PR21-1
Auxiliary block......................................... 3-24
Available types....................................... 1-4
Block descriptions.................................. 2-1
CIO-110 ............................................... 2-12
Considerations.................................. PR1-2
Front panel............................................. 7-9
General specifications ......................... 1-16
Hardware drawing..................................A-4
Installation.................................. 5-3, PR4-1
Removal.......................................... PR30-1
Replacement........................................ 10-1
RLY-100............................................... 2-17
RLY-200............................................... 2-18
Specifications......................................... 2-1
Startup ................................................... 7-9
B
Base ....................................................... 3-15
Cable connection ................... 3-18, PR21-1
Clamp terminal wiring ..................... PR20-1
WBPEEUI240751C0
Clamp terminals (C type) .....................3-15
Color coding and markings ....................7-6
Ground plate ........................................3-19
Installation .........................................PR2-1
Removal ..........................................PR29-1
Replacement ........................................10-1
Screw terminal wiring ......................PR19-1
Screw terminals (S type) ......................3-15
Blank block installation.........................PR5-1
BLK-100 ....................................................2-7
Block power...............................................3-8
C
Cable connections
CIO..................................................PR17-1
RLY .................................................PR18-1
Termination base ............................PR21-1
Channel label ............................................6-6
CIO-100.....................................................2-8
Cable connection ............................PR17-1
Setup...............................................PR11-1
Wiring ................. PR19-1, PR20-1, PR21-1
CIO-110...................................................2-12
Cable connection ............................PR17-1
Setup...............................................PR15-1
Wiring ..............................................PR22-1
Compatibility with INFI 90 OPEN ..............1-8
Configuration......................................PR26-1
Alarming ...............................................6-15
Changes .................................................6-2
Controller................................................6-1
Download ...............................................6-1
Engineering units .................................6-13
Exception reporting ..............................6-13
Function codes .......................................6-7
I/O source.............................................6-14
Requirements.......................................3-24
Status reporting....................................6-15
Tools ......................................................6-1
Verification .............................................6-2
Connections check.............................PR27-1
Index - 1
Index (continued)
D
Design standards ....................................1-14
Device label...............................................6-4
Definition .........................................PR25-1
Diagnostics..............................................8-12
Digital channel indicators ..........................7-4
DIO-400 ..................................................2-13
Redundancy ....................................4-7, 4-9
Setup...............................................PR12-1
Wiring ................. PR19-1, PR20-1, PR21-1
Documentation
Conventions ................................1-12, 1-13
Harmony I/O...........................................1-1
How to use ...........................................1-11
Intended user .........................................1-9
Reference.............................................1-13
DOT-100 .................................................2-15
Redundancy ...........................................4-9
Relay replacement ..........................PR32-1
Setup...............................................PR13-1
Wiring ................. PR19-1, PR20-1, PR21-1
DOT-120 .................................................2-16
Redundancy ...........................................4-9
Relay replacement ..........................PR32-1
Setup...............................................PR14-1
Wiring ................. PR19-1, PR20-1, PR21-1
E
Engineering units ....................................6-13
Exception reporting .................................6-13
F
Failure modes, outputs............................3-20
Hnet stall mode ....................................6-15
FAULT indicator ........................................7-2
Features ....................................................1-8
Field power indicator .................................7-4
Firmware download...................................6-3
Flowcharts
I/O and auxiliary block installation..........5-3
Index - 2
Replacement ....................................... 10-1
Function codes .................................. 1-8, 6-7
I/O channel ............................................ 6-9
I/O device definition ............................... 6-8
Test status ........................................... 6-16
G
Glossary ................................................. 1-12
H
Hardware drawing
Auxiliary block........................................ A-4
I/O block ................................................ A-1
Harmony controller
Configuration ......................................... 6-1
Function codes ...................................... 1-8
Harmony Area Controller ....................... 1-7
Harmony Bridge Controller (BRC-100) .. 1-5
How to use this instruction...................... 1-11
I
I/O block ............................................ 3-6, 7-1
AIN-120 ................................................. 2-1
AIN-200 ................................................. 2-2
AIN-220 ................................................. 2-4
AIN-300 ................................................. 2-5
AOT-150 ................................................ 2-6
Available types ...................................... 1-4
BLK-100................................................. 2-7
Block descriptions.................................. 2-1
Block power indicators........................... 7-3
CIO-100 ................................................. 2-8
Connector pin assignments ................. 8-13
Considerations.................................. PR1-2
Device label ........................................... 6-4
Digital channel indicators....................... 7-4
DIO-400 ............................................... 2-13
DOT-100.............................................. 2-15
DOT-120.............................................. 2-16
Electronic ID .......................................... 6-4
WBPEEUI240751C0
Index (continued)
Field power indicator.............................. 7-4
General specifications ......................... 1-16
Hardware drawings ................................A-1
Initialization ............................................ 7-8
Installation.............................................. 5-3
Operating mode ..................................... 7-2
Problem reports ..................................... 8-6
Replacement........................................ 10-1
Specifications......................................... 2-1
Startup ................................................... 7-7
Status..................................................... 7-2
Status reports ...................................... 8-11
Stop/reset .............................................. 7-7
