ROSS CONTROLS® • ROSS CONTROLS® • ROSS CONTROLS® Installation & Service Instructions A10330 W66 Size 0 & W66 Size 00 ISO 15407-1 Subbase & Manifold Assembly ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Subbase Assembly Torque: Valve to Base Size 00 - 10 to 12 in.lb. (1.1 to 1.3 Nm) Size 0 - 15 to 18 in.lb. (1.7 to 2.0 Nm) 12 ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Pin 2 Pin 4 Pin 3 4-Pin M12 Wiring Type Pin #1 Pin #2 Pin #3 Pin #4 ISO N/A 12 Com 14 Service Kits Kit Number RPEJ02-02-80 RPEJ02-02-70 RPEJ01-03-80 RPEJ01-03-70 RD02P-01-80 RD01P-02-80 RD02BD0 Introduction RD01BD0 Follow these instructions when installing, operating, or servicing the product. RDX02BLK RDX01BLK Application Limits RDX02M2MB* These products are intended for use in general purpose compressed air systems only. Compliance with the rated pressure, temperature, and voltage is necessary - see Installation & Service Instructions packed with valve. 14 Pin 1 ! WARNING Air exhausting from one valve into the exhaust gallery of the manifold assembly may momentarily pressurize other valve circuits open to the same gallery. Design the circuit such that there is no hazard or consequence of damage from this action. 4 Wiring - ISO 20401 Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. 2 RDX02M2MGSKT RDX01M2MGSKT Description Items Included (Qty) 18mm End Plate Kit, 1/4" NPT 18mm End Plate Kit, 1/4" BSPP 1 (1), 2 (1), 4 (2) 5 (2), 6 (1), 7 (2) 26mm End Plate Kit, 3/8" NPT 26mm End Plate Kit, 3/8" BSPP 18mm Intermediate Air Supply Base Kit, Not Shown 1/8" NPT 26mm Intermediate Air Supply Base Kit, Not Shown 1/4" NPT 18mm Manifold Port Not Shown (3 per Kit) Isolation Disc Kit 26mm Manifold Port Not Shown (3 per Kit) Isolation Disc Kit 18mm Blanking Plate Kit Not Shown 26mm Blanking Plate Kit Not Shown Manifold to Manifold 4 (10), 5 (10), 7 (10) Bolt Kit 02 Manifold to Manifold Gasket Kit 01 Manifold to Manifold Gasket Kit * Use this Number for both sizes, RPJLP02 & RPJLP01. W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation 4 7 5 7 4 5 5 6 7 5 4 7 4 2 5 1 3 7 4 2 5 3 7 4 2 Size 0 Manifold Assembly 4 Torque - Item Number 5 25 to 35 in-lb (2.82 to 3.95 Nm) 7 5 7 4 5 5 7 4 2 5 6 4 4 1 7 2 5 2 3 4 7 2 4 5 1 3 4 2 7 Size 00 Manifold Assembly Manifold to Manifold Assembly 1. Lay Right End Plate (when looking at Cylinder Ports) Port Side down. 2. Place Gasket in gasket track and Retaining Nut in slot. 3. Place Manifold on top and tighten using Screw and Washer (both sides). 4. Repeat Steps 2 and 3 until all manifold slices are assembled. 5. Attach Left End Plate. 6. Lay Manifold on flat surface and check for straightness. Tighten all bolts per torque specifications. Item Number Description 1 Left End Plate 2 Gasket 3 Manifold 4 Retaining Nut 5 Screw 6 Right End Plate 7 Washer For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0807 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10330 Installation & Service Instructions A10326 Size 0 (26mm) & Size 00 (18mm) ISO 15407 Valve Service ALERT: Remove Control 12 & 14 Pipe Plugs in Subbase or Manifold Before Installing Valve. ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Safety Guide ISSUED: June, 2013 Supersedes: August, 2007 issue NOTE: The operator identification describes the ports that are connected when the operator is energized: operator 12 connects Port 1 to Port 2; operator 14 connects Port 1 to Port 4. Other ports may also be connected, or blocked – see symbols on the valve. ! CAUTION: It is recommended that double solenoid and double remote air pilot operated 2-Position valves be mounted so that the axis of the valve spool is in the horizontal plane. Lubrication Factory Pre-lubed. If lubricating in service, use paraffin based mineral oil with 150 to 200 SSU viscosity @100°F. CAUTION: Do not use oils that are synthetic, reconstituted, ! have an alcohol content or a detergent additive. Application Limits These products are intended for use in general purpose compressed air systems only. Operating Pressure Range: For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Maximum: 145 PSIG (1000 kPa) Minimum: See Chart ! WARNING Internal Pilot FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Single Solenoid - 2-Position Double Solenoid- 2-Position Single Remote - 2-Position Double Remote Pilot - 2-Position Double Solenoid - 3-Position Double Remote Pilot - 3-Position Single Solenoid - 2-Position Air Return / Spring Assist Single Remote Pilot - 2-Position Air Return / Spring Assist External Pilot * Size 0 & Size 00 Series Min. PSIG (kPa) Size 0 Min. PSIG (kPa) Size 00 25 (173) 25 (173) Vacuum Vacuum 35 (241) Vacuum Vacuum Vacuum 35 (241) Vacuum 30 (207 30 (207) Vacuum Vacuum * External Pilot Pressure / Remote Pilot Signal - 45 to 145 PSIG (310 to 1000 kPa). Introduction Follow these instructions when installing, operating, or servicing the product. Ambient Temperature Range: -15°C to 49°C (5°F to 120°F) Voltage Range: Rated Voltage +10%, -15% Port Identification / Connections / Symbols Port Single Dual No. Pressure Pressure 1 Inlet Exhaust 2 Outlet Outlet 3 Exhaust Inlet 4 Outlet Outlet 5 Exhaust Inlet 12, 14 Pilot ports for External Pilot or Remote Pilot ! CAUTION: Solenoid versions of this valve contain solid 4 2 14 4 2 12 51 3 5 Port, 3-Position Power Center 4 2 4 2 12 14 51 3 5 Port, 3-Position Closed Center 12 14 5 1 3 5 Port, 2-Position 12 14 5 1 3 5 Port, 3-Position Open Center Valves may be used for single outlet (3-Way) by plugging an outlet Port. state components that can be damaged by transient voltage spikes, over-voltage or high temperature. To protect against premature solenoid failure, please read and adhere to the following: If this solenoid operated valve is used in a circuit with other inductive loads, the solenoid should be electrically protected with a voltage suppression device (e.g. transient voltage suppressor or varistor) that has a minimum rating of 1.6 times the rated voltage of the solenoid valve and sufficient capacity to dissipate the energy of other inductive loads. www.rosscontrols.com 1 Series W66 Size 0 (26mm) & Series W66 Size 00 (18mm) ISO 15407 Valve Service 8. Install Base Gasket (19) onto pin on bottom of valve. For ! CAUTION: Solenoid versions of this valve are to be earth Internal Pilot Pressure, be sure the letters “I” are visible. For grounded through the direct metal to metal contact External Pilot Pressure, be sure the letters “X” are visible. of the valve body to an appropriately grounded metal See the valve to base gasket drawings below. mounting surface. Note: After servicing the valve in any way, apply pressure to the valve and check for leaks. If any leak exists, repeat assembly process and retest until valve is leak free. Servicing Valve Body Refer to Figures 1 and 2 to aid with disassembly and reassembly. 1. Remove Valve from base by removing Body to Base Screws (20). 2. For ISO 15407-2: Remove Connector (14) by carefully gripping the pins with a needle nose pliers and pull to remove. For ISO 15407-1: Go directly to Step 3. 3. Remove each End Cap (13 / 17 / 18) by removing the Screws (16). 4. Remove the Pistons (9 or 10), Spool Return Spring (22), if applicable, and the Spool (3, 5, 6 or 7), being careful not to scratch the valve body bore. 5. Using a clean, lint free cloth, clean sealing surfaces. 6. Apply a light coating of grease to each part noted in Figure 1 and the mating sealing surface of each of these parts. 7. Reassemble valve in reverse order of disassembly, replacing the necessary parts. Care must be taken when reassembling the End Caps. Install Item 14 Connector after Item 13 Operator End Cap is installed on the Body. Note pin kink orientation in Figure 1. Item 1 2 3 4 5 6 7 8 9 10 11 12 Description Item Body, Single Solenoid Body, Double Solenoid Spool - 2-Position (Seals Assembled) Seal - Spool Spool - 3-Position CC (Seals Assembled) Spool - 3-Position OC (Seals Assembled) Spool - 3-Position PC (Seals Assembled) Seal, Operator Piston Operator Piston, 2-Position Operator Piston, 3-Position End Cap Gasket Solenoid / Circuit Board Assy 13 14 15 16 17 13 12 11 15 9 Note: Pins with kinks face away from body. 16 (See Torque Chart) 4 13 14 Remove before attempting to remove Item13 from Item 1, Body 12 8 11 1 3 17 22 19 20 (See Torque Chart) 11 21 4 2 11 8 9 8 14 Double Remove before attempting to remove Item13 from Item 1, Body 12 16 (See Torque Chart) Single Solenoid, 2-Position, ISO 15407-2 15 Note: Pins with kinks face away from body. 16 (See Torque Chart) 13 3 9 Solenoid, 2-Position, ISO 15407-2 20 (See Torque Chart) 11 2 12 4 5 4 6 4 7 CE 15 10 8 19 8 10 PC 14 Remove before attempting to remove Item13 from Item 1, Body Double Solenoid, 3-Position, ISO 15407-2 Figure 1 2 18 16 (See Torque Chart) 19 21 11 12 APB Note: Pins with kinks face away from body. 19 20 21 22 23 24 Lightly grease with provided lubricant. Inspect for nicks, scratches, and surface imperfections. If present, reduced service life is probable and future replacement should be planned. Clean with lint-free cloth. 20 (See Torque Chart) 16 (See Torque Chart) 18 Description Solenoid Operator End Cap Connector O-Ring Screws, Operator to Body Return Operator End Cap, Single Solenoid Return Operator End Cap, Double Solenoid Body to Base Gasket Screws, Body to Base Connector, 2-Pin Spool Return Spring M12 Insert Assembly O-Ring © 2013 ROSS CONTROLS®. All Rights Reserved. 18 16 (See Torque Chart) Series W66 Size 0 (26mm) & Series W66 Size 00 (18mm) ISO 15407 Valve Service 16 (See Torque Chart) 20 (See Torque Chart) 23 18 12 11 4 9 8 16 (See Torque Chart) 24 11 1 3 17 22 19 Single Solenoid, ISO 15407-1 16 (See Torque Chart) 20 (See Torque Chart) 23 18 12 11 2 4 11 8 9 8 18 16 (See Torque Chart) 18 16 (See Torque Chart) 24 3 12 9 19 Double Solenoid, ISO 15407-1 16 (See Torque Chart) 20 (See Torque Chart) 23 18 12 11 24 2 11 12 APB 4 5 4 6 4 7 CE 10 8 19 8 10 PC Double Solenoid, 3-Position, ISO 15407-1 Figure 2 Valve Mounting Torque Specifications (Item 20) Body Service Kits Valve Kit Number Description Kit Includes (Qty) Valve to Base W66 Size 0 W66 Size 00 Size 0 Size 00 RPS5501P RPS5601P 2-Position Body Service Kit All parts below plus Return Spring (1) Torque - in.lb. (Nm) 15 to 18 (1.7 to 2.0) 10 to 12 (1.1 to 1.3) Size 0 Size 00 RPS5502P RPS5602P 3-Position CC Body Service Kit Spool (1) Size 0 Size 00 RPS5503P RPS5603P 3-Position OC Body Service Kit Piston Assembly (2) Grease Tube (1) Size 0 Size 00 RPS5504P RPS5604P 3-Position PC Body Service Kit Accessory Kits Operator Cap to Body Torque Specifications (Item 16 ) Cap to Body W66 Size 0 / W66 Size 00 Torque - in.lb. (Nm) 5 to 7 (.6 to .80) Valve to Base Gaskets Valve Kit Number Description (Qty) Size 0 Size 00 RPS5587P RPS5687P Valve Bolt Kit 12 Size 0 Size 00 RPS5505P RPS5605P Body to Base Gasket Kit – Standard 5 Size Part Number Size 0 RPS5605P Size 00 RPS5505P “X” Indicates External Pilot www.rosscontrols.com “ ”Indicates Internal Pilot 3 Series W66 Size 0 (26mm) & Series W66 Size 00 (18mm) ISO 15407 Valve Service Remote Pilot Block Installation ! Warning: Not following instruction may result in Remote Pilot Block damage or inadequate thread engagement, which may lead to personal injury, property damage, or economic loss. 5 Important: • Remove pressure and electrical connections before installation. • All threads on tie rods and screws must be free of rust, water or other debris, which could prevent finger thread engagement. Valve Step 1: Install Tie Rods 4 1. Install two Tie Rods (3) to the base, torque finger tight. 2. Adjust tie rod height to 28.5 / 28.0 mm (1.12 / 1.10 inch) as figure shows. 1 3. If finger tight height exceeds 28.5 mm (1.12 inch), use mechanical tightening as necessary to get the proper height. Remote Pilot Block Body Note: “Base” could be a manifold, sub-base or sandwich flow control. Max: 28.5 mm (1.12 Inch) Min: 28.0 mm (1.10 Inch) 6* 2 2 3 Base 4 2 Step 2: Install Remote Pilot Block 1. Lay the Pilot Block Gasket (2) on the Base. Make sure the two rubber projections are face up and the orientation of the gasket is correct. Base 2. Engage both Tie Rods (3) into mounting holes on the Remote Pilot Block. 3. Carefully engage the Plug into the Base. Figure 3 4. Continue to lower the Pilot Block Body by carefully engaging the two rubber projections on the gasket into the appropriate holes on the Pilot Block Body. 5. Press the Pilot Block Body by hand firmly. To confirm the gasket is indeed attached to the Pilot Block Body, lift the Body by about one half inch. Both rubber projections should remain in the holes. 6. Lay the Pilot Block Body back on the Base. Step 3: Install Valve 1. Locate Valve Gasket (4) on bottom of Valve. 2. Install valve onto Pilot Block Body. 3. Carefully engage the Valve Plug. 4. Using hex wrench, tighten two Screws (5) – torque 1.5 to 1.7 Nm (13 to 15 in-lb) for W66 Size 0, 0.9 to 1.1 Nm (8 to 10 in-lb) for W66 Size 00. Step 4: Leakage Check 1. Apply pressure to base and check for audible leakage at various joints. If any are present, do not not operate the valve, repeat the assembly procedure until satisfied. ISO 15407-2 Size 00 Pilot Block Body Shown (Valve & Base shown for reference only) Component List The components listed below are for identification purposes only, some of these components are available in various Sandwich Regulator Kits, some are not available due to special factory assembly. Individual components are not sold separately since all kit components should be installed when serviced. Item 1 2 3 4 5 6 Description Remote Pilot Block Body Pilot Block Gasket Tie Rods Valve Gasket Mounting Screws Protective Cap* *Install Item 6, Protective Cap, in manifold over electrical plug if servicing manifold assembly with valve or remote pilot block removed and power is on. Remove cap before re-installing valve or remote pilot block. For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0613 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation © Copyright 2013, ROSS CONTROLS®. All Rights Reserved. Form A10326 Installation & Service Instructions A10321 Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) ISSUED: August, 2007 Supersedes: None RPSSNACM12A ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. RPSSNACM12A Analog Current In Female Connector M12-A Female Connector M12-B 1 0 MOD NET 0 LED Indicators 1 RPSSNAVM12A Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. RPSSNAVM12A Analog Voltage In Female Connector M12-A 0 Female Connector M12-B 1 MOD NET 0 LED Indicators 1 ! WARNING Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) The sealed IP67 housing of these modules requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) I/O connectors are sealed M12 style. The mounting base ships with the module. The RPSSNACM12A and RPSSNAVM12A modules are shown below. FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 3 for the analog input modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Install the Analog Input Module To Install the Analog Input Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 3 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Module Will Bridge Two Bases RPSSNACM12A Analog Current In 0 1 MOD NET 0 1 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. Remove the Analog Input Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Wire the Analog Input Modules Following are wiring instructions for the analog input modules. RPSSNACM12A and RPSSNAVM12A (view into connector) Pin 1 - 24VDC Pin 2 - Input 0 (M12-A) Input 1 (M12-B) Pin 3 - Common Pin 4 - Common Pin 5 - No Connect ATTENTION ! IMPORTANT Analog modules have ear th grounded metal rings. This should be considered when choosing shielded cables and grounding techniques. Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O modules. These messages are mapped into the processor’s memory. These I/O analog input modules produce 6 bytes of input data (scanner Rx) and fault status data. They do not consume I/O data (scanner Tx). Default Data Map for the Analog Input Modules RPSSNACM12A and RPSSNAVM12A Message Size: 6 Bytes 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Produces Input Channel 0 High Byte Input Channel 0 Low Byte (Scanner Rx) Input Channel 1 High Byte Input Channel 1 Low Byte Status Byte for Channel 1 Status Byte for Channel 0 O U H L H L C C O U H L H L C C R R H L A A M F R R H L A A M F A A A A Consumes (scanner Tx) No consumed data Where: CF = Channel Fault Status, 0 = no error, 1 = fault CM = Calibration Mode; 0 = normal, 1 = calibration mode LA = Low Alarm; 0 = no error, 1 = fault HA = High Alarm; 0 = no error, 1 = fault LLA = Low/Low Alarm; 0 = no error, 1 = fault HHA = High/High Alarm; 0 = no error, 1 = fault UR = Underrange; 0 = no error; 1 = fault OR = Overrange; 0 = no error; 1 = fault EDS File Requirements The EDS files are available online at: www.rosscontrols.com/rosslit.htm www.rosscontrols.com 5 Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Add Analog Input Modules to RSLogix 5000 I/O Configuration If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSNACM12A module from the list of Parker modules. To add your analog input modules to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the RPSSCCNA or 1738-ACNR Shown), right click and select New Module. • Enter a name and click OK. - For EtherNet/IP, highlight the RPSSCENA or1738-AENT (Shown), right click and select New Module. • Notice that the RPSSNACM12A is now under the I/O configuration. 6 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) If your RSLogic 5000 is Version 13.X: • Choose the equivalent Rockwell Automation module from the list of modules. Troubleshoot With the Indicators RPSSNACM12A RPSSNACM12A Analog Current In 0 1 Module Status Indicator MOD Network Status Indicator NET 0 1 Indication I/O Status Indicators Probable Cause Module Status Serial Bus Modules Equivalent Rockwell Automation 1738 ArmorPoint Modules RPSSNACM12A 1738-IE2CM12 RPSSNAVM12A 1738-IE2VM12 • Enter a name (optional), slot number, and comm. format. Make sure to choose Compatible Module for Electronic Keying setting. Off No power applied to device Green Device operating normally Flashing Green Device needs commissioning due to missing, incomplete, or incorrect configuration Flashing Red Recoverable fault Red Unrecoverable fault may require device replacement Flashing Red/Green Device is in self-test Indication Probable Cause Network Status • Choose Next to set RPI. • Choose Finish. Notice that the analog input module is now under the I/O configuration Off Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Flashing Green Device is on line but has no connections in the established state. Green Device is on line and has connections in the established state. Flashing Red One or more I/O connections in timed-out state. Red Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Flashing Red/Green Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Indication Probable Cause I/O Status Off Module in CAL mode Solid Green Normal (channel scanning inputs) Flashing Green Channel being calibrated Solid Red No power or major channel fault Flashing Red Channel at end of range (over or under) www.rosscontrols.com 7 Serial Bus 24 VDC Analog Input Modules, Series A (RPSSNACM12A, RPSSNAVM12A) Specifications - Following are specifications for the RPSSNACM12A and RPSSNAVM12A analog input modules. Analog Input Modules Inputs per Module Input Voltage 2 single ended, nonisolated RPSSNAVM12A only 0-10V (user configurable) (-0.0V under, +0.5V over) ±10V (user configurable) (-0.5V under, +0.5V over) RPSSNACM12A only 4-20 mA 0-20 mA RPSSNACM12A - 60Ω RPSSNAVM12A - 100kΩ RPSSNACM12A - 16 bits - over 0-21 mA; 0.32μA/cnt RPSSNAVM12A - 15 bits plus sign; 320μV/cnt in unipolar or bipolar mode 0.1% Full Scale @ 25°C RPSSNACM12A - 30ppm/°C RPSSNAVM12A - 5ppm/°C 100 ms @ Notch = 60 Hz (default) 120 ms @ Notch = 50 Hz 24 ms @ Notch = 250 Hz 12 ms @ Notch = 500 Hz 70 ms @ Notch = 60 Hz (default) 80 ms @ Notch = 50 Hz 16 ms @ Notch = 250 Hz 8 ms @ Notch = 500 Hz 0-10,000 ms (default = 0 ms) RPSSNAVM12A only 200kΩ Delta Sigma 120 dB -60 dB -3 dB Notch filter 15.7 Hz @ Notch = 60 Hz 13.1 Hz @ Notch = 50 Hz 65.5 Hz @ Notch = 250 Hz 131 Hz @ Notch = 500 Hz Signed integer Input Current Input Impedance Resolution Absolute Accuracy1 Accuracy Drift w/Temp. Input Update Rate (per module) Step Response (per module) Digital Filter Time Constant Input Resistance Conversion Type Common Mode Rejection Ratio Normal Mode Rejection Ratio Data Format General Specifications Maximum Overload Calibration Indicators Keyswitch Position PointBus Current Power Dissipation Thermal Dissipation, Maximum Isolation Voltage (continuous voltage withstand rating) External DC Power Supply Voltage Voltage Range Supply Current Dimensions Imperial (Metric) Operating Temperature Storage Temperature Relative Humidity Shock Vibration ESD Immunity Radiated RF Immunity EFT/B Immunity Surge Transient Immunity Conducted RF Immunity Emissions Enclosure Type Rating Mounting Base Screw Torque Wiring Category2 Weight Certifications: (when product is marked) Imperial (Metric) Fault protected to 28.8VDC Factory calibrated 1 green/red module status indicator, logic side 1 green/red network status indicator, logic side 2 green/red input status indicators, logic side 3 75 mA @ 5VDC RPSSNACM12A - 0.6W @ 28.8VDC RPSSNAVM12A - 0.75W @ 28.8VDC RPSSNACM12A - 2.0 BTU/hr. @ 28.8VDC RPSSNAVM12A - 2.5 BTU/hr. @ 28.8VDC 50V rms Tested at 1250VAC rms for 60s 24VDC nominal 10-28.8VDC RPSSNACM12A - 10 mA @ 24VDC; RPSSNAVM12A - 15 mA @ 24VDC 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz IEC 61000-4-2: 6kV contact discharges, 8kV air discharges IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz IEC 61000-4-4: ±3kV at 5kHz on signal ports IEC 61000-4-5: ±2kV line-earth(CM) on shielded ports IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz CSPR 11: Group 1, Class A Meets IP65/66/67 (when marked) #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 - on signal ports 0.637 lb. (0.289 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Includes offset, gain, non-linearity and repeatability error terms. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10321 Installation & Service Instructions A10322 Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) ISSUED: August, 2007 Supersedes: None RPSSTACM12A ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. RPSSTACM12A Analog Current Out Female Connector M12-A Female Connector M12-B 1 0 MOD NET 0 LED Indicators 1 RPSSTAVM12A Safety Guide RPSSTAVM12A For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Analog Voltage Out Female Connector M12-A 0 Female Connector M12-B 1 MOD NET 0 LED Indicators 1 ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) The sealed IP67 housing of these modules requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) I/O connectors are sealed M12 style. The mounting base ships with the module. The RPSSTACM12A and RPSSTAVM12A modules are shown below. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. www.rosscontrols.com 1 Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 4 for the analog output modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Install the Analog Output Module To Install the Analog Output Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 4 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Module Will Bridge Two Bases RPSSTACM12A Analog Current Out 0 1 MOD NET 0 1 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. Remove the Analog Output Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Wire the Analog Output Modules Following are wiring instructions for the analog output modules. RPSSTACM12A and RPSSTAVM12A (view into connector) Pin 1 - Output 0 (M12-A) Output 1 (M12-B) Pin 2 - 24VDC Pin 3 - Common Pin 4 - Common Pin 5 - No Connect ATTENTION ! IMPORTANT Analog modules have ear th grounded metal rings. This should be considered when choosing shielded cables and grounding techniques. Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O modules. These messages are mapped into the processor’s memory. These I/O analog output modules produce 2 bytes of input data (scanner Rx - fault status). They consume 4 bytes of output data (scanner Tx). Default Data Map for the Analog Output Modules RPSSTACM12A and RPSSTAVM12A Message Size: 2 Bytes 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Produces High Byte-Channel 1 Status Low Byte-Channel 0 Status (Scanner Rx) Not H L C C Not H L C C Used C C M F Used C C M F A A A A Where: CF = Channel Fault Status, 0 = no error, 1 = fault CM = Calibration Mode; 0 = normal, 1 = calibration mode LCA = Low Clamp Alarm; 0 = no error, 1 = fault HCA = High Clamp Alarm; 0 = no error, 1 = fault RPSSTACM12A and RPSSTAVM12A Message Size: 4 Bytes 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Consumes Output Channel 0 High Byte Output Channel 0 Low Byte (scanner Tx) Output Channel 1 High Byte Output Channel 1 Low Byte EDS File Requirements The EDS files are available online at www.rosscontrols.com/rosslit.htm. www.rosscontrols.com 5 Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Add Analog Output Modules to RSLogix 5000 I/O Configuration If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSTACM12A module from the list of Parker modules. To add your analog output modules to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the RPSSCCNA or 1738-ACNR (Shown), right click and select New Module. • Enter a name and click OK. - For EtherNet/IP, highlight the RPSSCENA or 1738-AENT (Shown), right click and select New Module. • Notice that the RPSSTACM12A is now under the I/O 6 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) configuration. If your RSLogic 5000 is Version 13.X: • Choose the equivalent Rockwell Automation module from the list of modules. Troubleshoot With the Indicators RPSSTACM12A RPSSTACM12A Analog Current Out 1 0 Module Status Indicator MOD Network Status Indicator NET 0 1 Indication I/O Status Indicators Probable Cause Module Status Serial Bus Modules RPSSTACM12A RPSSTAVM12A Off No power applied to device Green Device operating normally Flashing Green Device needs commissioning due to missing, incomplete, or incorrect configuration Equivalent Rockwell Automation 1738 ArmorPoint Modules 1738-OE2CM12 Flashing Red Recoverable fault 1738-OE2VM12 Red Unrecoverable fault may require device replacement Flashing Red/Green Device is in self-test Indication Probable Cause • Enter a name (optional), slot number, and comm. format. Make sure to choose Compatible Module for Electronic Keying setting. Network Status • Choose Next to set RPI. • Choose Finish. Notice that the analog output module is now under the I/O configuration Off Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Flashing Green Device is on line but has no connections in the established state. Green Device is on line and has connections in the established state. Flashing Red One or more I/O connections in timed-out state. Red Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Flashing Red/Green Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Indication Probable Cause I/O Status RPSSTAVM12A Off RPSSTACM12A Module in CAL mode Solid Green Device operating normally Flashing Green Channel being calibrated Flashing Red Low or High Clamp Open wire or no power Solid Red No power Not used www.rosscontrols.com 7 Serial Bus 24 VDC Analog Output Modules, Series A (RPSSTACM12A, RPSSTAVM12A) Specifications - Following are specifications for the RPSSTACM12A and RPSSTAVM12A analog output modules. Analog Output Modules Outputs per Module Output Voltage 2 single ended, nonisolated RPSSTAVM12A 0V output until communication established 0-10V (user configurable) (0.0V under, +5V over) ±10V (user configurable) (-0.5V under, +5V over) 0 mA output until communication established 4-20 mA user configurable 0-20 mA user configurable RPSSTACM12A 13 bits - over 0-21 mA 2.5μA/cnt (average value - typical range: 2.3-2.7μA/cnt) RPSSTAVM12A 14 bits (13 plus sign) 1.28μV/cnt in unipolar or bipolar mode 0.1% Full Scale @ 25°C RPSSTACM12A - 30ppm/°C RPSSTAVM12A - 5ppm/°C RPSSTACM12A - 0-750kΩ RPSSTAVM12A - 3 mA Digital to analog converter RPSSTACM12A - 16μs RPSSTAVM12A - 20μs Signed integer Output Current Resolution Absolute Accuracy1 Accuracy Drift w/Temp. Resistive Load on mA Output Current Load on Output, Maximum Conversion Type Conversion Rate Data Format General Specifications Calibration Step Response to 63% of FS Indicators Factory calibrated 24μs 1 green/red module status indicator, logic side 1 green/red network status indicator, logic side 2 green/red output status indicators, logic side 4 75 mA @ 5VDC RPSSTACM12A 750Ω load on each output - 1.23W 0Ω load on each output - 1.83W RPSSTAVM12A 1.0W RPSSTACM12A 750Ω load on each output - 4.19 BTU/hr. 0Ω load on each output - 6.24 BTU/hr. RPSSTAVM12A 3.4 BTU/hr. 50V rms Tested at 1250VAC rms for 60s Keyswitch Position PointBus Current Power Dissipation - Maximum at 28.8VDC Thermal Dissipation - Maximum at 28.8VDC Isolation Voltage (continuous voltage withstand rating) External DC Power Supply Voltage Voltage Range Supply Current Dimensions Operating Temperature Imperial (Metric) Storage Temperature Relative Humidity Shock Vibration ESD Immunity Radiated RF Immunity EFT/B Immunity Surge Transient Immunity Conducted RF Immunity Emissions Enclosure Type Rating Mounting Base Screw Torque Wiring Category2 Weight Imperial (Metric) Certifications: (when product is marked) 24VDC nominal 10-28.8VDC RPSSTACM12A: 70 mA @ 24VDC (including outputs @ 20 mA) RPSSTAVM12A: 35 mA @ 24VDC (including outputs @ 3 mA) 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g, Non-operating 50g IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz IEC 61000-4-2: 6kV contact discharges 8kV air discharges IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz IEC 61000-4-4: ±3kV at 5kHz on signal ports IEC 61000-4-5: ±2kV line-earth(CM) on shielded ports IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz CSPR 11: Group 1, Class A Meets IP65/66/67 (when marked) #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 - on signal ports 0.637 lb. (0.289 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Includes offset, gain, non-linearity and repeatability error terms. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10322 Installation & Service Instructions A10317 Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. RPSSSE24A 24VDC Expansion Power Supply RPSSSE24A 24V dc Power Supply Wire Marker System Power Field Power Mini 7/8” Power Connector LED Indicators P AO UW XE R ATTENTION Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus 24VDC Expansion Power Supply, Series A ! Do not connect 120/240VAC to the RPSSSE24A terminals. Damage to the supply will result. ATTENTION ! You can only use the RPSSSE24A expansion power unit with the I/O adapters. (RPSSSE24A) The 24VDC expansion power supply unit (RPSSSE24A) passes 24VDC field power to the I/O modules to the right of the power supply. This unit extends the backplane bus power for up to 17 I/O modules to the right of the supply and creates a new field voltage partition. The expansion power supply also separates field power from I/O modules to the left of the unit, effectively providing functional and logical partitioning for: • separating field power between input and output modules • separating field power to the analog and digital modules • grouping modules to perform a specific task or function You can use multiple expansion power units with the I/O adapters to assemble a full system. For instance, if you are using the RPSSCDM12A or RPSSCDM18PA adapter, you may use a RPSSSE24A expansion power unit to add additional modules in 5 to 17 module increments. For example, if you had a 36 module system with a I/O adapter, you would have two RPSSSE24A expansion power units to provide more PointBus current for modules to the right of the supply. ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 1 for the RPSSSE24A dc expansion power supply Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) Install the 24VDC Expansion Power Supply Wire the 24VDC Expansion Power Supply To Install the Power Supply, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 1 aligns with the notch in the base. 2. Position the power supply vertically above the mounting base. The module will bridge two bases. Following are wiring instructions for the 24VDC Expansion Power Supply. Module Will Bridge Two Bases RPSSSE24A Male In Connector (Mini 7/8”) (view into connector) Pin 1 - User Power + Pin 2 - Adapter Power + RPSSSE24A 24V dc Power Supply Pin 3 - Adapter Power Pin 4 - User Power - System Power Note: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for RPSSSE24A. It is converted to 5VDC to power isysNet modules. Field Power P AO UW XE R 3. Push the power supply down until it engages the orange latching mechanism. You will hear a clicking sound when the power supply is properly engaged. The locking mechanism will lock the power supply to the base. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. Remove the 24VDC Expansion Power Supply From the Mounting Base To Remove the Power Supply from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. Install a Replacement RPSSSE24A to an Existing System 1. Remove the module to the right of the power supply from the mounting base. 2. If you have not done so already, remove the existing power supply from the mounting base. 3. Position the replacement power supply vertically above the mounting base. 4. Push the power supply down until it engages the orange latching mechanism. You will hear a clicking sound when the power supply is properly engaged and locked to the base. 5. Place the module to the right of the power supply back onto the mounting base. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) Specifications Following are specifications for the RPSSSE24A Power Supply. 24VDC Expansion Power Supply - RPSSSE24A I/O Module Capacity 5 to 17 I/O modules depending on each module's current rating Power Supply In order to comply with CE Low Voltage Directives (LVD), you must use a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power the adapter. Inputs Voltage Rating 12VDC, 24VDC nominal 10-28.8VDC range Operating Voltage 10-28.8VDC Input Current, Maximum 6A for 10ms Backplane Output Current 5VDC, 1.3A Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 400 mA Indicators 1 Green Field Power Status Indicator 1 Green 5V System Power Indicator Module Location Between I/O modules in system Breaks field power bus PointBus Output Current 1A at 10-19.2V input; 1.3A at 19.2-28.8V input Input Overvoltage Protection Reverse polarity protected Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications Power Consumption, Maximum 9.8W @ 28.8VDC Power Dissipation, Maximum 3.0W @ 28.8VDC Thermal Dissipation, Maximum 10.0 BTU/hr. @ 28.8VDC Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested at 1250VAC rms for 60s Field Power Bus Supply Voltage Voltage Range Supply Current 12VDC, 24VDC nominal 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz www.rosscontrols.com 5 Serial Bus 24VDC Expansion Power Supply, Series A (RPSSSE24A) General Specifications (continued) EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel Weight 0.637 lb. (0.289 kg) Imperial (Metric) 1 Wiring Category 1 - on power ports Keyswitch Position 1 Certifications: (when product is marked) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10317 Installation & Service Instructions A10318 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A, RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) ISSUED: August, 2007 Supersedes: None RPSSN8M12A ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. RPSSN8M12A 24V dc In Female Connector M12-A Female Connector M12-BFemale 0 2 1 3 MOD NET 0 1 2 3 Female Connector M12-C 4 6 5 7 LED Indicators 4 5 6 7 Female Connector M12-D RPSSN8M23A Safety Guide RPSSN8M23A 24V dc In For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Introduction MOD Follow these instructions when installing, operating, or servicing the product. NET 0 1 2 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A, RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) The sealed IP67 housing of these modules requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) I/O connectors are sealed M8 (pico) or M12 (micro) or M23 styles. The mounting base ships with the module. RPSSN8M8A Female Connector M8-A Female Connector M8-C Female Connector M8-E 1 2 3 Female Connector M8-B MOD NET 0 5 6 7 3 LED Indicators 4 5 6 Female Connector M8-G Female Connector M8-D 1 2 4 LED Indicators 4 Female M23 Connector 5 6 7 ! WARNING RPSSN8M8A 24V dc In 0 3 FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. Connector M8-F The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. Female Connector M8-H EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. 7 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A drilling dimensions mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 1 for the IsysNet 24VDC digital input modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Install the Digital Input Module To Install the Digital Input Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 1 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Module Will Bridge Two Bases RPSSN8M12A 24V dc In 0 2 1 3 MOD NET 0 1 2 3 4 6 5 7 4 5 6 7 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. Remove the Digital Input Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Wire the Input Modules Following are wiring instructions for the digital input modules. RPSSN8M8A RPSSP8M8A RPSSN8M23A RPSSP8M23A 1 8 9 7 2 10 12 6 3 11 4 (view into connector) Pin 1 - 24VDC Pin 3 - Common Pin 4 - Input 0 (M8-A) Input 1 (M8-B) Input 2 (M8-C) Input 3 (M8-D) Input 4 (M8-E) Input 5 (M8-F) Input 6 (M8-G) Input 7 (M8-H) Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 - 5 (view into connector) Pin 7 - Input 6 Pin 8 - Input 7 Pin 9 - Return (Com) Pin 10 - Return (Com) Pin 11 - 24VDC Pin 12 - Chassis Input 0 Input 1 Input 2 Input 3 Input 4 Input 5 RPSSN8M12A RPSSP8M12A Sink Input modules (RPSSN8) require PNP type input device. Source Input modules (RPSSP8) require NPN type input device. Wiring examples (RPSSN8M8A and RPSSP8M8A shown): Common Sink Input Module Input PNP 24 VDC 2-Wire Input Device Digital Input Module Common Source Input Module Input NPN 24 VDC 2-Wire Input Device Common Sink Input Module Input PNP 24 VDC 3-Wire Input Device Common Source Input Module (view into connector) Pin 1 - 24VDC Pin 2 - Input 1 (M12-A) Pin 4 - Input 0 (M12-A) Input 3 (M12-B) Input 2 (M12-B) Input 5 (M12-C) Input 4 (M12-C) Input 7 (M12-D) Input 6 (M12-D) Pin 3 - Common Pin 5 - No Connect Input Module Part Number 8 Digital Inputs M12 (NPN Sinking - Requires PNP Sourcing Input Device) RPSSN8M12A 8 Digital Inputs M12 (PNP Sourcing -Requires NPN Sinking Input Device) RPSSP8M12A 8 Digital Inputs M8 (NPN Sinking - Requires PNP Sourcing Input Device) RPSSN8M8A 8 Digital Inputs M8 (PNP Sourcing - Requires NPN Sinking Input Device) RPSSP8M8A 8 Digital Inputs M23 12-Pin (PNP Sourcing Requires NPN Sinking Input Device) RPSSP8M23A 8 Digital Inputs M23 12-Pin (NPN Sinking Requires PNP Sourcing Input Device) RPSSN8M23A ATTENTION Input NPN 24 VDC 3-Wire Input Device ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O modules. These messages are mapped into the processor’s memory. These I/O input modules produce 1 byte of input data (scanner Rx - status). They do not consume I/O data (scanner Tx). If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSN8M8A module from the list of Parker modules. Default Data Map for the Input Modules RPSSN8M8A, RPSSN8M12A, RPSSN8M23A, RPSSP8M8A, RPSSP8M12A, RPSSP8M23A Message Size: 1 Byte 7 6 5 4 3 2 1 0 Produces Channel Ch7 Ch6 Ch5 Ch4 Ch3 Ch2 Ch1 Ch0 (Scanner Rx) Status Where: 0 = OFF, 1 = ON EDS File Requirements The EDS files are available online at www.rosscontrols.com/rosslit. htm. Add 24 VDC Input Modules to RSLogix 5000 I/O Configuration • Enter a name and click OK. To add your input modules to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the RPSSCCNA or 1738-ACNR (Shown), right click and select New Module. - For EtherNet/IP, highlight the RPSSCENA or 1738-AENT (Shown), right click and select New Module. 6 • Notice that the RPSSN8M8A is now under the I/O configuration. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) If your RSLogic 5000 is Version 13.X: • Choose the equivalent Rockwell Automation module from the list of modules. Troubleshoot With the Indicators RPSSN8M12A RPSSN8M12A 24V dc In 0 2 1 3 MOD NET Module Status Indicator Network Status Indicator 0 1 2 3 4 6 5 7 4 I/O Status Indicators 5 6 7 Serial Bus Modules Equivalent Rockwell Automation 1738 ArmorPoint Modules RPSSN8M8A 1738-IB8M8 RPSSN8M12A 1738-IB8M12 RPSSN8M23A 1738-IB8M23 RPSSP8M8A 1738-IV8M8 RPSSP8M12A 1738-IV8M12 RPSSP8M23A 1738-IV8M23 Indication Module Status Off Green Flashing Green Flashing Red Red Flashing Red/Green • Enter a name (optional), slot number, and communication format. Make sure to choose Compatible Module for Electronic Keying setting. Indication Network Status Off Flashing Green Green Flashing Red Red • Choose Next to set RPI. • Choose Finish. Notice that the input module is now under the I/O configuration Flashing Red/Green Indication I/O Status Off Yellow www.rosscontrols.com Probable Cause No power applied to device Device operating normally Device needs commissioning due to missing, incomplete, or incorrect configuration Recoverable fault Unrecoverable fault may require device replacement Device is in self-test Probable Cause Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Device is on line but has no connections in the established state. Device is on line and has connections in the established state. One or more I/O connections in timed-out state. Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Probable Cause Input is in the off state Input on 7 Serial Bus 24 VDC Input Modules, Series A (RPSSN8M8A, RPSSN8M12A, RPSSN8M23A,RPSSP8M8A, RPSSP8M12A, RPSSP8M23A) Specifications - Following are specifications for the digital input modules. Digital Input Modules Inputs per Module Voltage, Off-State Input, Maximum Voltage, On-State Input, Maximum Minimum Nominal Current, Off-State Input, Maximum Current, On-State Input, Maximum Minimum Nominal Input Impedance, Maximum Nominal Input Delay Time OFF to ON Input Delay Time, ON to OFF Input Point Density Field Power Bus Supply Voltage Range Nominal Keyswitch Position LED Indicators RPSSN8M - 8 (1 group of 8) nonisolated, sinking RPSSP8M - 8 (1 group of 8) nonisolated, sourcing 5VDC 28.8VDC 10VDC 24VDC 1.5 mA 5 mA 2 mA 4 mA @ 24VDC 4.7 kΩ 3.6 kΩ 0.5 ms hardware + (0-63 ms selectable1) 0.5 ms hardware + (0-63 ms selectable1) 2, 4, or 8 10 to 28.8VDC 24VDC 1 2, 4, or 8 yellow input status, logic side 1 green/red network status, logic side 1 green/red module status, logic side Point Bus Current, Maximum 75 mA @ 5VDC Power Dissipation, Maximum RPSSN8M - 1.6W @ 28.8VDC Thermal Dissipation, Maximum RPSSN8M - 5.5 BTU/hr. @ 28.8VDC Isolation Voltage 50V rms (continuous-voltage withstand rating) Tested at 1250VAC rms for 60s Dimensions Imperial (Metric) 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±3kV at 5kHz on signal ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on signal ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel Weight Imperial (Metric) 0.64 lb. (0.29 kg) 1 - on signal ports Wiring Category2 Certifications: c-UL-us UL Listed Industrial Control Equipment, (when product is marked) certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Input OFF to ON or ON to OFF delay is time from a valid input signal to recognition by the module. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10318 Installation & Service Instructions A10319 Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) ISSUED: August, 2007 Supersedes: None ! WARNING RPSST8M12A To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. RPSST8M12A 24V dc Out Female Connector M12-A Female Connector M12-B 0 2 1 3 MOD NET 0 1 2 Female Connector M12-C LED Indicators 3 4 6 5 7 4 5 6 7 Female Connector M12-D RPSST8M8A Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. RPSST8M8A 24V dc Out 1 Female Connector M8-A 0 Follow these instructions when installing, operating, or servicing the product. Female Connector M8-C 2 4 5 Serial Bus 24 VDC Output Modules, Series A Female Connector M8-E Female Connector M8-G 6 7 Introduction Female Connector M8-B Female Connector M8-D MOD 3 NET 0 1 2 (RPSST8M23A, RPSST8M12A, RPSST8M8A) The sealed IP67 housing of these modules requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) I/O connectors are sealed M8 (pico) or M12 (micro) or M23 styles. The mounting base ships with the module. The RPSST8M23A, RPSST8M12A, and RPSST8M8A modules are shown below. 4 5 6 7 Female Connector M8-F Female Connector M8-H ! WARNING RPSST8M23A FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. RPSST8M23A 24V dc Out MOD NET 0 Female Connector M23 LED Indicators 3 1 2 3 4 5 6 7 LED Indicators This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 1 for the RPSST8M digital output modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Install the Digital Output Module To Install the Digital Output Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 1 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Module Will Bridge Two Bases RPSST8M12A 24V dc Out 0 2 1 3 MOD NET 0 1 2 3 4 6 5 7 4 5 6 7 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. Remove the Digital Output Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Wire the Output Modules Following are wiring instructions for the digital output modules. RPSST8M23A 1 RPSST8M8A 8 9 7 2 10 12 6 3 11 4 5 (view into connector) (view into connector) Pin 1 - Output 0 Pin 7 - Output 6 Pin 1 - 24VDC Pin 2 - Output 1 Pin 8 - Output 7 Pin 3 - Common Pin 3 - Output 2 Pin 9 - Return (Com) Pin 4 - Output 3 Pin 10 - Return (Com) Pin 5 - Output 4 Pin 11 - 24VDC Pin 6 - Output 5 Pin 12 - Chassis Pin 4 - Output 0 (M8-A) Output 1 (M8-B) Output 2 (M8-C) Output 3 (M8-D) Output 4 (M8-E) Output 5 (M8-F) Output 6 (M8-G) Output 7 (M8-H) RPSST8M12A ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. (view into connector) Pin 1 - 24VDC Pin 2 - Output 1 (M12-A) Output 3 (M12-B) Output 5 (M12-C) Output 7 (M12-D) Pin 4 - Output 0 (M12-A) Output 2 (M12-B) Output 4 (M12-C) Output 6 (M12-D) Pin 3 - Common Pin 5 - No Connect Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O modules. These messages are mapped into the processor’s memory. These I/O output modules produce 1 byte of input data (scanner Rx - status). They consume 1 byte of I/O data (scanner Tx). Default Data Map for the Output Modules RPSST8M23A, RPSST8M12A, RPSST8M8A Message Size: 1 Byte 7 6 5 4 3 2 1 0 Produces Ch7 Ch6 Ch5 Ch4 Ch3 Ch2 Ch1 Ch0 Channel (Scanner Rx) Status Consumes Ch7 Ch6 Ch5 Ch4 Ch3 Ch2 Ch1 Ch0 Output (Scanner Tx) State Where: Channel Status 0 = no error, 1 = error; Output State 0 = OFF, 1 = ON EDS File Requirements The EDS files are available online at www.rosscontrols.com/rosslit.htm. www.rosscontrols.com 5 Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Add 24 VDC Output Modules to RSLogix 5000 I/O Configuration If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSST8M12A module from the list of Parker modules. To add your output modules to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the RPSSCCNA or 1738-ACNR (Shown), right click and select New Module. • Enter a name and click OK. - For EtherNet/IP, highlight the RPSSCENA or 1738-AENT (Shown), right click and select New Module. • Notice that the RPSST8M12A is now under the I/O configuration. 6 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Troubleshoot With the Indicators If your RSLogic 5000 is Version 13.X: RPSST8M12A • Choose the equivalent Rockwell Automation module from the list of modules. RPSST8M12A 24V dc Out 0 2 1 3 MOD NET Module Status Indicator Network Status Indicator 0 1 2 3 4 5 6 7 4 I/O Status Indicators 5 6 7 Serial Bus Modules Equivalent Rockwell Automation 1738 ArmorPoint Modules RPSST8M8A 1738-OB8EM8 RPSST8M12A 1738-OB8EM12 RPSST8M23A 1738-OB8EM23* Indication Module Status Off Green Flashing Green Flashing Red Red * 1738-OB8EM23 profile will be available in RSLogix 5000 v15. To use 1738-OB8EM23 in RSLogix 5000 v13, choose 1738-OB8EM12 profile and disable keying. • Enter a name (optional), slot number, and communication format. Make sure to choose Compatible Module for Electronic Keying setting. Flashing Red/Green Indication Network Status Off Flashing Green Green Flashing Red Red Flashing Red/Green • Choose Next to set RPI. • Choose Finish. Notice that the output module is now under the I/O configuration Indication I/O Status Off Yellow Flashing Red Red www.rosscontrols.com Probable Cause No power applied to device Device operating normally Device needs commissioning due to missing, incomplete, or incorrect configuration Recoverable fault Unrecoverable fault may require device replacement Device is in self-test Probable Cause Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Device is on line but has no connections in the established state. Device is on line and has connections in the established state. One or more I/O connections in timed-out state. Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Probable Cause Output is inactive Output is active and under control Open circuit detection. No load. (Off-State only) Short circuit detected. (On-State only) 7 Serial Bus 24 VDC Output Modules, Series A (RPSST8M23A, RPSST8M12A, RPSST8M8A) Specifications - Following are specifications for the digital output modules. Digital Output Modules Outputs per Module Voltage Drop, On-State Output, Maximum Voltage, Off-State Output, Maximum Voltage, On-State Output, Maximum Minimum Nominal Current Leakage, Off-State Output, Maximum Current, On-State Output Minimum Output Current Rating Output Delay Time OFF to ON, Maximum1 Output Delay Time, ON to OFF, Maximum1 Output Point Density Output Surge Current, Maximum External DC Power Supply Current External DC Power Supply Voltage Range External DC Power Supply Voltage Nominal Keyswitch Position LED Indicators PointBus Current, Maximum Power Dissipation, Maximum Thermal Dissipation, Maximum Isolation Voltage (continuous-voltage withstand rating) Dimensions (includes I/O module Inches and mounting base) (Millimeters) Operating Temperature Storage Temperature Relative Humidity Shock Vibration ESD Immunity Radiated RF Immunity EFT/B Immunity Surge Transient Immunity Conducted RF Immunity Emissions Enclosure Type Rating Mounting Base Screw Torque Wiring Category2 Weight Imperial (Metric) Certifications: (when product is marked) 8 (1 group of 8) nonisolated, sourcing 0.2VDC (sourcing modules) 0.7VDC (sinking module) 28.8VDC 28.8VDC 10VDC 24VDC 0.5 mA 1.0 mA per channel 1.0 A per channel, not to exceed 3.0 A maximum per module 0.1 ms 0.1 ms 2, 4, 8 2 A for 10 ms, repeatable every 3 seconds 32 mA 10 to 28.8VDC 24VDC 1 2, 4, or 8 yellow/red output status, logic side 1 green/red network status, logic side 1 green/red module status, logic side 75 mA @ 5VDC RPSST8M - 2.0W @ 28.8VDC RPSST8M - 6.8 BTU/hr. @ 28.8VDC 50V rms Tested at 1250VAC rms for 60s 4.72H x 2.82W x 1.65D (120H x 72W x 42D) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz IEC 61000-4-2: 6kV contact discharges 8kV air discharges IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz IEC 61000-4-4: ±3kV at 5kHz on signal ports IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on signal ports IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz CSPR 11: Group 1, Class A Meets IP65/66/67 (when marked) #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 - on signal ports 0.64 lb. (0.29 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. OFF to ON or ON to OFF delay is time from a valid output “on” or “off” signal to output energization or de-energization. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10319 Installation & Service Instructions A10312 Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) The sealed IP67 housing of these modules requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) The RPSSV32A module is shown below. The RPSSV32A valve driver module provides an interface between the serial bus system and the valve assembly. This module will always be the last module on the serial bus. It controls 32 digital outputs at 24VDC. Depending on valve selection, it can control up to 32 single solenoid valves or 16 double solenoid valves. RPSSV32A S A V32 S O PSS R Mod lt Fau Net Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Outputs 1- 24 Connector Outputs 25- 32 Connector ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) 3.02 (76.6) Drill and Tap for M4 Screw 5.39 (137.0) Drill and Tap for M6 Screw Install the 32 Point Valve Driver To Install the 32 Point Valve Driver, Proceed as Follows: 1. Assemble the valve driver to the manifold interface plate using four M4 screws, torqued 11 to 13 in. lbs. 2. Plug the 32 point valve driver onto the previous mounting base or communication adapter. Wire the 32 Point Valve Driver Following are wiring instructions for the 32 point valve driver. Use the appropriate harness assembly based on your manifold wiring/interconnect system. Harness Assembly Kit Numbers Series W66, Size 0 Series W66, Size 00 Series W65, Size 1 Series W65, Size 2 Series W65, Size 3 1 to 24 Outputs 25 to 32 Outputs RPS5624P RPS5632P RPS4024P RPS4032P Plug the 2X15 connector into the valve driver module for 1-24 outputs. If you have more than 24 outputs, plug the 2X5 connector into the valve driver module for 25-32 outputs. Outputs 1- 24 Connector Outputs 25- 32 Connector Plug the 2X10 and 1X10 connectors into the interconnect board in the valve manifold. EDS File Requirements The EDS file is available online at www.rosscontrols.com/rosslit.htm ATTENTION ! Make sure all four screws are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 3 Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) Setup the 32 Point Valve Driver in ControlNet Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O modules. These messages are mapped into the processor’s memory. The 32 point valve driver produces 1 byte of input data (scanner Rx - status), and consumes 1 byte of I/O data (scanner Tx). Default Data Map for the 32 Point Valve Driver RPSSV32A Message Size: 1 Byte Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Produce 0 Output Output Output Output Output Output Output Output 7 6 5 4 3 2 1 0 Produce 1 Output Output Output Output Output Output Output Output 15 14 13 12 11 10 9 8 Produce 2 Output Output Output Output Output Output Output Output 23 22 21 20 19 18 17 16 Produce 3 Output Output Output Output Output Output Output Output 31 30 29 28 27 26 25 24 Produce 4 Fault Fault Fault Fault Fault Fault 28-31 24-27 20-23 16-19 12-15 8-11 Fault 4-7 Fault 0-3 Step 1: Load 32 Point Valve Driver EDS file to RSLinx • Download EDS file from www.rosscontrols.com/rosslit.htm • On your computer, follow Start Rockwell Software RSLinx Tools EDS Hardware Installation Tool to load the EDS file to RSLinx Step 2: Add Controller and Communication Module to the RSLogix 5000 I/O Configuration • Add a controller and a communication module (Serial Bus RPSSCCNA or Rockwell 1738-ACNR) to I/O configuration. Reference pages 4-1 through 4-7 of Rockwell publication 1734-UM008 (follow www.rockwell.com Support Support Overview Online manuals and literature I/O 1734 POINT and 1734D POINT Block I/O and find POINT I/O ControlNet Adapter User Manual) for a similar setup procedure. Step 3: Add 32 Point Valve Driver to RSLogix 5000 I/O Configuration. If your RSLogic 5000 is Version 15.X or greater: • Highlight the RPSSCCNA under I/O configuration, right click and select New Module. • Choose the RPSSV32A module from the list of Parker modules. Consume 0 Output Output Output Output Output Output Output Output 7 6 5 4 3 2 1 0 Consume 1 Output Output Output Output Output Output Output Output 15 14 13 12 11 10 9 8 Consume 2 Output Output Output Output Output Output Output Output 23 22 21 20 19 18 17 16 Consume 3 Output Output Output Output Output Output Output Output 31 30 29 28 27 26 25 24 • Enter a name (optional) and click OK. Setup the 32 Point Valve Driver in DeviceNet Step 1: Load 32 Point Valve Driver EDS file to RSLinx • Download EDS file from www.rosscontrols.com/rosslit.htm • On your computer, follow Start Rockwell Software RSLinx Tools EDS Hardware Installation Tool to load the EDS file to RSLinx Step 2: Configure the DeviceNet Scanner Subnet • Reference Chapter 4 of the Serial Bus DeviceNet Adapters User Manual Bulletin 601 (Form #A10311) for detailed information. Make sure to add RPSSV32A to the DeviceNet Adapter’s scanlist. Step 3: Add the Serial Bus DeviceNet Adapter to the DeviceNet Scanner’s Scanlist • Reference Chapter 5 of the Serial Bus DeviceNet Adapters User Manual Bulletin 601 (Form #A10311) for detailed information. Step 4: Use 32 Point Valve Driver in RSLogix 5000 • Access RPSSV32A data via DeviceNet Scanner in the ladder logic program. 4 Notice that the 32 Point Valve Drive Module is now under I/O Configuration. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) If your RSLogic 5000 is Version 13.X: • Highlight the 1738-ACNR under I/O configuration, right click and select New Module. • Choose the Generic 1738 module from the list of Allen-Bradley modules. Setup the 32 Point Valve Driver in EtherNet/IP Step 1: Load 32 Point Valve Driver EDS file to RSLinx • Download EDS file from www.rosscontrols.com/rosslit.htm • On your computer, follow Start Rockwell Software RSLinx Tools EDS Hardware Installation Tool to load the EDS file to RSLinx Step 2: Set IP Address for EtherNet/IP Scanner and Adapter • Set IP address using Rockwell BootP/DHCP utility for EtherNet/IP scanner and PSSCENA or 1738-AENT adapter. Reference pages 3-7 through 3-10 of Rockwell publication 1734-UM011 (follow www.rockwell.com Support Support Overview Online manuals and literature I/O 1734 POINT and 1734D POINT Block I/O and find POINT I/O Ethernet Adapter User Manual) for similar information. Step 3: Add EtherNet/IP Scanner and Adapter to RSLogix 5000 I/O configuration. • Add EtherNet/IP scanner and PSSCENA or 1738-AENT adapter to I/O configuration. Reference pages 4-4 to 4-8 of Rockwell publication 1734-UM011 for similar information. • Enter a name (optional), an appropriate slot number and the connection parameters as shown in this screen capture. Step 4: Add 32 Point Valve Driver to RSLogix 5000 I/O Configuration. If your RSLogic 5000 is Version 15.X or greater: • Highlight the PSSCENA under I/O configuration, right click and select New Module. • Choose the RPSSV32A module from the list of Ross modules. • Choose Next to set RPI. • Choose Finish. Notice that the 32 Point Valve Driver Module is now under the I/O configuration. Step 4: Download the Program to the Controller and Configure the RPSSCCNA or 1738-ACNR Adapter. • Reference pages 4-11 through 4-15 of Rockwell publication 1734UM008 for similar setup procedure. • Enter a name (optional) and click OK. Step 5: Schedule I/O Module Connections • Reference pages 4-15 through 4-19 of Rockwell publication 1734UM008 for similar setup procedure. Step 6: Access Module Data via the RPSSCCNA or 1738-ACNR Adapter. • Make sure the 32 outputs of RPSSV32A appear in Controller Tags. Use the information in the ladder logic program to access module data. • Reference pages 4-19 through 4-22 of Rockwell publication 1734UM008 for similar information. Notice that the 32 Point Valve Drive Module is now under I/O Configuration. www.rosscontrols.com 5 Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) If your RSLogic 5000 is Version 13.X: • Highlight the 1738-AENT under I/O configuration, right click and select New Module. • Choose the Generic 1738 module from the list of Allen-Bradley modules. Setup the 32 Point Valve Driver in Profibus Step 1: Configure Valve Driver Module in SST Profibus Configuration Utility Note: SST-PFB-CLX is used here for example. For different Profibus scanners, refer to appropriate documentation for setup information. • Download GSD file from www.rosscontrols.com/rosslit.htm • In SST Profibus Configuration Utility, follow Library Add GSD to load the GSD file to SST Profibus. • In SST Profibus Configuration Utility, follow Browse Search for devices to load the GSD file to SST Profibus • Right click on the found device, follow GSD files and click on appropriate GSD for RPSSV32A. • Add RPSSV32A as slave to SST-PFB-CLX master. • Detailed information can be found in the SST-PFB-CLX User Guide (Ver. 1.4 715-0022), which is available on www.woodhead.com. Step 2: Add SST Profibus Scanner in RSLogix 5000 I/O Configuration • Add SST-PFB-CLX scanner I/O configuration. Reference pages 36 to 39 of the SST-PFB-CLX User Guide, for detailed information. • Notice that the SST-PFB-CLX scanner is now under the I/O configuration. • Enter a name (optional), an appropriate slot number and the connection parameters as shown in this screen capture. Step 3: Access Module Data via the SST-PFB-CLX Scanner and Create Ladder Program. • Reference Chapter 7 of the SST-PFB-CLX User Guide for addressing information. • Choose Next to set RPI. • Choose Finish. Notice that the 32 Point Valve Driver Module is now under the I/O configuration. Step 5: Access Module Data via the RPSSCENA or 1738-AENT Adapter and Create Ladder Program. • Make sure the 32 outputs of RPSSV32A appear in Controller Tags. Use the information in the ladder logic program to access module data. • Reference pages 4-13 through 4-14 of Rockwell publication 1734UM011 for similar information. Step 6: Download the Program to the Controller • Reference pages 4-13 through 4-14 of Rockwell publication 1734UM011 for similar information. 6 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) Troubleshoot With the Indicators RPSSV32A ROSS RPSSV32A Module Status Indicator Mod Net Fault Network Status Indicator Output Fault Status Indicator Indication Probable Cause Module Status Off No power applied to device Green Device operating normally Flashing Green Device needs commissioning due to missing, incomplete, or incorrect configuration Flashing Red Recoverable fault Red Unrecoverable fault - may require device replacement Flashing Red/Green Device is in self-test Indication Probable Cause Network Status Off Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Flashing Green Device is on line but has no connections in the established state. Green Device is on line and has connections in the established state. Flashing Red One or more I/O connections in timed-out state. Red Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Flashing Red/Green Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Indication Probable Cause Output Fault Status Off Outputs operating normally Red Over current, short circuit or over temperature detected on one or more outputs. (On-State only) www.rosscontrols.com 7 Serial Bus 32 Point Valve Driver, Series A (RPSSV32A) Specifications – Following are specifications for the 32 point valve driver. 32 Point Valve Driver Outputs per Module Voltage Drop, On-State Output, Maximum Voltage, Off-State Output, Maximum Voltage, On-State Output, Maximum Minimum Nominal Output Current Rating Output Surge Current, Maximum Current Leakage, Off-State Output, Maximum Current, On-State Output Minimum Output Delay Time OFF to ON, Maximum1 Output Delay Time, ON to OFF, Maximum1 External DC Power Supply Voltage Range External DC Power Supply Voltage Nominal General Specifications LED Indicators PointBus Current, Maximum Operating Temperature Storage Temperature Relative Humidity Shock Vibration ESD Immunity Radiated RF Immunity EFT/B Immunity Surge Transient Immunity Conducted RF Immunity Emissions Enclosure Type Rating Mounting Base Screw Torque Wiring Category2 Certifications: (when product is marked) 32, sourcing 0.2VDC 28.8VDC 28.8VDC 10VDC 24VDC 200 mA per channel, not to exceed 6.0 A per module 0.5 A for 10 ms, repeatable every 3 seconds 0.1 mA 200 mA per channel 0.1 ms 0.1 ms 10 to 28.8VDC 24VDC 1 output status 1 green/red network status, logic side 1 green/red module status, logic side 75 mA @ 5VDC IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz IEC 61000-4-2: 6kV contact discharges 8kV air discharges IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz IEC 61000-4-4: ±3kV at 5kHz on signal ports IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on signal ports IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz CSPR 11: Group 1, Class A Meets IP65/66/67 (when marked) #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 - on signal ports c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. OFF to ON or ON to OFF delay is time from a valid output “on” or “off” signal to output energization or de-energization. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10312 Installation & Service Instructions A10315 Serial Bus ControlNet Adapter, Series A (RPSSCCNA) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus ControlNet Adapter, Series A (RPSSCCNA) The sealed IP67 housing of the adapter requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) ControlNet connectors are two redundant TNC style network connectors and one mini style power connector. The ControlNet adapter is shown below. RPSSCCNA ControlNet A RPSSCCNA Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. TNC Style Connectors Node Address Switches Mini 7/8" Auxiliary Power Connector ControlNet B X10 X1 Adapter Status PointBus Status ControlNet A Status ControlNet B Status System Power Adapter Power PWR ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. Serial Bus ControlNet Adapter User Manual The Serial Bus ControlNet Adapter User Manual PSS-UM003A-EN-P is not available at this time. Please refer to Rockwell Automation 1734 POINT I/O ControlNet Adapter User Manual 1734-UM008A-EN-P for similar setup information, which is available online at http://literature.rockwellautomation.com/. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form A10325) (available online at www.rosscontrols.com/rosslit.htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Before You B egin Configure Autobaud To effectively use your adapter, note the following considerations. The adapter cannot reconfigure an I/O module that you previously configured to operate at a fixed baud rate. When you reuse a Serial Bus I/O module from another Serial Bus I/O system, configure the module to autobaud before using it with the adapter. Understanding Messaging Class 3 (Explicit Message) requests through the adapter to a specific I/O module may not always receive a response from the I/O module. In the case where the I/O module does not reply to the request, the adapter responds with an error code indicating a time-out. Establish I/O Connections When you power up a Serial Bus I/O system and establish I/O connections, the outputs transition to the Idle state, applying Idle state data before going to RUN mode. This occurs even when the controller making the connection is already in RUN mode. Mount the Adapter and I/O Base To mount the adapter on a wall or panel, use the screw holes provided in the adapter. A mounting illustration for the adapter with I/O bases is shown below. 1.9 (47.2) Adapter 2.0 (50) 0.87 (22) I/O Module Ground 2.0 (50) 3.13 (79.4) 5.98* (151.9) I/O Module Ground 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) 3.02 (76.6) Drill and Tap for M4 Screw 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Grounding Each Serial Bus base has two mounting holes, with the one on the right being the means to ground each module. Each module must be grounded. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the adapter using #8 (M4) screws. 4. Ground the system using the ground lug connection in the I/O base. (The ground lug connection is also a mounting hole.) www.rosscontrols.com 3 Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Set the Node Address To set the node address, adjust the switches on the front of the module (refer to the illustration on page 1). Use a small blade screwdriver to rotate the switches. Line up the small notch on the switch with the number setting you wish to use. The two switches are most significant digit (MSD) and least significant digit (LSD). The switches can be set from 01 through 99. The module reads the switches at power-up only. This example shows the node address set at 63. The rotary switches are read periodically. If the switches have been changed since the last time they were read and they no longer match the on line address, a minor fault will occur, which is indicated by a flashing red Adapter Status LED. • Choose Next to set RPI. • Choose Finish. Notice that the RPSSCCNA is now under the I/O configuration. If your RSLogic 5000 is Version 13.X: • Choose the 1738-ACNR/A from the list of modules. EDS File Requirements The EDS file is available online at www.rosscontrols.com/rosslit.htm. Add ControlNet Adapter to RSLogix 5000 I/O Configuration To add your RPSSCCNA to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000, highlight the ControlNet Scanner, right click and select New Module. If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSCCNA module from the list of Parker modules. • Enter a name, an appropriate node address, and chassis size. Make sure to choose Compatible Module for Electronic Keying setting. • Choose Next to set RPI. • Choose Finish. Notice that the 1738-ACNR is now under the I/O configuration • Enter a name, an appropriate address and chassis size. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Wire the ControlNet Adapter Following are wiring instructions for the ControlNet Adapter. TNC Cables • Connect TNC cables to Channel A or B for single media. • Connect TNC cables to Channel A and B for redundant media. RPSSCCNA Auxiliary Power (Mini 7/8") Male In Connector (view into connector) Pin 1 - User Power + Pin 2 - Adapter Power + Pin 3 - Adapter Power Pin 4 - User Power - NOTE: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for adapter. It is converted to 5VDC to power Serial Bus modules. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Troubleshoot with the Indicators RPSSCCNA ControlNet A RPSSCCNA ControlNet B X10 X1 Adapter Status PointBus Status ControlNet A Status ControlNet B Status System Power Adapter Power PWR Adapter Status Indicator PointBus Status Indicator ControlNet A Status Indicator ControlNet B Status Indicator System Power Indicator Adapter Power Indicator Indication Adapter Status Off Alternating Red/Green Flashing Red Solid Red Flashing Green Solid Green No power applied to device LED powerup test (module self-test) Recoverable fault has occurred: - Firmware (NVS) update - MAC ID changed - CPU load exceeded Unrecoverable fault has occurred: - Self-test failure (checksum failure at powerup, ramtest failure) at powerup - Firmware fatal error Waiting for connection or ControlNet cable break Module is operating correctly (normal mode) Indication PointBus Status Off Probable Cause Alternating Red/Green Flashing Red LED powerup test Red Flashing Green Green 6 Probable Cause Device is not powered check module status indicator Recoverable fault has occurred: - At power up the number of expected modules does not equal the number of modules present - A module is missing - Node fault (I/O connection timeout) Unrecoverable fault has occurred: - The adapter is bus off - The adapter has failed its dup_MAC_ID check Adapter is on line with no connections established: - Adapter chassis size has not been configured - Controller in program/idle mode - ControlNet cable break Adapter is on line with connections established (normal operation, in run mode) Indication Probable Cause ControlNet A/B Status (Viewed Together) Both Steady Off Reset, no power or entire network interface deactivated Alternating Self-test mode Red/Green Alternating Red/Off Bad/invalid node configuration (such as dup_MAC_ID) Both Steady Red Failed link interface Indication Probable Cause ControlNet A/B Status (Viewed Individually) Steady Off Channel disabled or channel not supported Flashing Red/Green Invalid link configuration Flashing Red/Off Severe link error - link fault or no MAC frames received Flashing Green/Off Temporary channel error or listen-only Steady Green Normal operation - MAC frames are being received without detected error Indication System Power* Off Green Indication Adapter Power** Off Green Probable Cause Not active - Field power is off, overloaded backplane or dc-dc converter problem Power on - dc-dc converter active (5V) Probable Cause Not active - Field power is off Power on - 24V present * System Power Indicator shows the 5V power output from the dc-dc converter. ** Adapter Power Indicator shows the 24V power input to the dc-dc converter. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus ControlNet Adapter, Series A (RPSSCCNA) Specifications Following are specifications for the RPSSCCNA ControlNet adapter. ControlNet Adapter - RPSSCCNA Expansion I/O Capacity • Maximum of 63 modules • Maximum of 5 Rack Optimized connections (for digital modules only) • Maximum of 25 Direct connections • RPSSCCNA backplane current output = 1.0A maximum. See the list below for backplane current consumption for each I/O catalog number and the current consumption for each of the modules connected to the RPSSCCNA. Verify that it is below 1.0A. • Backplane current can be extended beyond 1.0A with a RPSSSE24A Backplane Extension Power Supply. The RPSSSE24A can supply up to an additional 1.3A of backplane current. • Multiple RPSSSE24A modules can be used to reach the maximum of 63 modules. Cat. No. PointBus Current Requirements RPSSN8xxx RPSSP8xxx RPSST8xxx RPSSTR4M12A RPSSNACM12A RPSSNAVM12A RPSSTACM12A RPSSTAVM12A RPSSS23A RPSSV32A ControlNet Communication Rate 75 mA 75 mA 75 mA 90 mA 75 mA 75 mA 75 mA 75 mA 75 mA 75 mA 5Mbits /s (fixed value) Power Supply Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC 10-28.8VDC range Inrush Current 6A maximum for 10ms Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 425 mA Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications LED Indicators 1 green/red Adapter status 2 green/red ControlNet status 1 green/red PointBus status 1 green System Power (PointBus 5V power) 1 green Adapter Power (24V from field supply) Power Consumption, Maximum 10.2W @ 28.8VDC Power Dissipation, Maximum 5.0W @ 28.8VDC Thermal Dissipation, Maximum 16.9 BTU/hr. @ 28.8VDC Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested at 1250VAC for 60s Field Power Bus Nominal Voltage Supply Voltage Supply Current 24VDC 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 4.41H x 2.83W x 2.56D (112H x 72W x 65D) www.rosscontrols.com 7 Serial Bus ControlNet Adapter, Series A (RPSSCCNA) General Specifications (continued) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports ±3kV at 5kHz on signal ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports ±2kV line-earth(CM) on shielded ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel Wiring Category1 1 - on power ports 1 - on communications ports Weight Imperial (Metric) Certifications: (when product is marked) 0.80 lb. (0.36 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions CI ControlNet Int'l conformance tested to ControlNet specifications 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10315 Installation & Service Instructions A10313 Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) ISSUED: August, 2007 Supersedes: None ! RPSSCDM12A WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. M12 Connector RPSSCDM12A DeviceNet Out DeviceNet In Node Address Switches Adapter Status DeviceNet Status X10 X1 PointBus Status System Power Adapter Power PWR Mini 7/8" Auxiliary Power Connector ROSS RPSSCDM18PA Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Mini 7/8" Connector RPSSCDM18PA DNet Out DNet In Node Address Switches Mini 7/8" Auxiliary Power Connector Adapter Status DeviceNet Status X10 X1 PWR PointBus Status System Power Adapter Power ROSS ! WARNING Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) The sealed IP67 housing of these adapters requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) DeviceNet connectors are sealed Micro (M12) or Mini (7/8") styles. The DeviceNet adapters are shown below. Serial Bus DeviceNet Adapters User Manual The Serial Bus DeviceNet Adapters A10311 is available online at www.rosscontrols.com/rosslit.htm. FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form A10325) (available online at www.rosscontrols.com/rosslit.htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Mount the Adapter and I/O Base To mount the adapter on a wall or panel, use the screw holes provided in the adapter. A mounting illustration for the adapter with I/O bases is shown below. 1.9 (47.2) Adapter 2.0 (50) 0.87 (22) I/O Module Ground 2.0 (50) 3.13 (79.4) 5.98* (151.9) I/O Module Ground 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Grounding Each Serial Bus base has two mounting holes, with the one on the right being the means to ground each module. Each module must be grounded. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the adapter and I/O bases using #8 (M4) screws. 4. Ground the system using the ground lug connection in the I/O base. (The ground lug connection is also a mounting hole.) www.rosscontrols.com 3 Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Set the Node Address Valid node addresses are 00 through 63. Set the node address using either the rotary switches, RSNetWorx for DeviceNet™, DeviceNetManager™, or another software configuration tool. Setting the switches at any number from 64 through 99 lets the software have address control. Each module is shipped with the switches set for node address 63. Remove the caps on the front of the module to access the switches (refer to the illustrations on page 1). The two switches are: • X10 (most significant digit) – left side of module • X1 (least significant digit) – right side of module This example shows the node address set at 63. To reset the node address, use a small blade screwdriver to rotate the switches. Line up the small notch on the switch with the number setting you wish to use and then cycle power. The rotary switches are read periodically. If the switches have been changed since the last time they were read and they no longer match the on line address, a minor fault will occur, which is indicated by a flashing red Adapter Status LED. Settings of 64 through 99 cause the module to use the last valid node address stored internally. Example: The last setting internally was 40. If a change is made to 68, and then you power up, the address will default to 40. The module is equipped with AutoBaud detect. AutoBaud lets the module read the settings already in use on your DeviceNet network and automatically adjusts to follow those settings. EDS File Requirements The EDS files are available online at www.rosscontrols.com/rosslit. htm. Open Configuration Method For using DeviceNet Adapters without RSNetWorx™ or RSLogix™ 5000, refer to document “User Guide: Configuration of the Pneumatics Platform using CIP™ Explicit Messaging", which is available online at www.rosscontrols.com/rosslit.htm 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Wire the DeviceNet Adapters Following are wiring instructions for the DeviceNet Adapters. RPSSCDM12A (Micro M12 A - Coding Key) Female Out Connector Male In Connector (view into connector) Pin 1 - Drain Pin 2 - +V Pin 3 - -V Pin 4 - CAN_High Pin 5 - CAN_Low RPSSCDM18PA (Mini 7/8") Female Out Connector Male In Connector (view into connector) Pin 1 - Drain Pin 2 - +V Pin 3 - -V Pin 4 - CAN_High Pin 5 - CAN_Low DeviceNet Auxiliary Power (Mini 7/8") Male In Connector (view into connector) Pin 1 - User Power + Pin 2 - Adapter Power + Pin 3 - Adapter Power Pin 4 - User Power - NOTE: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for adapter. It is converted to 5VDC to power modules. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Troubleshoot with the Indicators RPSSCDM18PA RPSSCDM18PA DNet Out Adapter Status Indicator DNet In Adapter Status DeviceNet Status X10 X1 PointBus Status System Power Adapter Power PWR ROSS Indication Adapter Status Off Green Flashing Red Red Flashing Red/Green Probable Cause No power applied to device Device operating normally Recoverable fault Unrecoverable fault may require device replacement Device is in self-test DeviceNet Status Indicator PointBus Status Indicator System Power Indicator Adapter Power Indicator Indication PointBus Status Off Flashing Green Green Indication DeviceNet Status Off Flashing Green Green Flashing Red Red Probable Cause Flashing Red Device is not on line: - Device attempting to Autobaud - Device has not completed dup_MAC-id test - Device not powered - check module status indicator Device is on line but has no connections in the established state Device is on line and has connections in the established state One or more I/O connections in timed-out state Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. (Possible duplicate MAC ID or baud rate mismatch). Red Flashing Red/Green Indication System Power* Off Green Indication Adapter Power** Off Green Probable Cause Device is not on line: - Device has not completed dup_MAC-id test - Device not powered - check module status indicator Device is on line but has no connections in the established state Device is on line and has connections in the established state One or more I/O connections in timed-out state Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. (Possible duplicate MAC ID or baud rate mismatch). Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Probable Cause Not active - Field power is off, overloaded backplane or dc-dc converter problem. System power on - dc-dc converter active (5V). Probable Cause Not active - Field power is off. System power on, 24V present. * System Power Indicator shows the 5V power output from the dc-dc converter. ** Adapter Power Indicator shows the 24V power input to the dc-dc converter. 6 ® © 2007 ROSS CONTROLS . All Rights Reserved. Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) Specifications Following are specifications for the DeviceNet adapters. R DeviceNet Adapters - RPSSCDM12A, RPSSCDM18PA Expansion I/O Capacity • DeviceNet adapter backplane current output = 1.0A maximum. See the list below for backplane current consumption for each I/O catalog number and the current consumption for each of the modules connected to the DeviceNet adapter. Verify that it is below 1.0A. • Backplane current can be extended beyond 1.0A with a RPSSSE24A Backplane Extension Power Supply. The RPSSSE24A can supply up to an additional 1.3A of backplane current. • Multiple RPSSSE24A modules can be used to reach the maximum of 63 modules. Cat. No. PointBus Current Requirements RPSSN8xxx RPSSP8xxx RPSST8xxx RPSSTR4M12A RPSSNACM12A RPSSNAVM12A RPSSTACM12A RPSSTAVM12A RPSSS23A RPSSV32A DeviceNet Communication Rate 75 mA 75 mA 75 mA 90 mA 75 mA 75 mA 75 mA 75 mA 75 mA 75 mA 125K bit/s (500m maximum) 250K bit/s (250m maximum) 500K bit/s (100m maximum) DeviceNet Power Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC nominal DeviceNet Input Voltage Range 11-25VDC DeviceNet specification Input Overvoltage Protection Reverse polarity protected DeviceNet Power Requirements 24VDC (+4% = 25VDC) @ 30 mA maximum Power Supply Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC 10-28.8VDC range Input Overvoltage Protection Reverse polarity protected Inrush Current 6A maximum for 10ms PointBus Output Current 1A maximum @ 5VDC +5% (4.75-5.25) Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 400 mA Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications LED Indicators 1 green/red Adapter status 1 green/red DeviceNet status 1 green/red PointBus status 1 green System Power (PointBus 5V power) 1 green Adapter Power (24V from field supply) Power Consumption, Maximum 8.1W @ 28.8VDC www.rosscontrols.com 7 Serial Bus DeviceNet Adapters, Series A (RPSSCDM12A, RPSSCDM18PA) General Specifications (continued) Power Dissipation, Maximum 2.8W @ 28.8VDC Thermal Dissipation, Maximum 9.5 BTU/hr. @ 28.8VDC Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested at 1250VAC rms for 60s Serial Power Bus Nominal Voltage Supply Voltage Supply Current 24VDC 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 4.41H x 2.83W x 2.56D (112H x 72W x 65D) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports ±3kV at 5kHz on signal ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports ±2kV line-earth(CM) on shielded ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel Wiring Category1 1 - on power ports 1 - on communications ports Weight Imperial (Metric) Certifications: (when product is marked) 0.80 lb. (0.36 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions ODVA ODVA conformance tested to DeviceNet specifications 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10313 Installation & Service Instructions A10316 Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) ISSUED: August , 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) The sealed IP67 housing of the adapter requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) The EtherNet/IP connector is a sealed D-coded M12 (micro) style. The EtherNet/IP adapter is shown below. RPSSCENA EtherNet I/P RPSSCENA Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. M12 Connector X100 I P X10 Network Address Switches Mini 7/8" Auxiliary Power Connector X1 A D D R E S S Adapter Status Network Activity Network Status PointBus Status System Power PWR Adapter Power ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. Serial Bus EtherNet/IP Adapter User Manual The Serial Bus EtherNet/IP Adapter User Manual PSS-UM004A-EN-P is not available at this time. Please refer to Rockwell Automation 1734 POINT I/O EtherNet/IP Adapter User Manual 1734-UM011A-EN-P for similar setup information, which is available online at http://literature.rockwellautomation.com/. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form A10325) (available online at www.rosscontrols.com/rosslit.htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) When you power up a Serial Bus I/O system and establish I/O connections, the outputs transition to the Idle state, applying Idle state data before going to RUN mode. This occurs even when the controller making the connection is already in RUN mode. Before You B egin To effectively use your adapter, note the following considerations. Determine Compatibility If using the adapter with an Allen-Bradley 1756-ENBT module or 1788-ENBT module, use the following required firmware versions for these bridge modules: • 1756-ENBT firmware version 2.3 or greater • 1788-ENBT firmware version 1.33 or greater If you use the BootP Utility to assign IP addresses to the adapter, use version 2.3.2 or greater. Understanding Messaging Class 3 (Explicit Message) requests through the adapter to a specific I/O module may not always receive a response from the I/O module. In the case where the I/O module does not reply to the request, the adapter responds with an error code indicating a time-out. Configure Autobaud The adapter cannot reconfigure an I/O module that you previously configured to operate at a fixed baud rate. When you reuse a Serial Bus I/O module from another Serial Bus I/O system, configure the module to autobaud before using it with the adapter. Open Configuration Method For using Serial Bus EtherNet/IP Adapters without RSNetWorx™ or RSLogix™ 5000, refer to document “User Guide: Configuration of the isysNet™ Pneumatics Platform using Explicit Messaging", which is available at www.rosscontrols.com/rosslit.htm. Establish I/O Connections Mount the Adapter and I/O Base To mount the adapter on a wall or panel, use the screw holes provided in the adapter. A mounting illustration for the adapter with I/O bases is shown below. 1.9 (47.2) Adapter 2.0 (50) 0.87 (22) I/O Module Ground 2.0 (50) 3.13 (79.4) 5.98* (151.9) I/O Module Ground 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) 3.02 (76.6) Drill and Tap for M4 Screw 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Grounding Each Serial Bus base has two mounting holes, with the one on the right being the means to ground each module. Each module must be grounded. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the adapter using #8 (M4) screws. 4. Ground the system using the ground lug connection in the I/O base. (The ground lug connection is also a mounting hole.) www.rosscontrols.com 3 Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) Set the Network Address To set the network address, you can: • Adjust the switches on the front of the module • Use a Dynamic Host Configuration Protocol (DHCP) server • Retrieve the IP address from nonvolatile memory The adapter reads the switches first to determine if the switches are set to a valid number. You set the node address by adjusting the 3 switches on the front of the module (refer to the illustration on page 1). Use a small blade screwdriver to rotate the switches. Line up the small notch on the switch with the number setting you wish to use. Valid settings range from 001 through 254. If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSCENA module from the list of Parker modules. This example shows the network address set at 163. • Enter a name, an appropriate I/P address and chassis size. When the switches are set to a valid number, the adapter’s IP address will be 192.168.1.xxx (where xxx represents the number set on the switches). The adapter’s subnet mask will be 255.255.255.0 and the gateway address will be set to 0.0.0.0. When the adapter is reading the network address set on the switches, the adapter will not have a host name assigned to it or use any Domain Name System. If the switches are set to an invalid number (i.e., 000 or a value greater than 254), the adapter checks to see if DHCP is enabled. If DHCP is enabled, the adapter asks for an address from a DHCP server. The DHCP server will also assign other Transport Control Protocol (TCP) parameters. If DHCP is not enabled, the adapter will use the IP address (along with other TCP configurable parameters) stored in nonvolatile memory. • Choose Next to set RPI. • Choose Finish. Notice that the RPSSCENA is now under the I/O configuration. EDS File Requirements The EDS file is available online at www.rosscontrols.com/rosslit.htm. If your RSLogic 5000 is Version 13.X: • Choose the 1738-AENT/A from the list of modules. Add EtherNet/IP Adapter to RSLogix 5000 I/O Configuration To add your RPSSCENA to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000, highlight the EtherNet/IP Scanner, right click and select New Module. • Enter a name, an appropriate IP address, and chassis size. Make sure to choose Compatible Module for Electronic Keying setting. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) Wire the EtherNet/IP Adapter Following are wiring instructions for the EtherNet/IP Adapter. RPSSCENA Network Connector (D-Coded M12) Female In Connector (view into connector) Pin 1 - Tx + Pin 2 - Rx + Pin 3 - Tx Pin 4 - Rx - • Choose Next to set RPI. • Choose Finish. Notice that the 1738-AENT is now under the I/O configuration RPSSCENA Auxiliary Power (Mini 7/8") Male In Connector (view into connector) Pin 1 - User Power + Pin 2 - Adapter Power + Pin 3 - Adapter Power Pin 4 - User Power - NOTE: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for adapter. It is converted to 5VDC to power Serial Bus modules. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) Troubleshoot with the Indicators RPSSCENA EtherNet I/P RPSSCENA X100 Adapter Status Indicator I P X10 X1 A D D R E S S Adapter Status Network Activity Network Status PointBus Status System Power PWR Adapter Power Network Activity Indicator Network Status Indicator PointBus Status Indicator System Power Indicator Adapter Power Indicator Indication Adapter Status Off Flashing Red/Green Green Flashing Red Solid Red No power applied to device LED power up test (module self-test) Device is operating normally Recoverable fault has occurred: - Firmware (NVS) update - Network IP address changed - CPU load exceeded Unrecoverable fault has occurred: - Self-test failure (checksum failure at power up, ramtest) failure at power up - Firmware fatal error Indication Network Activity Off Flashing Green/Off Green Probable Cause Indication Network Status Off Probable Cause Flashing Green Green Flashing Red Red Flashing Red/Green 6 Probable Cause No link established Transmit or receive activity Link established Device is not initialized. The module does not have an IP address. No CIP connections. Device has an IP address, but no CIP connections are established. CIP connections. Device on line, has an IP address, and CIP connections are established. One or more Ethernet® connections has timed out. No link. The module is not physically connected to a powered Ethernet device. The module is performing a self test (only occurs during power up test). Indication PointBus Status Off Flashing Red/Green Red Green Indication System Power* Off Green Indication Adapter Power** Off Green Probable Cause Device not powered check module status indicator Recoverable fault has occurred: - At power up the number of expected modules does not equal the number of modules present - A module is missing - Node fault (I/O connection timeout) Unrecoverable fault has occurred: - The adapter is bus off - Controller in program/idle mode - Ethernet cable open Adapter is on line with connections established (normal operation, run mode) Probable Cause Not active - Field power is off, overloaded backplane or dc-dc converter problem System power on - dc-dc converter active (5V) Probable Cause Not active - Field power is off Power on - 24V present * System Power Indicator shows the 5V power output from the dc-dc converter. ** Adapter Power Indicator shows the 24V power input to the dc-dc converter. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) Specifications Following are specifications for the RPSSCENA EtherNet/IP adapter. EtherNet/IP Adapter - RPSSCENA Expansion I/O Capacity • Maximum of 63 modules • Maximum of 5 Rack Optimized connections (for digital modules only) • Maximum of 25 Direct connections • RPSSCENA backplane current output = 1.0A maximum. The actual number of modules can vary. Add up the current requirements of the modules you want to use to make sure they do not exceed the amperage limit of 1.0A for the RPSSCENA. • Backplane current can be extended beyond 1.0A with a RPSSSE24A Backplane Extension Power Supply. Add multiple RPSSSE24A modules to reach the 63 module maximum. Cat. No. PointBus Current Requirements RPSSN8xxx RPSSP8xxx RPSST8xxx RPSSTR4M12A RPSSNACM12A RPSSNAVM12A RPSSTACM12A RPSSTAVM12A RPSSS23A RPSSV32A EtherNet/IP Communication Rate 75 mA 75 mA 75 mA 90 mA 75 mA 75 mA 75 mA 75 mA 75 mA 75 mA 10/100Mbits /s, half or full-duplex Power Supply Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC nominal 10-28.8VDC range Inrush Current 6A maximum for 10ms Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 400 mA Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications LED Indicators 1 green/red Adapter status 1 green Network activity 1 green/red Network status 1 green/red PointBus status 1 green System Power (PoinrBus 5V power) 1 green Adapter Power (24V from field supply) Power Consumption, Maximum 8.1W @ 28.8VDC Power Dissipation, Maximum 2.8W @ 28.8VDC Thermal Dissipation, Maximum 9.5 BTU/hr. @ 28.8VDC PointBus Output Current, Maximum 1A @ 5VDC ±5% (4.75 - 5.25) Input Overvoltage Protection Reverse polarity protected Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested to withstand 1250VAC rms for 60s Field Power Bus Nominal Voltage Supply Voltage Supply Current 24VDC 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 4.41H x 2.83W x 2.56D (112H x 72W x 65D) www.rosscontrols.com 7 Serial Bus EtherNet/IP Adapter, Series A (RPSSCENA) General Specifications (continued) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports ±2kV at 5kHz on communications ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports ±2kV line-earth(CM) on unshielded communications port (tested as balanced circuits) Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 Wiring Category Weight 1 - on power ports 1 - on communications ports Imperial (Metric) Certifications: (when product is marked) 0.80 lb. (0.36 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions EtherNet/IP ODVA conformance tested to EtherNet/IP specifications 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10316 Installation Safety Guidelines for Selecting and Using ROSS CONTROLS Products and Related Accessories ! WARNING: FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF ROSS CONTROLS PRODUCTS, ASSEMBLIES OR RELATED ITEMS (“PRODUCTS”) CAN CAUSE DEATH, PERSONAL INJURY, PROPERTY DAMAGE. POSSIBLE CONSEQUENCES OF FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THESE PRODUCTS INCLUDE BUT ARE NOT LIMITED TO: • Unintended or mistimed cycling or motion of machine members or failure to cycle • Work pieces or component parts being thrown off at high speeds. • Failure of a device to function properly for example, failure to clamp or unclamp an associated item or device. • Explosion • Suddenly moving or falling objects. • Release of toxic or otherwise injurious liquids or gasses. Before selecting or using any of these Products, it is important that you read and follow the instructions below. 1. GENERAL INSTRUCTIONS 1.1. Scope: This safety guide is designed to cover general guidelines on the installation, use, and maintenance of ROSS CONTROLS Valves, FRLs (Filters, Pressure Regulators, and Lubricators), and related accessory components. 1.2. Fail-Safe: Valves, FRLs, and their related components can and do fail without warning for many reasons. Design all systems and equipment in a fail-safe mode, so that failure of associated valves, FRLs or related accessory components will not endanger persons or property. 1.3 Relevant International Standards: For a good guide to the application of a broad spectrum of pneumatic fluid power devices see: ISO 4414:1998, Pneumatic Fluid Power – General Rules Relating to Systems. See www.iso.org for ordering information. 1.4. Distribution: Provide a copy of this safety guide to each person that is responsible for selection, installation, or use of Valves or FRL products. Do not select, or use ROSS CONTROLS valves or FRLs without thoroughly reading and understanding this safety guide as well as the specific ROSS CONTROLS publications for the products considered or selected. 1.5. User Responsibility: Due to the wide variety of operating conditions and applications for valves and FRLs ROSS CONTROLS and its distributors do not represent or warrant that any particular valve or FRL is suitable for any specific end use system. This safety guide does not analyze all technical parameters that must be considered in selecting a product. The user, through its own analysis and testing, is solely responsible for: • Making the final selection of the appropriate valve, FRL or accessory. • Assuring that all user’s performance, endurance, maintenance, safety, and warning requirements are met and that the application presents no health or safety hazards. • Complying with all existing warning labels and / or providing all appropriate health and safety warnings on the equipment on which the valves or FRLs are used; and, • Assuring compliance with all applicable government and industry standards. 1.6. Safety Devices: Safety devices must not be removed, defeated or designed around. 1.7. Warning Labels: Warning labels must not be removed, painted over or otherwise obscured. 1.8. Intake / Exhaust Restriction: Do not restrict the air flow in the supply line. To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action. Do not restrict a poppet valve’s exhaust port as this can adversely affect its operation. Exhaust silencers must be resistant to clogging and have flow capacities at least as great as the exhaust capacities of the valves. Contamination of the silencer can result in reduced flow and increased back pressure. 1.9. Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device. A double valve without a self-contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve. All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism. 1.10. Additional Questions: Call the appropriate ROSS CONTROLS technical service department if you have any questions or require any additional information. See the ROSS CONTROLS publications for the product being considered or used, or call your local distributor or ROSS CONTROLS' Technical Service department at 1-888-TEK-ROSS in the U.S.A. (1-706-356-3708 outside the U.S.A.). You may find your local ROSS distributor at www.rosscontrols.com. 2. PRODUCT SELECTION INSTRUCTIONS 2.1. Flow Rate: The flow rate requirements of a system are frequently the primary consideration when designing any pneumatic system. System components need to be able to provide adequate flow and pressure for the desired application. 2.2. Pressure Rating: Never exceed the rated pressure of a product. Consult product labeling, ROSS CONTROLS catalogs or the instruction sheets supplied for maximum pressure ratings. 2.3. Temperature Rating: Never exceed the temperature rating of a product. Excessive heat can shorten the life expectancy of a product and result in complete product failure. 2.4. Environment: Many environmental conditions can affect the integrity and suitability of a product for a given application. Ross Controls products are designed for use in general purpose industrial applications. If these products are to be used in unusual circumstances such as direct sunlight and/or corrosive or caustic environments, such use can shorten the useful life and lead to premature failure of a product. 2.5. Lubrication and Compressor Carryover: Some modern synthetic oils can and will attack nitrile seals. If there is any possibility of synthetic oils or greases migrating into the pneumatic components check for compatibility with the seal materials used. Consult the factory or product literature for materials of construction. 2.6. Polycarbonate Bowls and Sight Glasses: All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only. Do not fail to use the metal bowl guard, where provided, to minimize danger from high pressure fragmentation in the event of bowl failure. To avoid potential polycarbonate bowl failures: • Do not locate polycarbonate bowls or sight glasses in areas where they could be subject to direct sunlight, impact blow, or temperatures outside of the rated range. • Do not expose or clean polycarbonate bowls with detergents, chlorinated hydro-carbons, keytones, esters, liquefied petroleum gas, or certain alcohols. • Do not use polycarbonate bowls or sight glasses in air systems where compressors are lubricated with fire resistant fluids such as phosphate ester and di-ester lubricants. 2.7. Chemical Compatibility: For more information on plastic component chemical compatibility see ROSS' Catalog 104G (or later version). This can be downloaded at www.rosscontrols.com or can be obtained from your local ROSS distributor. 2.8. Product Rupture: Product rupture can cause death, serious personal injury, and property damage. • Do not connect pressure regulators or other ROSS CONTROLS products to bottled gas cylinders. • Do not exceed the maximum primary pressure rating of any pressure regulator or any system component. • Consult product labeling or product literature for pressure rating limitations. 2.9 ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type, wrong size, or inadequately maintained silencer installed with a ROSS product. 3. PRODUCT ASSEMBLY AND INSTALLATION INSTRUCTIONS 3.1. Component Inspection: Prior to assembly or installation a careful examination of the valves and FRLs must be performed. All components must be checked for correct style, size, and catalog number. DO NOT use any component that displays any signs of nonconformance. 3.2. Installation Instructions: ROSS CONTROLS published installation instructions must be followed for installation of ROSS CONTROLS valves and FRLs. These instructions are provided with every ROSS CONTROLS valve and FRL sold, or by going to www.rosscontrols.com/rosslit.htm. All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment. In addition, overhauled or serviced valves must be functionally tested prior to installation or use. 3.3. Air Supply: The air supply or control medium supplied to valves and FRLs must be moisture-free if ambient temperature can drop below freezing 4. VALVE AND FRL MAINTENANCE AND REPLACEMENT INSTRUCTIONS 4.1. Maintenance: Even with proper selection and installation, valve and FRL service life may be significantly reduced without a continuing maintenance program. The severity of the application, risk potential from a component failure, and experience with any known failures in the application or in similar applications should determine the frequency of inspections and the servicing or replacement of ROSS CONTROLS products so that products are replaced before any failure occurs. A maintenance program must be established and followed by the user and, at minimum, must include instructions 4.2 through 4.9. 4.2. Installation and Service Instructions: Before attempting to service or replace any worn or damaged parts consult the appropriate service bulletin or installation / instruction sheet for the for the valve or FRL in question for the appropriate practices to service the unit in question. These Service and Installation Instructions are provided with every ROSS CONTROLS valve and FRL sold, or are available by calling 1-800-GET-ROSS, or by accessing the ROSS CONTROLS web site at www.rosscontrols.com. 4.3. Lockout / Tagout Procedures: Be sure to follow all required lockout and tagout procedures when servicing equipment. For more information see: ANSI/ASSE Z244.1-2003 and OSHA Standard – 29 CFR, Part 1910.147, Appendix A, The Control of Hazardous Energy – (Lockout / Tagout) 4.4. Visual Inspection: Any of the following conditions requires immediate system shut down and replacement of worn or damaged components: • Air leakage: Look and listen to see if there are any signs of visual damage to any of the components in the system. Leakage is an indication of worn or damaged components. • Damaged or degraded components: Look to see if there are any visible signs of wear or component degradation. • Kinked, crushed, or damaged hoses. Kinked hoses can result in restricted air flow and lead to unpredictable system behavior. • Any observed improper system or component function: Immediately shut down the system and correct malfunction. • Excessive dirt build-up: Dirt and clutter can mask potentially hazardous situations. Caution: Leak detection solutions should be rinsed off after use. 4.5. Routine Maintenance Issues: • Remove excessive dirt, grime and clutter from work areas. • Make sure all required guards and shields are in place. 4.6. Functional Test: Before initiating automatic operation, operate the system manually to make sure all required functions operate properly and safely. 4.7. Service or Replacement Intervals: It is the user’s responsibility to establish appropriate service intervals. Valves and FRLs contain components that age, harden, wear, and otherwise deteriorate over time. Environmental conditions can significantly accelerate this process. Valves and FRLs need to be serviced or replaced on routine intervals. Service intervals need to be established based on: • Previous performance experiences. • Government and / or industrial standards. • When failures could result in unacceptable down time, equipment damage or personal injury risk. 4.8. Servicing or Replacing of any Worn or Damaged Parts: To avoid unpredictable system behavior that can cause death, personal injury and property damage: • Follow all government, state and local safety and servicing practices prior to service including but not limited to all OSHA Lockout Tagout procedures (ANSI/ASSE Z244.1-2003 and OSHA Standard – 29 CFR, Part 1910.147, Appendix A, The Control of Hazardous Energy – Lockout / Tagout). • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to system and ROSS CONTROLS products before installation, service, or conversion. • Installation, servicing, and / or conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversions air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or if the product does not operate properly, do not put product or system into use. • Warnings and specifications on the product should not be covered or painted over. If masking is not possible, contact your local representative for replacement labels. 4.9. Putting Serviced System Back into Operation: Follow the guidelines above and all relevant Installation and Maintenance Instructions supplied with the valve or FRL to insure proper function of the system. Printed in U.S.A -0607 © Copyright 2007, ROSS CONTROLS. All Rights Reserved Form A10332 Installation & Service Instructions A10323 Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) The sealed IP67 housing of the module requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) The I/O connector is a sealed M12 (micro) style. The mounting base ships with the module. The RPSSS23A module is shown below. RPSSS23A RPSSS23A ASCII Interface M12 Connector MOD NET LED Indicators TxD RxD ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. IMPORTANT The I/O module must be mounted on a grounded metal mounting plate or other conductive surface. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 2 for the specialty modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Install the RS-232 ASCII Module Wire the RS-232 ASCII Module To Install the RS-232 ASCII Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 2 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Following are wiring instructions for the RS-232 ASCII module. RPSSS23A Module Will Bridge Two Bases RPSSS23A ASCII Interface (view into connector) Pin 1 - No Connect MOD Pin 2 - Tx + NET Pin 3 - Rx + Pin 4 - Common TxD RxD Pin 5 - No Connect IMPORTANT 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. The RPSSS23A module has earth grounded metal rings. This should be considered when choosing shielded cables and grounding techniques. Remove the RS-232 ASCII Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. Communicate With Your Module The RS-232 ASCII module operates as the PointBus front-end to your serial device. Data can be exchanged with the master through a polled, cyclic, or change of state connection. The module produces and consumes 4 to 132 bytes of data. EDS File Requirements The EDS file is available online at www.rosscontrols.com/rosslit.htm 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Add RS-232 ASCII Module to RSLogix 5000 I/O Configuration • Enter a name (optional), slot number, and comm. format. Make sure to choose Compatible Module for Electronic Keying setting. To add your RS-232 ASCII module to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the 1738-ACNR, right click and select New Module. • Choose Next to set RPI. • Choose Finish. Notice that the RS-232 ASCII module is now under the I/O configuration - For EtherNet/IP, highlight the 1738-AENT, right click and select New Module. • Choose the equivalent Rockwell Automation module 1738-232ASCM12 from the list of modules. www.rosscontrols.com 5 Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Troubleshoot With the Indicators RPSSS23A RPSSS23A ASCII Interface Module Status Indicator MOD Network Status Indicator NET TxD I/O Status Indicators RxD Indication Module Status Off Green Flashing Green Flashing Red Red Flashing Red/Green Indication Network Status Off Flashing Green Green Flashing Red Red Flashing Red/Green 6 Probable Cause No power applied to device Device operating normally Device needs commissioning due to missing, incomplete, or incorrect configuration Recoverable fault Unrecoverable fault may require device replacement Device is in self-test Probable Cause Indication Probable Cause Transmit/Receive Status Flashing Check wiring, ground, and Rx Transmit/Receive connection. User parameter object to view record numbers. Flashing Receive/ Check wiring. Watch the Tx light. If it Off Transmit does not flash, check to ensure that you are properly initiating transmission. Use the EDS parameter object to try transmitting and watch the light. If it flashes, you are not properly initiating transmission via I/O messaging. If it does flash, check the remote device. Off Transmit/ Check connections as you may have Green Receive wired the device backwards. Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Device is on line but has no connections in the established state. Device is on line and has connections in the established state. One or more I/O connections in timed-out state. Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Specifications Following are specifications for the RPSSS23A RS-232 ASCII module. RS-232 ASCII Module - RPSSS23A Inputs per Module 1 full duplex Input Voltage “0”, Asserted, ON, Space, Active “1”, Disasserted, OFF, Mark, Inactive Signal with respect to Signal Ground (SG) +3 to +25VDC -3 to -25VDC Indicators 1 green/red module status indicator, logic side 1 green/red network status indicator, logic side 2 green TXD, RXD status indicators, logic side Keyswitch Position 2 (specialty) Current, Maximum 75 mA @ 5VDC Power Dissipation, Maximum 0.75W @ 28.8VDC Thermal Dissipation, Maximum 2.5 BTU/hr. @ 28.8VDC Isolation Voltage (continuous voltage withstand rating) 50V rms Tested at 1250VAC rms for 60s External DC Power Supply Voltage Voltage Range Supply Current 24VDC nominal 10-28.8VDC 15 mA @ 24VDC Fault protected to 28.8VDC Serial Port Parameters Serial Character Framing 7N2, 7E1, 7O1, 8N1, 8N2, 8E1, 8O1, 7E2, 7O2 Serial Port Comm Speed 9600, 1200, 2400, 4800, 19.2k, 38.4k Serial Port Receive from ASCII Device Maximum Number of Receive Characters 1-128 Receive Record Start Mode No, exclude, include start delimiter Receive Start Delimiter ASCII character Receive Record End Mode No, exclude, include start delimiter Receive End Delimiter ASCII character Send (Produce) on DeviceNet to Master Receive String Data Type Array, short_string, string Pad Mode Pad mode disabled, enabled Pad Character ASCII character Receive Swap Mode Disabled, 16-bit, 24-bit, 32-bit swap DeviceNet Handshake Mode Master/slave handshake, produce immediate Produce Assembly Size 4-132 Serial Data 0-128 bytes Receive Transaction ID 0-255 Serial Port Transmit to ASCII Device Maximum Number of Transmit Characters 1-128 Transmit End Delimiter Mode No, exclude, include end delimiter Transmit End Delimiter Character ASCII Consume on DeviceNet from Master Consume String Data Type Array, short_string, string Transmit Swap Mode Disabled, 16-bit, 24-bit, 32-bit swap DeviceNet Record Header Mode Transmit handshake/immediate Consume Assembly Size 4-132 www.rosscontrols.com 7 Serial Bus I/O RS-232 ASCII Module, Series A (RPSSS23A) Serial Port Transmit/Explicit Messages Transmit Serial Data String 0-128 bytes Transmitted Serial Data Length 0-128 bytes Transmit Transaction ID 0-255 Status TX FIFO overflow, RX FIFO overflow, RX parity error, handshake error, new data flag General Specifications Dimensions Inches (Metric) 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10 to 500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±2kV at 5kHz on communications ports Surge Transient Immunity IEC 61000-4-5: ±2kV line-earth(CM) on shielded ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 2 - on communications ports Wiring Category Weight Imperial (Metric) Certifications: (when product is marked) 0.637 lb. (0.289 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10323 Installation & Service Instructions A10327 Size 0 & Size 00 ISO 15407-2 Interposed Flow Controls ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. The “Interposed” Flow Control is intended for use with the respective subbase or manifold mounted valves. Size 0 & Size 00 valves and flow controls are designed in conformance to ISO 15407-2. Size 0 & Size 00 Flow Controls are only recommended for use with Common Port versions of Interposed Regulators. The Flow Control is to be assembled between the regulator and the subbase or manifold. If used with Independent Port version of Interposed Regulator, functionality is limited as follows: “Interposed” Flow Control used in conjunction with Independent Port version of Interposed Regulator - Adjust speed with the adjusting screw labeled “5”. It adjusts the speed of exhaust flow from cylinder ports “2” and “4”. Independent speed adjustment is not possible. This could result in different exhaust speeds for cylinder ports “2” and “4” since line pressure is supplied to one cylinder port and a regulated pressure is supplied to the other. The other adjusting screw is non-functional. Lubrication Factory Pre-lubed. If lubricating in service, use paraffin based mineral oil with 150 to 200 SSU viscosity @100°F. ! CAUTION: Do not use oils that are synthetic, reconstituted, have an alcohol content or a detergent additive. Application Limits: These products are intended for use in general purpose compressed air systems only. Operating Pressure Range: Maximum 145 PSIG, 1000kPa Ambient Temperature Range: -15°C to 49°C (5°F to 120°F) ANSI Symbol: 5 5 Valve Side 4 1 2 4 1 2 Base Side 3 3 Installation: (See Figure 1, Size 00 Interposed Flow Control shown as example) Introduction Follow these instructions when installing, operating, or servicing the product. Installation & Operating Instructions: An “Interposed” Flow Control controls the flow of air from the valve exhaust ports to atmosphere. The Size 0 & Size 00 4-Way valve is typically used with a double acting cylinder alternately pressurizing one end while exhausting the other. Cylinder speed can be influenced by restricting the exhaust path. ! Warning: Not following instruction may result in Interposed Fow Control damage or inadequate thread engagement, which may lead to personal injury, property damage, or economic loss. Important: • Remove pressure and electrical connections before installation. • All threads on tie rods and screws must be free of rust, water or other debris, which could prevent finger thread engagement. W66 Size 0 & W66 Size 00 Interposed Flow Controls Step 1: Install Tie Rods 1. Install two Tie Rods (6) to the base, torque finger tight. 2. Adjust tie rod height to 28.5/28.0 mm (1.12/1.10 inch) as figure shows. 3. If finger tight height exceeds 28.5 mm (1.12 inch), use mechanical tightening as necessary to get the proper height. Max: 28.5 mm (1.12 Inch) Min: 28.0 mm (1.10 Inch) 2 4 Note: “Base” could be a manifold or a sub-base. 4 4. Using hex wrench, tighten two Screws (4) – torque 1.5 to 1.7 Nm (13 to 15 in-lb) for Size 0, 0.9 to 1.1 Nm (8 to 10 in-lb) for Size 00. Step 4: Leakage Check 1. Apply pressure to base and check for audible leakage at various joints. If any are present, do not not operate the valve, repeat the assembly procedure until satisfied. Note: If both a Interposed Flow Control and Interposed Regulator is to be installed, the Flow Control should be installed between the Regulator and the Base. Refer to Interposed Regulator Installation & Service Instructions (A10329) for Interposed Regulator installation. Adjustment Procedures: Valve Electrical Plug 5 Valve Body 1 3 5 For Size 0 & Size 00 Both Adjusting Screws (4) are located at the 12 End of the assembly. Adjustment screw labeled “5” controls the flow of air from cylinder Port 4 to exhaust Port 5. With a double solenoid valve this occurs when Operator #12 is actuated. With a single solenoid valve this occurs when Operator #14 is not actuated. Adjustment screw labeled “3” controls air from cylinder Port 2 to exhaust Port 3. 1. Turn both adjustment screws clockwise until fully closed and then counterclockwise slightly. 2. While cycling valve with cylinder adjust clockwise to decrease speed or counterclockwise to increase speed. 2 Component List 3 The components listed below are for identification purposes only, some of these components are available in various Interposed Flow Control Kits, some are not available due to special factory assembly. Individual components are not sold separately since all kit components should be installed when serviced. 2 Base Figure 1 (Size 00 Shown) Step 2: Install Interposed Flow Control 1. Lay the Interposed Flow Control Gasket (2) on the Base. Make sure the two rubber projections are face up and the orientation of the gasket is correct. 2. Engage both Tie Rods (3) into mounting holes on Flow Control Body, lower the Flow Control body. 3. Carefully engage the Electrical Plug into the Base. 4. Continue to lower the Flow Control Body by carefully engaging the two rubber projections on the gasket into the appropriate holes on the Flow Control Body. 5. Press the Flow Control Body by hand firmly. To confirm the gasket is indeed attached to the Flow Control Body, lift the Flow Control Body by about one half inch. Both rubber projections should remain in the holes. 6. Lay the Flow Control Body back on the Base. Step 3: Install Valve 1. Locate Valve Gasket (5) on bottom of Valve Body. 2. Install valve onto Flow Control. 3. Carefully engage the Valve Electrical Plug. Item 1 2 3 4 5 Description Flow Control Body Flow Control / Regulator Gasket Tie Rods Mounting Screws Valve Gasket Interposed Flow Control Kits Kit Size Number Item # (Qty) Size 00 RPS5635 1, 2, 3 (2) Size 0 RPS5535 1, 2, 3 (2) Kit Includes Description 18mm Interposed Flow Control Kit with Plug-in (Type 2) 26mm Interposed Flow Control Kit with Plug-in (Type 2) 1 (Without Elect. 18mm Interposed Flow Control Plug), 2, 3 Kit without Plug-in (Type 1) (2) 1 (Without Elect. 26mm Interposed Flow Control Size 0 RPS5542 Plug), 2, 3 (2) Kit with Plug-in (Type 1) 18mm Interposed Flow Control Size 00 RPS5636 3 (12) Tie Rod Kit 26mm Interposed Flow Control Size 0 RPS5536 3 (12) Tie Rod Kit Size 00 RPS5642 For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0807 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10327 Installation & Service Instructions A10328 Size 0 & Size 00 ISO 15407-2 Manifold Installation ISSUED: August, 2007 Supersedes: None Application Limits ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. These products are intended for use in general purpose compressed air systems only. Compliance with the rated pressure, temperature, and voltage is necessary - see Installation & Service Instructions packed with valve. Wiring Instructions for Individual Base Wiring 1. Follow all requirements for local and national electrical codes. 2. Remove end cover from base by backing off the two captive screws. 3. Connect wires as shown in chart. 4. An external ground connection must be attached to the green ground screw of every base in an assembly. 5. Disregard unused wires or terminals. 6. Reassemble cover to base by tightening screws from 0.8 to 1.0 Nm (7 to 9 in-lbs). Subbase Wiring Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. 4 3 ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. Comm Ground (Customer) 12 Terminal Ground (Ross) 14 Terminal Connections 14 Solenoid 12 Solenoid Valves with Wires Black Wires Red Wires Valves with Terminal Block (Will accept 18 to 24 Gauge Wires) 14 and Com Terminals 12 and Com Terminals EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Manifold Wiring ! WARNING Air exhausting from one valve into the exhaust gallery of the manifold assembly may momentarily pressurize other valve circuits open to the same gallery. Design the circuit such that there is no hazard or consequence of damage from this action. Introduction Follow these instructions when installing, operating, or servicing the product. 