Type and model ..................................... 7-1
I/O channel, FC 222, 223, 224, 225 ......... 6-9
I/O device definition, FC 221 .................... 6-8
I/O module ................................................ 3-7
Front panel............................................. 7-1
Installation......................................... PR3-1
Rear panel ............................................. 7-5
Removal.......................................... PR28-1
Replacement........................................ 10-1
IISAC01 station
Problem report ....................................... 8-9
Indicators
Block power ........................................... 7-3
Digital channel ....................................... 7-4
FAULT ................................................... 7-2
Field power ............................................ 7-4
NORMAL ............................................... 7-2
Status.............................................. 7-2, 8-2
Initialization ............................................... 7-8
Input/output
Analog IN ............................................... 3-1
Analog OUT ........................................... 3-3
Channel data ....................................... 6-11
Digital IN ................................................ 3-4
Digital OUT ............................................ 3-5
I/O source ............................................ 6-14
Inputs/output ............................................. 3-1
Installation ................................................ 5-1
Auxiliary block........................................ 5-3
WBPEEUI240751C0
I/O block .................................................5-3
Parts numbers and nomenclature ........11-1
Installation preparation.........................PR1-1
Instruction content...................................1-10
Intended user ............................................1-9
J
Jumpers
AIN-120 .............................................PR6-1
AIN-200 .............................................PR7-1
AIN-220 .............................................PR8-1
AIN-300 .............................................PR9-1
AOT-150..........................................PR10-1
CIO-100...........................................PR11-1
CIO-110...........................................PR15-1
DIO-400...........................................PR12-1
DOT-100 .........................................PR13-1
DOT-120 .........................................PR14-1
L
Labels........................................................6-3
Channel..................................................6-6
Device ....................................................6-4
Duplicate ................................................6-6
Front panel .............................................7-5
M
Machine fault timer..................................3-12
Maintenance..............................................9-1
Memory ...................................................3-11
N
Nomenclature
Abbreviated ..........................................1-13
Auxiliary blocks ....................................11-1
Cables ..................................................11-4
I/O blocks .............................................11-1
Related equipment ...............................1-14
NORMAL indicator ....................................7-2
Index - 3
Index (continued)
O
Offline diagnostics..............................PR24-1
P
Part numbers and nomenclatures ...........11-1
Preventive maintenance schedule ............9-1
Problem report
I/O block .................................................8-6
IISAC01 station ......................................8-9
Procedure
AIN-120 setup ...................................PR6-1
AIN-200 setup ...................................PR7-1
AIN-220 setup ...................................PR8-1
AIN-300 setup ...................................PR9-1
AOT-150 setup................................PR10-1
Auxiliary block installation .................PR4-1
Auxiliary block removal ...................PR30-1
Base installation ................................PR2-1
Base removal ..................................PR29-1
Blank block installation......................PR5-1
CIO cable connection......................PR17-1
CIO-100 setup.................................PR11-1
CIO-110 setup.................................PR15-1
Connections check..........................PR27-1
Device label definition .....................PR25-1
DIO-400 setup.................................PR12-1
DOT-100 setup................................PR13-1
DOT-100/120 relay replacement.....PR32-1
DOT-120 setup................................PR14-1
I/O module installation.......................PR3-1
I/O module removal.........................PR28-1
I/O system configuration .................PR26-1
Installation preparation......................PR1-1
Offline diagnostics ...........................PR24-1
RLY cable connection .....................PR18-1
RLY-100 relay replacement ............PR33-1
RLY-200 relay replacement ............PR34-1
RLY-200 setup ................................PR16-1
Wiring and cabling disconnection....PR31-1
Wiring, cable connection .................PR21-1
Wiring, CIO-110 block .....................PR22-1
Index - 4
Wiring, clamp terminal base ........... PR20-1
Wiring, RLY-100/200 block ............. PR23-1
Wiring, screw terminal base ........... PR19-1
R
Redundancy .................................... 3-20, 4-1
Relay replacement.................................. 10-1
DOT-100......................................... PR32-1
DOT-120......................................... PR32-1
RLY-100 ......................................... PR33-1
RLY-200 ......................................... PR34-1
Repair ..................................................... 10-1
Replacement procedures ....................... 10-1
Reset ........................................................ 7-7
RLY-100 ................................................. 2-17
Cable connection............................ PR18-1
Relay replacement.......................... PR33-1
Wiring ............................................. PR23-1
RLY-200 ................................................. 2-18
Cable connection............................ PR18-1
Relay replacement.......................... PR34-1
Setup .............................................. PR16-1
Wiring ............................................. PR23-1
S
Serial links .............................................. 3-12
Redundancy ........................................ 3-13
Station ................................................. 3-13
Shaping algorithms................................. 6-16
Specifications ......................................... 1-16
Station, IISAC01 .......................2-8, 3-13, 8-9
Status indicators ................................ 7-2, 8-2
Stop/reset ................................................. 7-7
Suspect................................................... 6-11
Switch, special operations (SW2).... 3-15, 7-5
System overview ...................................... 1-2
T
Test status, FC 226 ................................ 6-16
Time synchronization................................ 6-3
WBPEEUI240751C0
Index (continued)
Troubleshooting ........................................ 8-1
W
Wiring
Cable connection ............................ PR21-1
WBPEEUI240751C0
CIO-110 block .................................PR22-1
Clamp terminal base .......................PR20-1
RLY-100/200 block..........................PR23-1
Screw terminal base........................PR19-1
Worksheets ..........................................PR1-3
Index - 5
WBPEEUI240751C0
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Form WBPEEUI240751C0 Litho in U.S.A. 699
Copyright © 1999 by ABB Automation Inc., as an Unpublished Work
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