12B 14A 14B 12A Ground (Customer) Common W66 Size 0 & W66 Size 00 ISO 15407-2 Manifold Installation 3 5 3 2 7 12 3 G 2 Standard 9 3/5 Blocked 1 6 7 7 1 3 2 2 8 4 Blocked 5, 3, 1 3 Blocked 5, 3 16-Pin Terminal Strip 2 (Shown with Cover Removed) 2 4 3 2 2 1 12 G 10 2 14 End 3/5 1 12 G Detail A 10 3/5 12 12 12 End G G 3/5 3/5 1 16-Pin Terminal Strip End Plate See Detail A Item # Description 1 2 3 4 5 Left End Plate Tie Rod (3 per Base) Gasket - Standard Manifold Base (Size 00) Gasket - Blocked 1 External Ground Location (Green Screw) 1 25-Pin D-Sub End Plate Item # Description 6 7 8 9 10 Gasket - Blocked 1, 3, 5 Manifold Base (Size 0) Right End Plate Mounting Screws Pipe Plug Assembly Techniques 1. Lay Left Hand End Plate (Item 1) on left side (when looking at cylinder ports). 2. Attach three Tie Rods (Item 2) to the Left End Plate (Item 1) by hand tightening them down completely and then backing off 1-2 turns. Mount the Gasket (Item 3) over the Tie Rods. 3. Add Manifold Base (Item 4). Place 3 Tie Rods (Item 2) through the Base and screw into the Tie Rods mounted in the Left End Plate by hand tightening them down completely and then backing off 1-2 turns. 4. Build manifold vertically by adding remaining Manifolds, Gaskets and Tie Rods. 5. Place Right Hand End Plate and tighten screws to torque specification. 6. Check the manifold for straightness. Loosen and tighten bolts if needed. 7. Add Valves and Accessories. All Manifold Assemblies should be leak tested before operation. ! Caution: If the socket head cap screws do not engage the last tie rod, it is because the stack of uncompressed gaskets causes the manifolds and gaskets to be longer than the tie rod sets. It will be necessary to lengthen the tie rod sets by backing away each tie rod from its adjacent tie rod about one or two turns. This stack length 2 1 External Ground Location (Green Screw) M23, 12-Pin Round or 19-Pin Round End Plate problem is likely to occur at 6 or 7 manifold bases and worsens with each additional manifold Manifold Assembly Wiring Instructions 1. Follow all requirements for local and national electrical codes. 2. An External Ground Connection must be attached to the Manifold Assembly. An external ground location is provided on the Manifold End Plate (See drawing). All 25-Pin, D-Sub versions must use this ground connection. 19-Pin and 16-Pin Terminal Strip versions may omit this connection only if the ground is connected through the connector. Otherwise, the external ground connection location must be used. Manifold / End Plate Assembly Torque Values W66 Size 0 / W66 Size 00 Torque - in.lb. (Nm) 65 to 70 (7.3 to 7.9) Manifold Kits Kit Number Description Item Number RPS5612P Size 00 Manifold Hardware Kit 2 RPS5512P Size 0 Manifold Hardware Kit 2 RPS561AP Size 00 / Size 0 Manifold to Manifold Gasket Kit (Standard) 3 RPS561BP Size 00 / Size 0 Manifold to Manifold Gasket Kit (Blocked #1 Port) 5 RPS561CP Size 00 / Size 0 Manifold to Manifold Gasket Kit (Blocked #1, 3, 5 Ports) 6 RPS561DP Size 00 / Size 0 Manifold to Manifold Gasket Kit (Blocked #3, 5 Ports) 7 © 2007 ROSS CONTROLS®. All Rights Reserved. W66 Size 0 & W66 Size 00 ISO 15407-2 Manifold Installation 25-Pin, D-Sub Connector (Male) 16-Pin Terminal Block Terminal G 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Valve Solenoid GND COM 1 C 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Address G C 1 2 3 4 5 6 7 8 9 10 111213 1415 16 Pin Number 2 4 Push Orange Lever with Screwdriver Insert Wire into Hole. Strip Length 10mm. Use 18-22 AWG Wire. 6 8 10 12 Pin Number 1 2 14 15 16 17 18 14 16 18 19 20 21 22 20 22 24 23 24 25 Address 1 3 5 3 4 5 6 7 9 11 13 7 8 9 10 15 17 19 21 11 12 13 23 Common Face View - Male D-Sub, 25-Pin Connector 25-Pin, D-Sub Cable (Female) 19-Pin Round Brad Harrison Pin Number 1 2 3 4 5 6 7 8 9 10 Address 1 2 3 4 N/A 5 Common 6 7 8 11 10 9 13 19 17 16 8 1 12 18 7 Pin Number 11 12 13 14 15 16 17 18 19 2 3 14 15 4 5 6 Address 9 Ground 10 11 12 13 14 15 16 Face View - Male 19-Pin Connector 19-Pin Round Cable Specifications Common Pin “7” is rated for 8 amps. Cable common wire must be greater than total amperage of solenoids on a manidfold assembly. Example: 8 station manifold, 16 solenoids, 120VAC - 16 x .039 amps = .63 total amp rating. NEMA 4 rated with properly assembled NEMA 4 rated cable. Part Number Description Length R333030P80M050 Brad Harrison (Female to Male Cable) 16.40 ft. R333030P80M100 Brad Harrison (Female to Male Cable) 32.80 ft. Pin Color Number Address 1 Black 1 2 Brown 3 3 Red 5 4 Orange 7 5 Yellow 9 6 Green 11 7 Blue 13 8 Purple 15 9 Gray 17 10 White 19 11 Pink 21 12 Lt Green 23 13 Common Black / White Pin Number Color 14 15 16 17 18 19 20 21 22 23 24 25 Brown / White Red / White Orange / White Green / White Blue / White Purple / White Red / Black Orange / Black Yellow / Black Green / Black Gray / Black Pink / Black Address 2 4 6 8 10 12 14 16 18 20 22 24 25-Pin, D-Sub Cable Specifications Common Pin “13” is rated for 3 amps. Common wire rating must be greater than total amperage of all solenoids on a manifold assembly. IP65 rated with properly assembled IP65 rated cable. M23, 12-Pin Round Connector (Male) Pin Number 1 2 3 4 5 6 Address Input 0 Input 1 Input 2 Input 3 Input 4 Input 5 1 8 7 2 9 12 6 10 3 11 5 4 Pin Number 7 8 9 10 11 12 Address Input 6 Input 7 Ret (Common) Ret (Common) Not Used Ground Face View - Male M23, 12-Pin Connector M23, 12-Pin Round Connector (Female) Pin Number 1 2 3 4 5 6 Address Input 0 Input 1 Input 2 Input 3 Input 4 Input 5 8 1 2 7 9 10 3 11 6 11 4 5 Pin Number 7 8 9 10 11 12 Address Input 6 Input 7 Ret (Common) Ret (Common) Not Used Ground Face View - Female M23, 12-Pin Connector For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0407 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation Copyright 2007, ROSS CONTROLS. All Rights Reserved Form A10328 Installation & Service Instructions A10331 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation ISSUED: August, 2007 Supersedes: None Wiring Instructions for Individual Base Wiring ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. 1. Follow all requirements for local and national electrical codes. 2. Remove end cover from base by backing out the two screws. 3. Connect wires as shown in chart. 4. An external ground connection must be attached to the green ground screw of every base in an assembly. 5. Disregard unused wires or terminals. 6. Reassemble cover to base by tightening screws from 0.8 to 1.0 Nm (7 to 9 in-lbs). Connections Ground (Terminal Block applications only) Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. ! WARNING Air exhausting from one valve into the exhaust gallery of the manifold assembly may momentarily pressurize other valve circuits open to the same gallery. Design the circuit such that there is no hazard or consequence of damage from this action. Application Limits These products are intended for use in general purpose compressed air systems only. Compliance with the rated pressure, temperature, and voltage is necessary - see Installation & Service Instructions packed with valve. 14 12 12 Solenoid Red Wires 12 and Com Terminals Black Red 14 Terminal 3, 4 or 5-Pin Connector Subbase With Auto C, F, G Com Terminal 12 Terminal Ground (All Other Applications)) Subbase With Terminal Block Green Subbase With Wires Ground (Terminal Block Applications Only) 14 12 14 Terminal Com Terminal 3, 4 or 5-Pin Connector Manifold With Auto C, F, G Black Red 12 Terminal Ground (All Other Applications)) Manifold With Terminal Block Green Manifold With Wires Wiring - Auto C, F, G Pin 1 (Green) Pin 2 (Black) Pin 1 (Brown) Pin 4 (Black) Pin 2 (White) Pin 3 (White) Wiring Type Pin #1 Pin 5 Pin 1 (White) (Black) Pin 2 (Red) 4-Pin M12 Enclosure “8” 3-Pin Mini Encl ‘7’ C, F, G Gnd Pin 4 (Orange) Pin 3 (Green) Pin 3 (Blue) 3-Pin Mini Enclosure “7” Introduction Follow these instructions when installing, operating, or servicing the product. 14 Solenoid Black Wires 14 and Com Terminals Bases with Wires Bases with Terminal Block (Will accept 18 to 24 Gauge Wires) 5-Pin Mini Enclosure “9” 4-Pin M12 Encl ‘8’ C F G 5-Pin Mini Encl ‘9’ C F G 14 N/A 12 12 Gnd 12 N/A Pin #2 14 Pin #3 Com Pin #4 N/A 12 14 Pin #5 N/A N/A N/A 14 12 12 12 14 Gnd Gnd Gnd 14 14 12 14 N/A 14 14 12 Com Com Com Size 1, 2 & 3 Subbase & Manifold Installation Wiring Instructions for Manifold Interconnect Wiring ! 19-Pin Round Collective Wiring Module CAUTION: An interruption of 10 milliseconds or greater to the power supplied to the solenoid of a solenoid operated valve may cause the valve to shift. Provision must be made to prevent power interruption of this duration to avoid unintended, potentially hazardous, consequences. For connection simplicity, the Interconnect Wiring System has a single common lead with an amperage limit of 3 amps continuous service. The following chart indicates the upper limit of solenoids that can be energized simultaneously. Voltage 25-Pin Code 42 42 B9 23 12VDC 24VAC* 24VDC 120VAC* 19-Pin D-Sub 13 24 20 24 Single Round 13 16 16 16 12-Pin M23 8 8 8 8 * Not CSA certified for 25-Pin, D-Sub option. The Interconnect Wiring System has great flexibility to meet user wiring needs. Each manifold base must be ordered with either a single or double address function. The single address circuit board works with single solenoid valves only. The double address circuit board works with both single and double solenoid valves. The end cover of each manifold base is labeled either “Single Address” or “Double Address”. Power signals are connected at the 25-Pin D-Sub Collective Wiring Module / Plate (Figure 1), 19-Pin Round Collective Wiring Module / Plate (Figure 2), or 12-Pin Round Collective Wiring Module / Plate (Figure 3). A single address base uses one signal; a double address base uses two signals, the first to the 14 solenoid, the second to the 12 solenoid. Signal usage is sequential through the bases. Any combination of single or double addresses may be used. 25-Pin D-Sub Collective Wiring Module Common Pin “13” is rated for 3 amps. Common wire rating MUST be greater than total amperage of all solenoids on a manifold assembly. Address 2 4 6 8 10 12 14 16 18 20 22 24 Pin Number 14 15 16 17 18 19 20 21 22 23 24 25 Pin Number 1 2 Address 1 3 5 3 4 5 6 7 7 9 11 13 15 17 19 8 9 10 11 12 21 23 13 Common Face View - Male D-Sub, 25-Pin Connector Address 1 3 Color Black Brown 5 7 9 11 13 Red Orange Yellow Green Blue Purple 15 Gray 17 White 19 Pink 21 Lt Green 23 Common Black / White Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 Pin Number 14 15 16 17 18 19 20 21 22 23 24 25 Color Brown / White Red / White Orange / White Green / White Blue / White Purple / White Red / Black Orange / Black Yellow / Black Green / Black Gray / Black Pink / Black Address 2 4 6 8 10 12 14 16 18 20 22 24 Face View -Female D-Sub, 25-Pin Connector Figure 1 2 Common Pin “7” is rated for 8 amps. Common wire rating MUST be greater than total amperage of all solenoids on a manifold assembly. Pin Number 1 2 3 4 5 6 7 8 9 10 Address 1 2 3 4 N/A 5 Common 6 7 8 11 10 9 2 13 19 17 16 8 1 12 18 7 3 14 15 4 5 6 Pin Number 11 12 13 14 15 16 17 18 19 Address 9 Ground 10 11 12 13 14 15 16 Face View - Male 19-Pin Connector Figure 2 12-Pin Round Collective Wiring Module Common Pins “9” and “10” are rated for 8 amps. Common wire rating MUST be greater than total amperage of all solenoids on a manifold assembly. Pin Number 1 2 3 4 5 6 Address Input 0 Input 1 Input 2 Input 3 Input 4 Input 5 1 8 7 2 9 12 6 10 3 11 4 5 Pin Number 7 8 9 10 11 12 Address Input 6 Input 7 Ret (Common) Ret (Common) Not Used Ground Face View - Male M23, 12-Pin Connector Pin Number 1 2 3 4 5 6 Address Input 0 Input 1 Input 2 Input 3 Input 4 Input 5 8 1 2 7 9 10 3 11 6 11 4 5 Pin Number 7 8 9 10 11 12 Address Input 6 Input 7 Ret (Common) Ret (Common) Not Used Ground Face View - Female M23, 12-Pin Connector Figure 3 Grounding Instructions The Collective Wiring addressing system is grounded by connecting a user supplied case wire to the outside ground screw on the End Plate (Size 1) or the Interface Plate (Size 2 / Size 3). Use 18 gauge, or larger, case wire. The Collective Wiring 25-Pin D-Sub internal ground is made by connecting the loose ring terminal to the ground screw provided at the internal wire passageway on the Size 1. The Size 2 / Size 3 internal ground connection is the ground screw on the Interface Plate located closer to the wire passageway. The collective wiring 12-Pin or 19-Pin Round Connector internal ground is made by connecting the lead wire with a ring terminal (ground wire) to the ground screw provided at the internal wire passageway (Size 1) or at the Interface Plate ground screw located closer to the wire passageway. An earth ground is recommended for all voltages. Follow standard electrical protocol. Air Piping Assembly Port Connections: Manifold stacks / subbases have three common air passage galleries. For Single pressure piping, connect the inlet supply to Port #1; Ports #3 and #5 are then the exhaust ports. For Dual pressure piping, connect the two inlet supplies to Port #3 and Port #5 (it is recommended that the higher pressure be supplied to Port #3); Port #1 is then the exhaust port. See Manifold © 2007 ROSS CONTROLS®. All Rights Reserved. Size 1, 2 & 3 Subbase & Manifold Installation Isolation (Page 8) if the application requires groups of valves with different pressure supplies. Connect the cylinder ports #2 and #4 to the cylinder or other device to be supplied with air from the valve. These ports are at the end (and bottom, if so ordered) of each base. Remote Pilot Signal Connections: Manifolds: For remote pilot signal valves, connect the pilot signal to the Remote Pilot Access Plate mounted directly under the valve body. NOTE: Signals into the remote pilot plate do not connect to the #12 or #14 galleries on the End Plates. See Remote Pilot Access Plate instructions. Note: If Pressure is supplied to one end of a manifold, the pressure port(s) on the opposite end must be plugged. External Pilot Connections: An external pilot supply is used when the main inlet pressure is below the minimum valve operating pressure or when the pilot pressure is different from the main inlet pressure. Supply pilot air to either Port #14 or Port #12 and plug the one not being used. Subbases: Connect pilot signal to the #12 and #14 Ports. Manifold Assembly with Interconnect Wiring the harness into the base connector circuit board. The connectors are keyed, there is only one assembly possible. Do not twist cables. Attach the Base to the Interconnect Wiring Plate by finger tightening the three Bolts (Item 4). Continue to mount each successive Gasket (Item 2) and Base (Item 3) to the previous Base. Lay the entire manifold on a flat surface, align for straightness and alternately tighten each screw incrementally to torque specifications in the torque chart. Place the right hand End Plate (Item 5) on last base and tighten screws (see torque chart). 3. NOTE: Transition Plates or Isolation Plugs must be properly placed as the construction of the stack progresses. See individual sections of this bulletin. 4. Add valves and accessories to the manifold (if not already attached). The final assembly should be leak and electrically tested before operation. The Interconnect Wiring System (Figure 4 & 5) makes the electrical connection user friendly. Each individual manifold base carries its own connector circuit board which self aligns and plugs into the circuit board of the mating manifold base. The power is supplied at the left end of the stack (as you are viewing the cylinder ports) by means of a plug-in harness or serial module. The stack assembly is built from left to right (viewing the cylinder ports). Start with the Interconnect Wiring Module Kit and add manifold bases as required. If the stack includes transitions from one valve size to another, the left most size is the smallest and then progressing to successively larger sizes. Follow the techniques described below for the easiest assembly. Consult the torque chart for screw tightening specifications. For Size 1 Valves (See Figure 4) Manifold / End Plate Assembly Torque Values 1. Lay Interconnect Wiring Plate (Item 1 / 7) port side down (when looking at Manifold Cylinder Ports) and expose the wiring harness. Locate Gasket (Item 2) in place on the Interconnect Wiring Plate (Item 1). 2. Bring the first station Manifold Base to the Interconnect Wiring Plate and plug in the two black connectors from Torque - in.lb. (Nm) Item 4 4 5 2 Internal Ground Location (Green Screw) 40 to 50 (4.5 to 5.6) 10 4 3 2 4 3 Items 1 and 6 2 2 1 4 2 Internal Ground Location (Green Screw) 4 4 4 9 8 OR OR External Ground Location (Green Screw) External Ground Location (Green Screw) 6 7 Figure 4 (Size 1 Valves Shown) Item # 1 2 3 4 5 Description Interconnect Wiring Plate (25-Pin, D-Sub Connector) Molded Gasket Manifold Base Mounting Screws Right Hand End Plate Item # Description 6 7 8 9 10 Interconnect Wiring Plate (12 or 19-Pin Connector) Interconnect Wiring Plate (Serial Bus) Dome Plug O-ring Plastic Plug www.rosscontrols.com 3 Size 1, 2 & 3 Subbase & Manifold Installation For Size 2 & Size 3 Valves (See Figure 5) 1. Attach four Tie Rods (Item 5) to the Interface Plate (Item 7) then mount the Gasket (Item 4), Collective Wiring Module (Item 6), Gasket (Item 4) and Cover (Item 3) over the Tie Rods. Attach these components with the four Screws (Item 1) and Washers (Item 2) provided. NOTE: The 25-Pin, D-Sub Collective Wiring Module has a ground wire with ring terminal which must be attached to the inner green screw on the Interface Plate before cover is attached. 2. Lay the Collective Wiring Module port side down and expose the wiring harness. Feed wires into wiring gallery and assemble Collective Wiring Module to Interface Plate. Locate Gasket (Item 8) in place on the Interface Plate (Item 7). 3. Bring the first station Manifold Base (Item 10) to the Interface Plate (Item 7) and plug in the two black connectors from the harness into the base connector circuit board. The connectors are keyed, there is only one assembly possible. Do not twist cables. Tighten the Base to the Interface Plate with the four Bolt / Washers (Item 11) provided with each Base to torque specifications shown in the torque chart. Continue to mount each Molded Track Seal (Item 12) and Base (Item 9) to the previous Base. Lay the entire manifold on a flat surface, align for straightness and alternately tighten each screw incrementally to torque specifications in the torque chart. Place the right hand End Plate (Item 13) on last base and tighten screws (see torque chart). 3. NOTE: Transition Plates or Isolation Plugs must be properly placed as the construction of the stack progresses. See individual sections of this bulletin. 4. Add valves and accessories to the manifold (if not already attached). The final assembly should be leak and electrically tested before operation. 11 13 Manifold / End Plate Assembly Torque Values Torque - in.lb. (Nm) Item 11 12 195 to 205 (22.0 to 23.2) 11 10 11 2 10 4 9 Internal Ground Location (Green Screw) 8 7 12 4 15 14 2 6 4 5 1 2 3 4 External Ground Location (Green Screw) OR OR 17 16 Figure 5 (Size 2 Manifold Assembly Shown) Item # 1 2 3 4 5 6 7 8 9 4 Description Cover Screw Cover Washer Collective Wiring Module Cover Collective Wiring Module Gasket Tie Rod Collective Wiring Module (25-Pin, D-Sub) Interface Plate (Top Ported) O-Rings Pilot Gallery O-Rings Item # 10 11 12 13 14 15 16 17 Description Manifold Base (Size 2) Mounting Screw & Lockwasher Molded Gasket Right Hand End Plate Isolation Plugs Pilot Isolation Plug Collective Wiring Module (12-Pin, Round) Collective Wiring Module (19-Pin, Round) © 2007 ROSS CONTROLS®. All Rights Reserved. Size 1, 2 & 3 Subbase & Manifold Installation Size 1 to Size 2 Manifold Assembly (See Figure 6) Isolator Plug Locations with Transition Plates Left The smaller manifold must be on the left side of the Transition Plate. The Transition Plate (Item 6) acts as a combination right end plate for the smaller manifold and left end plate for the larger manifold. 1. Lay Left Hand End Plate (when looking at cylinder ports) port side down. Place Gasket in gasket track. 2. Add Station 1 Manifold and tighten all 3 bolts finger tight. 3. Build manifold vertically by adding Gaskets, Isolator Plugs, Transition Plate and remaining Manifolds. 4. Lay entire manifold on a flat surface and tighten screws to torque specification. 5. Place Right Hand End Plate and tighten screws to torque specifications in chart. 6. Add Valves and Accessories. All Manifold Assemblies should be leak tested before operation. Right 2 2 4 4 Smaller Manifold Transition Plate Always on Left Larger Manifold Manifold / End Plate Assembly Torque Values Torque - in.lb. (Nm) Item 4 40 to 50 (4.5 to 5.6) Torque - in.lb. (Nm) Item 10 195 to 205 (22.0 to 23.2) 10 9 7 10 8 7 4 6 2 5 4 2 4 3 2 4b 1 2 4 4a 12 11 Figure 6 (Size 1 to Size 2 Transition Assembly) Item # 1 2 3 4a 4b 5 6 7 8 9 10 11 12 Description Interconnect Wiring Plate (25-Pin, D-Sub Connector Shown) (Size 1) Manifold Gasket (Size 1) Manifold Base (Size 1) Mounting Screws (M6 x 16mm) Mounting Screws (M6 x 25mm) Wire Harness Transition Plate (Size 1 to Size 2) Manifold Gasket (Size 2) Manifold Base (Size 2) Right End Plate (Size 2) Mounting Screws & Lock Washers (Size 2) Dome Plug O-ring www.rosscontrols.com 5 Size 1, 2 & 3 Subbase & Manifold Installation Size 1 to Size 3 Manifold Assembly (See Figure 7) Isolator Plug Locations with Transition Plates Left The smaller manifold must be on the left side of the Transition Plate. The Transition Plate (Item 6) acts as a combination right end plate for the smaller manifold and left end plate for the larger manifold. 1. Lay Left Hand End Plate (when looking at cylinder ports) port side down. Place Gasket in gasket track. 2. Add Station 1 Manifold and tighten all 3 bolts finger tight. 3. Build manifold vertically by adding Gaskets, Isolator Plugs, Transition Plate and remaining Manifolds. 4. Lay entire manifold on a flat surface and tighten screws to torque specification. 5. Place Right Hand End Plate and tighten screws to torque specifications in chart. 6. Add Valves and Accessories. All Manifold Assemblies should be leak tested before operation. Right 2 2 4 4 Smaller Manifold Transition Plate Always on Left Manifold / End Plate Assembly Torque Values Torque - in.lb. (Nm) Item 4 40 to 50 (4.5 to 5.6) Torque - in.lb. (Nm) Item 10 195 to 205 (22.0 to 23.2) Larger Manifold 10 9 7 10 8 7 4 6 2 5 4 2 4 3 11 2 4 1 2 4 4 O-ring Seal Lightly grease with provided lubricant. 13 12 Figure 7 (Size 1 to Size 3 Transition Assembly) Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 6 Description Interconnect Wiring Plate (25-Pin, D-Sub Connector Shown) (Size 1) Manifold Gasket (Size 1) Manifold Base (Size 1) Mounting Screws (Size 1) Wire Harness Transition Plate (Size 1 to Size 3) Manifold Gasket (Size 3) Manifold Base (Size 3) Right End Plate (Size 3) Mounting Screws & Lock Washers (Size 3) O-ring Seal Washer Dome Plug O-Ring © 2007 ROSS CONTROLS®. All Rights Reserved. Size 1, 2 & 3 Subbase & Manifold Installation Size 2 to Size 3 Manifold Assembly (See Figure 8) Isolator Plug Locations with Transition Plates Left The smaller manifold must be on the left side of the Transition Plate. The Transition Plate (Item 14) acts as a combination right end plate for the smaller manifold and left end plate for the larger manifold. 1. Lay Interface Plate (Item 7) with O-ring channels facing up. Place O-rings in correct channels. 2. Add Station 1 Manifold and tighten all 3 bolts finger tight. 3. Build manifold vertically by adding Gaskets, Isolator Plugs, Transition Plate and remaining Manifolds. 4. Lay entire manifold on a flat surface and tighten screws to torque specification. 5. Place Right Hand End Plate and tighten screws to torque specifications in chart. 6. Assemble Collective Wiring Module (Items 1 through 6) to Interface Plate (Item 7). 7. Add Valves and Accessories. All Manifold Assemblies should be leak tested before operation. Right 2 2 4 4 Smaller Manifold Transition Plate Larger Manifold Always on Left 12 18 17 Manifold / End Plate Assembly Torque Values Torque - in.lb. (Nm) Item 12 12 195 to 205 (22.0 to 23.2) 16 15 12 14 2 4 13 12 11 19 10 9 8 7 4 O-ring Seal 2 6 4 5 1 2 3 4 Lightly grease with provided lubricant. Figure 8 (Size 2 to Size 3 Transition Assembly) Item # 1 2 3 4 5 6 7 8 9 10 Item # Description Cover Screw Cover Washer Collective Wiring Module Cover Collective Wiring Module Gasket Tie Rod Collective Wiring Module (25-Pin, D-Sub) Interface Plate (Top Ported) O-Rings Pilot Gallery O-Rings Manifold Base (Size 2) 11 12 13 14 15 16 17 18 19 www.rosscontrols.com Description Manifold Base Gasket (Size 2) Mounting Screws & Lock Washers (Size 2 & Size 3) Wire Harness Transition Plate (Size 2 to Size 3) Manifold to Transition Plate Gasket (Size 3) Manifold Base (Size 3) Manifold to Transition Plate Gasket (Size 3) Right End Plate (Size 3) O-ring Seal Washer 7 Size 1, 2 & 3 Subbase & Manifold Installation Manifold Isolation Assembly Station Blanking Plate Inlet & exhaust galleries, and pilot supply / signal galleries may be isolated from those in adjacent manifolds through the use of isolation plugs. Note: air piloted valves, whether single or double, will need to be isolated at 14 and / or 12 galleries to prevent improper air pressure signals reaching adjacent valves. Figure 9 indicates typical assembly locations of the Main Gallery Plugs (Item 1) and the Pilot Gallery Plugs (Item 2). The following describes how to install plugs: 1. Determine which gallery is to be isolated between two manifolds. 2. Use the large Plugs (Item 1) from the service kits to isolate manifolds from the main gallery(s). 3. Apply a light coating of grease to isolation plug and insert it into counterbore of left manifold base. 4. Apply a light coating of grease to Gasket (Item 3) and assemble in manifold groove. 5. Assemble plugged manifold into manifold bank in its proper position. 6. Apply main pressure and check for leaks. If any are present, do not operate the valve - repeat the reassembly process until satisfactory. Use top Blanking Plate on a Manifold to reserve a place for a valve that will be added later to the manifold bank or to remove a valve from a manifold without having to remove the manifold block from the manifold bank. Place Gasket and Blanking Plate on Manifold and assemble using Mounting Screws provided with kit. Tighten screws to torque specifications shown in the torque chart below. Apply main pressure and check for leaks. If any are present, do not operate valves on the manifold bank - repeat the assembly process until satisfactory. Isolation Plug Kits Size 1 RPS4032CP (3) Size 2 RPS4132CP (3) Size 3 RPS4232CP (3) Valve Series Torque - in. lb. (Nm) Size 1 25 to 35 (2.8 to 3.9) Size 2 115 to 130 (12.9 to 14.7) Size 3 120 to 140 (13.6 to 15.8) 1 2 Remote Pilot Access Plate 4 Pilot Isolation Plug Kits RPS4033CP (2) 2 3 2 The Remote Pilot Access Plate provides access to the #12 and #14 valve pilot galleys for a Size 1, Size 2 & Size 3 manifold. It is required for Single or Double Remote Pilot Valves on a manifold. Hand tighten the tie rods into the base. 4 Size 2 Shown Figure 9 Isolator Plug Locations with Transition Plates Left Right 2 2 4 4 Smaller Manifold Transition Plate Larger Manifold Always on Left Hi-Flow Manifold Repair Kits Kit Number Description (Qty.) Item Number RPS4012P RPS4013P Size 1 Manifold to Manifold Screws (3) Size 1 Manifold to Manifold Gasket (1) 3 2 RPS4112P Size 2 / Size 3 Manifold to Manifold Screws and Washers (12) 10 RPS4113P RPS4213P Size 2 Manifold to Manifold Gasket (1) Size 3 Manifold to Manifold Gasket (1) 12 12 For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0807 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10331 Installation & Service Instructions A10314 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) The sealed IP67 housing of these adapters requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) PROFIBUS connectors are sealed M12 (micro) style. The PROFIBUS adapter is shown below. Shielding (See page 3 for details) RPSSCPBA RPSSCPBA M12 Connector Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Station Address Switches Mini 7/8" Auxiliary Power Connector Profibus DP Profibus Out Profibus In Adapter Status Profibus Status X10 X1 PointBus Status System Power PWR Adapter Power ROSS ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. Serial Bus PROFIBUS Adapter User Manual The Serial Bus PROFIBUS Adapter User Manual is not available at this time. Please refer to Rockwell Automation 1734 POINT I/O PROFIBUS Adapter User Manual 1734-UM005B-EN-P for similar setup information, which is available online at http://literature.rockwellautomation.com/. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form A10325) (available online at www.rosscontrols.com/rosslit.htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Mount the Adapter and I/O Base To mount the adapter on a wall or panel, use the screw holes provided in the adapter. A mounting illustration for the adapter with I/O bases is shown below. Adapter Ground PROFIBUS Adapter 1.9 (47.2) 2.0 (50) 0.87 (22) I/O Module Ground 2.0 (50) 3.13 (79.4) 5.98* (151.9) I/O Module Ground 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the adapter using #8 (M4) screws. 4. Ground the system using the ground lug connection in the I/O base. (The ground lug connection is also a mounting hole.) Grounding and Shielding Grounding: Each Serial Bus base has two mounting holes, with the one on the right being the means to ground each module. Each module must be grounded. Shielding: For PROFIBUS adapter, both PROFIBUS IN and PROFIBUS OUT metal shells are connected to the top screw hole metal ring. Shielded PROFIBUS cordsets are required to help reduce the effects of electrical noise coupling. One example of such a cordset is Brad Harrison's “360° Shielded Head” cordset, which can be found at www.connector.com. For more Grounding and Shielding information, please refer to A10324, “Industrial Automation Wiring and Grounding Guidelines”. www.rosscontrols.com 3 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Set the Station Address To set the station address, adjust the switches on the front of the module (refer to the illustration on page 1). Use a small blade screwdriver to rotate the switches. Line up the small notch on the switch with the number setting you wish to use. The two switches are most significant digit (MSD) and least significant digit (LSD). The switches can be set from 01 through 99. The module reads the switches at power-up only. This example shows the node address set at 63. GSD File Requirements Current functionality of a PROFIBUS adapter requires a GSD file. The file is easy to install and is available online at: www.rosscontrols. com/rosslit.htm. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Wire the PROFIBUS Adapter Following are wiring instructions for the PROFIBUS Adapter. RPSSCPBA (Micro M12, B - Coding Reverse Key) Female Out Connector Male In Connector (view into connector) Pin 1 - +5VBUS Pin 2 - A-Line Pin 3 - GNDBUS Pin 4 - B-Line Pin 5 - Not Used Note: Please refer to page 3, Mount the Adapter and I/O Base, for shielding information. RPSSCPBA Male Auxiliary (Mini 7/8") Male In Connector (view into connector) Pin 1 - User Power Pin 2 - Adapter Power Pin 3 - Protective GND Pin 4 - Adapter Power + Pin 5 - User Power + NOTE: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for adapter. It is converted to 5VDC to power Serial Bus modules. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Troubleshoot with the Indicators RPSSCPBA RPSSCPBA Profibus DP Profibus Out Profibus In Adapter Status Indicator Adapter Status Profibus Status X10 X1 PointBus Status System Power PWR Adapter Power ROSS Indication Adapter Status Off Green Red Indication Profibus Status Off Green Flashing Green Red Flashing Red 6 Probable Cause No power supplied Hardware check in progress Initialization in progress Operating normally Hardware check fault Profibus Status Indicator PointBus Status Indicator System Power Indicator Adapter Power Indicator Indication PointBus Status Off Green Flashing Red Probable Cause No power supplied Bus is off line Bus is on line (data exchange) Adapter has received a CLEAR command from the master Error in PROFIBUS initialization. No modules installed in the backplane. 1Hz: - Check_Configuration telegram rejected. - Maximum number of I/O modules in master configuration overridden. 2Hz: - SetPrm telegram rejected. - The first byte in user parameter data does not equal zero. - Maximum number of user parameter bytes overridden. Red Indication System Power* Off Green Indication Adapter Power** Off Green Probable Cause No power supplied Hardware check in progress Initialization in progress Normal operation 1Hz: - Incorrect I/O module installed. - I/O module removed from backplane. Critical link failure (BUS_OFF). Probable Cause Not active field. Power is off, overloaded backplane or dc-dc converter problem. System power (5V) present. Probable Cause Field power not applied. Field power (24V) applied. * System Power Indicator shows the 5V power output from the dc-dc converter. ** Adapter Power Indicator shows the 24V power input to the dc-dc converter. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Specifications Following are specifications for the RPSSCPBA PROFIBUS adapter. PROFIBUS Adapter - RPSSCPBA Expansion I/O Capacity • PROFIBUS adapter backplane current output = 1.0A maximum. See the list below for backplane current consumption for each I/O catalog number and the current consumption for each of the modules connected to the PROFIBUS adapter. Verify that it is below 1.0A. • Backplane current can be extended beyond 1.0A with a RPSSSE24A Backplane Extension Power Supply. The RPSSSE24A can supply up to an additional 1.3A of backplane current. • Multiple RPSSSE24A modules can be used to reach the maximum of 63 modules. Cat. No. PointBus Current Requirements RPSSN8xxx RPSSP8xxx RPSST8xxx RPSSTR4M12A RPSSNACM12A RPSSNAVM12A RPSSTACM12A RPSSTAVM12A RPSSS23A RPSSV32A 75 mA 75 mA 75 mA 90 mA 75 mA 75 mA 75 mA 75 mA 75 mA 75 mA Power Supply Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC nominal 10-28.8VDC range Input Overvoltage Protection Reverse polarity protected Inrush Current 6A maximum for 10ms PointBus Output Current 1A maximum @ 5VDC +5% (4.75-5.25 Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 400 mA Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications LED Indicators 1 green/red Adapter status 1 green/red PROFIBUS status 1 green/red PointBus status 1 green System Power (PointBus 5V power) 1 green Adapter Power (24V from field supply) Power Consumption, Maximum 8.1W @ 28.8VDC Power Dissipation, Maximum 2.8W @ 28.8VDC Thermal Dissipation, Maximum 9.5 BTU/hr. @ 28.8VDC Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested at 1250VAC rms for 60s Field Power Bus Nominal Voltage Supply Voltage Supply Current 24VDC 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 4.41H x 2.83W x 2.56D (112H x 72W x 65D) www.rosscontrols.com 7 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) General Specifications (continued) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports ±2kV at 5kHz on communications ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports ±2kV line-earth(CM) on shielded ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 Wiring Category Weight 1 - on power ports 1 - on communications ports Imperial (Metric) Certifications: (when product is marked) 0.80 lb. (0.36 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10314 Installation & Service Instructions A10314 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) The sealed IP67 housing of these adapters requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) PROFIBUS connectors are sealed M12 (micro) style. The PROFIBUS adapter is shown below. Shielding (See page 3 for details) RPSSCPBA RPSSCPBA M12 Connector Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. Station Address Switches Mini 7/8" Auxiliary Power Connector Profibus DP Profibus Out Profibus In Adapter Status Profibus Status X10 X1 PointBus Status System Power PWR Adapter Power ROSS ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. Serial Bus PROFIBUS Adapter User Manual The Serial Bus PROFIBUS Adapter User Manual is not available at this time. Please refer to Rockwell Automation 1734 POINT I/O PROFIBUS Adapter User Manual 1734-UM005B-EN-P for similar setup information, which is available online at http://literature.rockwellautomation.com/. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form A10325) (available online at www.rosscontrols.com/rosslit.htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Mount the Adapter and I/O Base To mount the adapter on a wall or panel, use the screw holes provided in the adapter. A mounting illustration for the adapter with I/O bases is shown below. Adapter Ground PROFIBUS Adapter 1.9 (47.2) 2.0 (50) 0.87 (22) I/O Module Ground 2.0 (50) 3.13 (79.4) 5.98* (151.9) I/O Module Ground 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the adapter using #8 (M4) screws. 4. Ground the system using the ground lug connection in the I/O base. (The ground lug connection is also a mounting hole.) Grounding and Shielding Grounding: Each Serial Bus base has two mounting holes, with the one on the right being the means to ground each module. Each module must be grounded. Shielding: For PROFIBUS adapter, both PROFIBUS IN and PROFIBUS OUT metal shells are connected to the top screw hole metal ring. Shielded PROFIBUS cordsets are required to help reduce the effects of electrical noise coupling. One example of such a cordset is Brad Harrison's “360° Shielded Head” cordset, which can be found at www.connector.com. For more Grounding and Shielding information, please refer to A10324, “Industrial Automation Wiring and Grounding Guidelines”. www.rosscontrols.com 3 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Set the Station Address To set the station address, adjust the switches on the front of the module (refer to the illustration on page 1). Use a small blade screwdriver to rotate the switches. Line up the small notch on the switch with the number setting you wish to use. The two switches are most significant digit (MSD) and least significant digit (LSD). The switches can be set from 01 through 99. The module reads the switches at power-up only. This example shows the node address set at 63. GSD File Requirements Current functionality of a PROFIBUS adapter requires a GSD file. The file is easy to install and is available online at: www.rosscontrols. com/rosslit.htm. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Wire the PROFIBUS Adapter Following are wiring instructions for the PROFIBUS Adapter. RPSSCPBA (Micro M12, B - Coding Reverse Key) Female Out Connector Male In Connector (view into connector) Pin 1 - +5VBUS Pin 2 - A-Line Pin 3 - GNDBUS Pin 4 - B-Line Pin 5 - Not Used Note: Please refer to page 3, Mount the Adapter and I/O Base, for shielding information. RPSSCPBA Male Auxiliary (Mini 7/8") Male In Connector (view into connector) Pin 1 - User Power Pin 2 - Adapter Power Pin 3 - Protective GND Pin 4 - Adapter Power + Pin 5 - User Power + NOTE: User power is the 24VDC power for field devices. Adapter power is the 24VDC power for adapter. It is converted to 5VDC to power Serial Bus modules. ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. www.rosscontrols.com 5 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Troubleshoot with the Indicators RPSSCPBA RPSSCPBA Profibus DP Profibus Out Profibus In Adapter Status Indicator Adapter Status Profibus Status X10 X1 PointBus Status System Power PWR Adapter Power ROSS Indication Adapter Status Off Green Red Indication Profibus Status Off Green Flashing Green Red Flashing Red 6 Probable Cause No power supplied Hardware check in progress Initialization in progress Operating normally Hardware check fault Profibus Status Indicator PointBus Status Indicator System Power Indicator Adapter Power Indicator Indication PointBus Status Off Green Flashing Red Probable Cause No power supplied Bus is off line Bus is on line (data exchange) Adapter has received a CLEAR command from the master Error in PROFIBUS initialization. No modules installed in the backplane. 1Hz: - Check_Configuration telegram rejected. - Maximum number of I/O modules in master configuration overridden. 2Hz: - SetPrm telegram rejected. - The first byte in user parameter data does not equal zero. - Maximum number of user parameter bytes overridden. Red Indication System Power* Off Green Indication Adapter Power** Off Green Probable Cause No power supplied Hardware check in progress Initialization in progress Normal operation 1Hz: - Incorrect I/O module installed. - I/O module removed from backplane. Critical link failure (BUS_OFF). Probable Cause Not active field. Power is off, overloaded backplane or dc-dc converter problem. System power (5V) present. Probable Cause Field power not applied. Field power (24V) applied. * System Power Indicator shows the 5V power output from the dc-dc converter. ** Adapter Power Indicator shows the 24V power input to the dc-dc converter. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) Specifications Following are specifications for the RPSSCPBA PROFIBUS adapter. PROFIBUS Adapter - RPSSCPBA Expansion I/O Capacity • PROFIBUS adapter backplane current output = 1.0A maximum. See the list below for backplane current consumption for each I/O catalog number and the current consumption for each of the modules connected to the PROFIBUS adapter. Verify that it is below 1.0A. • Backplane current can be extended beyond 1.0A with a RPSSSE24A Backplane Extension Power Supply. The RPSSSE24A can supply up to an additional 1.3A of backplane current. • Multiple RPSSSE24A modules can be used to reach the maximum of 63 modules. Cat. No. PointBus Current Requirements RPSSN8xxx RPSSP8xxx RPSST8xxx RPSSTR4M12A RPSSNACM12A RPSSNAVM12A RPSSTACM12A RPSSTAVM12A RPSSS23A RPSSV32A 75 mA 75 mA 75 mA 90 mA 75 mA 75 mA 75 mA 75 mA 75 mA 75 mA Power Supply Specifications Power Supply Note: In order to comply with CE Low Voltage Directives (LVD), you must use either a NEC Class 2, a Safety Extra Low Voltage (SELV) or a Protected Extra Low Voltage (PELV) power supply to power this adapter. A SELV supply cannot exceed 30V rms, 42.4V peak or 60VDC under normal conditions and under single fault conditions. A PELV supply has the same rating and is connected to protected earth. Input Voltage Rating 24VDC nominal 10-28.8VDC range Input Overvoltage Protection Reverse polarity protected Inrush Current 6A maximum for 10ms PointBus Output Current 1A maximum @ 5VDC +5% (4.75-5.25 Field Side Power Requirements, Maximum 24VDC (+20% = 28.8VDC) @ 400 mA Interruption Output voltage will stay within specifications when input drops out for 10ms at 10V with maximum load General Specifications LED Indicators 1 green/red Adapter status 1 green/red PROFIBUS status 1 green/red PointBus status 1 green System Power (PointBus 5V power) 1 green Adapter Power (24V from field supply) Power Consumption, Maximum 8.1W @ 28.8VDC Power Dissipation, Maximum 2.8W @ 28.8VDC Thermal Dissipation, Maximum 9.5 BTU/hr. @ 28.8VDC Isolation Voltage (continuous-voltage withstand rating) 50V rms Tested at 1250VAC rms for 60s Field Power Bus Nominal Voltage Supply Voltage Supply Current 24VDC 10-28.8VDC range 10A maximum Dimensions Inches (Millimeters) 4.41H x 2.83W x 2.56D (112H x 72W x 65D) www.rosscontrols.com 7 Serial Bus PROFIBUS Adapter, Series A (RPSSCPBA) General Specifications (continued) Operating Temperature IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) Storage Temperature IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) Relative Humidity IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5-95% non-condensing Shock IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 30g Non-operating 50g Vibration IEC60068-2-6 (Test Fc, Operating): 5g @ 10-500Hz ESD Immunity IEC 61000-4-2: 6kV contact discharges 8kV air discharges Radiated RF Immunity IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 30MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz EFT/B Immunity IEC 61000-4-4: ±4kV at 5kHz on power ports ±2kV at 5kHz on communications ports Surge Transient Immunity IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on power ports ±2kV line-earth(CM) on shielded ports Conducted RF Immunity IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz Emissions CSPR 11: Group 1, Class A Enclosure Type Rating Meets IP65/66/67 (when marked) Mounting Base Screw Torque #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 Wiring Category Weight 1 - on power ports 1 - on communications ports Imperial (Metric) Certifications: (when product is marked) 0.80 lb. (0.36 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity C-Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324, “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10314 Installation & Service Instructions A10320 Serial Bus Relay Output Module, Series A (RPSSTR4M12A) ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Safety Guide Introduction Follow these instructions when installing, operating, or servicing the product. Serial Bus Relay Output Module, Series A (RPSSTR4M12A) The sealed IP67 housing of the module requires no enclosure. (Note that environmental requirements other than IP67 may require an additional appropriate housing.) I/O connectors are sealed M12 (micro) style. The mounting base ships with the module. The RPSSTR4M12A module is shown below. RPSSTR4M12A Female Connector M12-A RPSSTR4M12A Form A Isolated Relay Out Female Connector M12-B 1 0 For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. MOD NET Female Connector M12-C 2 3 0 LED Indicators 1 2 3 Female Connector M12-D ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Important User Information ATTENTION Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Form #A10325) (available online at www.rosscontrols.com/rosslit. htm), describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of these differences, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will ROSS CONTROLS® be responsible or liable for indirect or consequential damages to persons or property resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, ROSS CONTROLS cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by ROSS CONTROLS with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of ROSS CONTROLS is prohibited. Throughout this manual we use notes to make you aware of safety considerations. WARNING ! Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. IMPORTANT Identifies information that is critical for successful application and understanding of the product. ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: • Identify a Hazard • Avoid a Hazard • Recognize the Consequence ! SHOCK HAZARD Labels may be located on or inside the equipment to alert people that dangerous voltage may be present. BURN HAZARD 2 Labels may be located on or inside the equipment to alert people that surfaces may be dangerous temperatures. ! Environment and Enclosure This equipment is intended for use in overvoltage Category II applications (as defined in IEC publication 60664-1), at altitudes up to 2000 meters without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR Publication 11. Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility in other environments due to conducted as well as radiated disturbance. This equipment is supplied as “enclosed” equipment. It should not require additional system enclosure when used in locations consistent with the enclosure type ratings stated in the Specifications section of this publication. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings, beyond what this product provides, that are required to comply with certain product safety certifications. NOTE: See NEMA Standards publication 250 and IEC publication 60529, as applicable, for explanations of the degrees of protection provided by different types of enclosure. Also, see the appropriate sections in this publication, as well as the publication A10324 (“Industrial Automation Wiring and Grounding Guidelines”), for additional installation requirements pertaining to this equipment. ATTENTION ! Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal operation. Follow these guidelines when you handle this equipment: • Touch a grounded object to discharge potential static. • Wear an approved grounding wrist strap. • Do not touch connectors or pins on component boards. • Do not touch circuit components inside the equipment. • If available, use a static-safe workstation. • When not in use, store the equipment in appropriate staticsafe packaging. © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Mount the I/O Base To mount the I/O base on a wall or panel, use the screw holes provided in the base. A mounting illustration for the base with an adapter is shown below. 1.9 (47.2) 2.0 (50) 0.87 (22) 2.0 (50) 3.13 (79.4) 5.98* (151.9) Adapter 2.39 (60.7) 4.02 (102) 4.32 (109.8) 1.81 (46) Inches (mm) Drill and Tap for M4 Screw 3.02 (76.6) 5.39 (137.0) Drill and Tap for M6 Screw * Depending on the type and number of manifolds, this dimension may vary. Consult Ross for specific information. Install the Mounting Base as Follows: 1. Lay out the required points as shown above in the drilling dimension drawing. 2. Drill the necessary holes for #8 (M4) machine or self-tapping screws. 3. Mount the base using #8 (M4) screws. 4. Ground the system using the ground lug connection. (The ground lug connection is also a mounting hole.) Mounting Base KeyswitchSet to position 7 for the RPSSTR4M12A relay output modules Ground Lug Connection Latching Mechanism www.rosscontrols.com 3 Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Install the Relay Output Module To Install the Relay Output Module, Proceed as Follows: 1. Using a bladed screwdriver, rotate the keyswitch on the mounting base clockwise until the number 7 aligns with the notch in the base. 2. Position the module vertically above the mounting base. The module will bridge two bases. Module Will Bridge Two Bases RPSSTR4M12A Form A Isolated Relay Out 1 0 MOD NET 2 3 0 1 2 3 3. Push the module down until it engages the latching mechanism. You will hear a clicking sound when the module is properly engaged. The locking mechanism will lock the module to the base. Remove the Relay Output Module From the Mounting Base To Remove the Module from the Mounting Base: 1. Put a flat blade screwdriver into the slot of the orange latching mechanism. 2. Push the screwdriver toward the I/O module to disengage the latch. The module will lift up off the base. 3. Pull the module off of the base. 4 4 ®. All Rights Reserved. © 2007 ROSS CONTROLS Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Wire the Relay Output Module Following are wiring instructions for the relay output module. RPSSTR4M12A ATTENTION ! Make sure all connectors and caps are securely tightened to properly seal the connections against leaks and maintain IP67 requirements. (view into connector) Pin 1 - 24VDC WARNING Pin 2 - Output 0B (M12-A) Output 1B (M12-B) Output 2B (M12-C) Output 3B (M12-D) Pin 4 - Output 0A (M12-A) Output 1A (M12-B) Output 2A (M12-C) Output 3A (M12-D) Pin 3 - Common Pin 5 - No Connect 3 2 Common 4 Output B – Load 1 Output A ! RPSSTR4M12A is rated for 5-28.8 VDC only. Do not connect it to an AC power source. 3 24VDC 2 Common 4 Output B 1 Output A + Load – Sourcing 24VDC + Sinking Load Powered by Internal Power Bus 3 Common 2 4 Output B 1 Output A – Load + + Power Supply 24VDC 3 Common 2 4 Output B – 1 Output A + Load Sinking – – Power Supply 24VDC + Sourcing Load Powered by External Power Bus Communicate With Your Module I/O messages are sent to (consumed) and received from (produced) the I/O module. These messages are mapped into the processor’s memory. The I/O relay output module consumes 1 byte of output data (scanner Tx - status). It does not produce data (scanner Rx). Default Data Map for the Relay Output Modules RPSSTR4M12A Message Size: 1 Byte 7 Consumes (Scanner Tx) 6 5 4 Not Used 3 2 1 0 Ch3 Ch2 Ch1 Ch0 Output State Where: 0 = OFF, 1 = ON EDS File Requirements The EDS file is available online at www.rosscontrols.com/rosslit.htm. 5 www.rosscontrols.com 5 Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Add Relay Output Module to RSLogix 5000 I/O Configuration If your RSLogic 5000 is Version 15.X or greater: • Choose the RPSSTR4M12A module from the list of Parker modules. To add your relay output module to RSLogix 5000 I/O configuration, follow these steps: • In RSLogix 5000: - For ControlNet, highlight the RPSSCCNA or 1738-ACNR (Shown), right click and select New Module. • Enter a name and click OK. - For EtherNet/IP, highlight the RPSSCENA or 1738-AENT (Shown), right click and select New Module. • Notice that the RPSSTR4M12A is now under the I/O configuration. 6 © 2007 ROSS CONTROLS®. All Rights Reserved. Serial Bus Relay Output Module, Series A (RPSSTR4M12A) If your RSLogic 5000 is Version 13.X: • Choose the equivalent Rockwell Automation module 1738-OW4M12/A. Troubleshoot With the Indicators RPSSTR4M12A RPSSTR4M12A Form A Isolated Relay Out 1 0 Module Status Indicator Network Status Indicator MOD NET 2 3 0 1 2 I/O Status Indicators 3 • Enter a name (optional), slot number, and comm. format. Make sure to choose Compatible Module for Electronic Keying setting. Indication Module Status Off Green Flashing Green Flashing Red Red Flashing Red/Green Indication Network Status Off • Choose Next to set RPI. • Choose Finish. Notice that the output module is now under the I/O configuration Flashing Green Green Flashing Red Red Flashing Red/Green Indication I/O Status Off Yellow www.rosscontrols.com Probable Cause No power applied to device Device operating normally Device needs commissioning due to missing, incomplete, or incorrect configuration Recoverable fault Unrecoverable fault may require device replacement Device is in self-test Probable Cause Device is not on line: - Device has not completed dup_MAC-id test. - Device not powered - check module status indicator. Device is on line but has no connections in the established state. Device is on line and has connections in the established state. One or more I/O connections in timed-out state. Critical link failure - failed communication device. Device detected error that prevents it from communicating on the network. Communication faulted device - the device has detected a network access error and is in communication faulted state. Device has received and accepted an Identity Communication Faulted Request - long protocol message. Probable Cause Output is inactive Output is active and under control 7 Serial Bus Relay Output Module, Series A (RPSSTR4M12A) Specifications - Following are specifications for the RPSSTR4M12A relay output module. Relay Output Modules Outputs per Module Output Voltage Range (load dependent) Output Current Rating (at rated power) Output Signal Delay OFF to ON, Maximum1 Output Delay Time, ON to OFF, Maximum1 Off-State Leakage Current (Max. at 240VAC) Power Rating (steady state) Initial Contact Resistance Switching Frequency, Maximum Operate/Release Time, Maximum Bounce Time Minimum Contact Load Expected Life of Electrical Contacts Fusing Keyswitch Position LED Indicators PointBus Current, Maximum Power Dissipation, Maximum Thermal Dissipation, Maximum Isolation Voltage Between any 2 sets of contacts Customer load to logic Field Power Bus Supply Voltage Voltage Range, Maximum Supply Current Dimensions Inches (Metric) Operating Temperature Storage Temperature Relative Humidity Shock Vibration ESD Immunity Radiated RF Immunity EFT/B Immunity Surge Transient Immunity Conducted RF Immunity Emissions Enclosure Type Rating Mounting Base Screw Torque Wiring Category2 Weight Imperial (Metric) Certifications: (when product is marked) 4 Form A isolated (normally open) electromechanical relays 5-28.8VDC @ 2.0A resistive Resistive: 2A @ 5-28.8VDC Inductive: 2.0A steady state @ 5-28.8VDC, L/R = 7 ms 10 ms (time from valid output on signal to relay energization by module) 26 ms (time from valid output off signal to relay deenergization by module) 1.2 mA and bleed resistor through snubber circuit 60W max. for 28.8VDC resistive output 60VA max. for 28.8VDC inductive output 30 mW 1 operation/3s (0.3 Hz at rated load) 10 ms 1.2 ms (mean) 100μA at 100 mVDC Minimum 100,000 operations @ rated loads Module outputs are not fused. If fusing is desired, you must supply external fusing. 7 4 yellow output status, logic side 1 green/red network status, logic side 1 green/red module status, logic side 90 mA @ 5VDC 0.5W @ 28.8VDC 1.7 BTU/hr. @ 28.8VDC Tested to withstand 2550VDC for 60s Tested to withstand 2550VDC for 60s None required 5-28.8VDC 2A per channel maximum, 8A per module 1.25H x 2.63W x 4.25D (31.75H x 66.80W x 107.95D) IEC 60068-2-1 (Test Ad, Operating Cold), IEC 60068-2-2 (Test Bd, Operating Dry Heat), IEC 60068-2-14 (Test Nb, Operating Thermal Shock): -20 to 60°C (-4 to 140°F) IEC 60068-2-1 (Test Ab, Un-packaged Non-operating Cold), IEC 60068-2-2 (Test Bb, Un-packaged Non-operating Dry Heat), -40 to 85°C (-40 to 185°F) IEC 60068-2-30 (Test Db, Un-packaged Non-operating Damp Heat): 5 to 95% non-condensing IEC60068-2-27 (Test Ea, Unpackaged Shock): Operating 15g, Non-operating 50g IEC60068-2-6 (Test Fc, Operating): 2g @ 10 to 500Hz IEC 61000-4-2: 6kV contact discharges, 8kV air discharges IEC 61000-4-3: 10V/m with 1kHz sine-wave 80%AM from 80MHz to 2000MHz 10V/m with 200Hz 50% Pulse 100%AM at 900Mhz 10V/m with 200Hz 50% Pulse 100%AM at 1890Mhz IEC 61000-4-4: ±3kV at 5kHz on signal ports IEC 61000-4-5: ±1kV line-line(DM) and ±2kV line-earth(CM) on signal ports IEC 61000-4-6: 10Vrms with 1kHz sine-wave 80%AM from 150kHz to 80MHz CSPR 11: Group 1, Class A Meets IP65/66/67 (when marked) #8 screw, 7.5 in. lbs. in Aluminum, 16 in. lbs. in Steel 1 - on signal ports 0.637 lb. (0.289 kg) c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada CE European Union 89/336/EEC EMC Directive, compliant with: EN 61000-6-4; Industrial Emissions EN 50082-2; Industrial Immunity EN 61326; Meas./Control/Lab., Industrial Requirements EN 61000-6-2; Industrial Immunity European Union 73/23/EEC LVD Directive, compliant with: EN61131-2; Programmable Controllers C- Tick Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions 1. OFF to ON or ON to OFF delay is time from a valid output “on” or “off” signal to output energization or de-energization. 2. Use this Conductor Category information for planning conductor routing. Refer to Publication A10324 “Industrial Automation Wiring and Grounding Guidelines”. Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10320 Installation & Service Instructions A10325 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Table of Contents Foreword ...................................................................................... 2 NEMA Standard Text ................................................................... 2 Section 1 Definitions ................................................................... 2 Section 2 General ........................................................................ 3 2.1 Ambient Temperature ........................................................ 3 2.2 Electrical Noise .................................................................. 3 2.3 Off-State Current ................................................................ 4 2.4 Polarity ............................................................................... 4 2.5 Rate of Rise-Voltage or Current (DV/DT or DI/DT) ............ 5 2.6 Surge Current ..................................................................... 5 2.7 Transient Overvoltage ........................................................ 6 Section 3 Application Guidelines ............................................... 6 3.1 General Application Precautions ........................................ 6 3.2 Circuit Isolation Requirements ........................................... 9 Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. 3.3 Special Application Considerations .................................... 9 3.4 Planning Electrical Noise Rejection ................................. 11 3.5 Countering the Effects of Off-State Current ..................... 13 3.6 Avoiding Adverse Environmental Conditions ................... 14 3.7 The Need for Education – Knowledge Leads to Safety ... 15 Section 4 Installation Guidelines ............................................. 16 4.1 Installation and Wiring Practice ........................................ 16 4.2 Enclosures (Cooling and Ventilating) ............................... 17 4.3 Special Handling of Electrostatic Sensitive Devices ........ 17 4.4 Compatibility of Devices with Applied Voltages and Frequencies .............................................................. 17 4.5 Testing Precautions ......................................................... 17 4.6 Startup Procedures .......................................................... 18 Section 5 Preventive Maintenance and Repair Guidelines .... 19 ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. 5.1 General ............................................................................ 19 5.2 Preventive Maintenance .................................................. 19 5.3 Repair ............................................................................... 20 5.4 Safety Recommendations for Maintenance Personnel .... 20 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls Foreword This ROSS CONTROLS® publication is formatted to harmonize with NEMA Standards Publication No. ICS 1.1-1984 (R1988, R1993, R1998, R2003) Industrial Control and Systems: Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls. The text of the NEMA Standard has been reprinted verbatim, with NEMA’s permission, in the left column, captioned “NEMA Standard Text”. The right column, captioned “Explanatory Information”, contains additional comments. The comments provide supplementary information to the NEMA Standard to help the reader better understand the characteristics of industrial equipment employing solid state technology. NEMA Standards Publication ICS 1.1-1984 (R1988, R1993, R1998, R2003) is available from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209. It may be purchased or a copy downloaded at no charge at www. nema.org/stds/ics1-1.cfm. NEMA Standard Text Explanatory Information SCOPE – This Standards Publication is intended to provide general guidelines for the application, installation, and maintenance of solid state control in the form of individual devices or packaged assemblies incorporating solid state components. The emphasis of the guidelines is personnel safety. Applicable NEMA standards and product related instructions should be carefully followed. (Supplementary Comments – Not part of NEMA STANDARDS PUBLICATION NO. ICS-1.1) SCOPE The scope of this ROSS CONTROLS Publication (A10325) is identical to the scope of NEMA Standards Publication No. ICS 1.1, quoted in the left column. Section 1 Definitions Electrical Noise – Unwanted electrical energy that has the possibility of producing undesirable effects in the control, its circuits and system. Electrical noise includes Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI). Electrical Noise Immunity – The extent to which the control is protected from a stated electrical noise. Electromagnetic Interference (EMI) – Electromagnetic disturbance that manifests itself in performance degradation, malfunction, or failure of electronic equipment. (IEC) Off-State Current – The current that flows in a solid state device in the off-state condition. Off-State Condition – The conditions of a solid state device when no control signal is applied. On-State Condition – The condition of a solid state device when conducting. Radio Frequency Interference (RFI) – RFI is used interchangeably with EMI. EMI is a later definition that includes the entire electromagnetic spectrum, whereas RFI is more restricted to the radio-frequency band, generally considered to be between 10k and 10G Hz. (IEC) Surge Current – A current exceeding the steady state current for a short time duration, normally described by its peak amplitude and time duration. Transient Overvoltage – The peak voltage in excess of steady state voltage for a short time during the transient conditions (e.g., resulting from the operations of a switching device). 2 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls Section 2 General General Comments (Sections 2 through 5 are classified as Authorized Engineering Information 11-15-1984.) Solid state devices provide many advantages such as high speed, small size, and the ability to handle extremely complex functions. However, they differ from electromechanical devices in the basic operating characteristics and sensitivity to environmental influences. In addition, solid state devices exhibit different failure mechanisms when overstressed. The comments which follow are intended to provide additional information to help the reader better understand the operating characteristics, environmental limitations, and failure modes of industrial equipment that incorporates solid state technology. Those who select, install, use, and service such equipment should apply that knowledge to make appropriate decisions that will optimize the performance and safety of their applications. Solid State and electro-mechanical controls can perform similar control functions, but there are certain unique characteristics of solid state controls which must be understood. In the application, installation and maintenance of solid state control, special consideration should be given to the characteristics described in 2.1 through 2.7. 2.1 Ambient Temperature Care should be taken not to exceed the ambient temperature range specified by the manufacturer. 2.2 Electrical Noise Performance of solid state controls can be affected by electrical noise. In general, complete systems are designed with a degree of noise immunity. Noise immunity can be determined through tests such as described in 3.4.2. Manufacturer recommended installation practices for reducing the effect of noise should be followed. C.2.1 Ambient Temperature Temperature of the air immediately surrounding an open solid state device is the ambient temperature which must be considered. When equipment is installed in an enclosure, the enclosure internal air temperature is the ambient temperature which must be considered. Solid state component manufacturers usually publish the component failure rate for an ambient temperature of 40 degrees Celsius. A useful rule of thumb is: The failure rate of solid state components doubles for every ten degrees Celsius rise in temperature. This rule of exponential increases in failure rate is a strong incentive for the user to keep the ambient temperature as low as possible. Also see sections 3.6.1, and 3.6.2. C.2.2 Electrical Noise Solid state devices are generally more susceptible to electrical noise interference than their electromechanical counterparts. The reasons are straightforward. The operating mechanism for electromechanical devices requires a deliberate input of electrical energy that can be converted into a sustained mechanical force that is strong enough to close the hard contacts and maintain the closure for the duration on the ON cycle. Most random electrical noise signals lack the energy content to produce that magnitude of mechanical force. The operating mechanism for solid state devices is totally different. The deliberate electric energy input is used to disturb the placement of the electrically charged particles within the molecular structure. This molecular displacement changes the electrical characteristic from that of an insulator to that of a conductor or vice versa. The required energy level is very low. In addition, a sustained signal is not required for components such as SCRs, triacs, and logic gates because these types are self-latching. Most random electrical noise signals are of the momentary low energy type. Since it is difficult to separate deliberate signals from random noise, the devices are thereby more susceptible. This is cause for special concern regarding the electrical environment and possible need for noise rejection measures. Also see sections 3.4, 3.4.1, 3.4.2, 3.4.3. www.rosscontrols.com 3 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 2.3 Off-State Current C.2.3 Off-State Current Solid state controls generally exhibit a small amount of current flow when in the off-state condition. Precautions must be exercised to ensure proper circuit performance and personnel safety. The value of this current is available from the manufacturer. Off-state current is also referred to as leakage current in the literature. A solid state “contact” is a solid block of material which is switched from ON to OFF by a change internally from a conductor to an insulator. Since a perfect insulator does not exist, there is always some leakage current present as long as voltage is applied to the device. The presence of leakage current indicates that OFF does not mean OPEN. The reader is warned that simply turning a solid state device OFF does not remove the possibility of a shock hazard. Solid state and electromechanical devices, used as inputs to solid state controls, must be compatible with the solid state equipment with which they are used. Solid state devices have inherent off-state current, as explained in the preceding paragraph. Electromechanical devices may also permit a small amount of current to flow when the device is in the “open” position due to poor insulation characteristics, which may be subject to further deterioration with age and use. An example is a switching device that employs a carbon brush in contact with an insulating segment of the switch in the off-state, such that a conductive film may be deposited by the brush on the insulating segment. Any input device that could produce an erroneous signal of sufficient magnitude to cause a malfunction of the solid state equipment, such as unintended turn ON or inability to turn OFF, should not be used with solid state controls. Also see section 3.5.2. C.2.4 Polarity 2.4 Polarity Incorrect polarity of applied voltages may damage solid state controls. The correct polarity of solid state controls should be observed. In some instances incorrect polarity can cause damage to controlled equipment or unintended actuation of outputs. This could result in personal injury due to an unexpected response of the controlled equipment or process. Also see section 3.3.2. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 2.5 Rate of Rise-Voltage or Current (DV/DT or DI/DT) C.2.5 Rate of Rise-Voltage or Current Solid state controls can be affected by rapid changes of voltage or current if the rate of rise (DV/DT and/or DI/DT) is greater than the maximum permissible value specified by the manufacturer. The DV/DT rating specifies the maximum rate at which voltage may be applied to the power terminals of a solid state device. Voltage applied at a rate exceeding the DV/ DT rating can switch the device ON without an input signal being applied. Electrical noise with high frequency content is one source of rapidly changing voltage. (DV/DT or DI/DT) Another common source of high DV/DT is an inductive load that is switched off faster than the stored energy can be dissipated. This fast switching produces “inductive kick voltages” that might exceed the DV/DT limit. The DI/DT rating specifies the maximum rate at which current flow may be increased when switching from OFF to ON. Currents that increase faster than the DI/DT rating cause localized hot spots due to current crowding in a small area until the entire cross section can become conductive. This results in gradual degradation of the device. Subsequent operations generally result in over dissipation and short circuit failures even under normal load conditions. The most common situations for high DI/DT are low load impedance, or capacitance loads. Manufacturers of solid state equipment usually include internal means to limit the rate of rise of voltage and current. Nonetheless, the user should be aware that additional external means may be necessary to adjust to the specific conditions of some installations. 2.6 Surge Current C.2.6 Surge Current Current of a value greater than that specified by the manufacturer can affect the solid state control. Current limiting means may be required. The manufacturer may specify allowable surge current. Common practice is to specify the peak sinusoidal current that can be allowed for one-half cycle at line frequency. The intent behind this practice is to give the user information for selecting an appropriate fuse or other current limiting means. Applications that require short term overcurrent capability (e.g., motor starting) must observe the manufacturer's restrictions on the number of times the device can be subjected to overcurrent in a specified time interval. The user should be aware that this specification may vary depending upon whether the conditions call for hot starts or cold starts. Hot start means that the solid state component is at or near the normal operating temperature due to previous operation history when the overcurrent condition occurs. Cold start means that the solid state component is at or below 40 degrees Celsius when the overcurrent condition occurs. www.rosscontrols.com 5 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 2.7 Transient Overvoltage Solid state controls may be affected by transient overvoltages which are in excess of those specified by the manufacturer. Voltage limiting means should be considered and may be required. Section 3 C.2.7 Transient Overvoltage Solid state devices are especially sensitive to excessive voltage. When the peak voltage rating is exceeded, even for a fraction of a second, permanent damage can occur. The crystalline structure of the device may be irretrievably altered and the device may no longer be able to turn OFF. The external symptom of this situation is exactly the same as that of an electromechanical device with welded contacts. Minimum Holding Current Another characteristic of concern is the minimum holding current requirement for triacs and SCRs. When the load current falls below the minimum value, typically 25 – 100 mA, the triac or SCR ceases conduction and passes only off-state current until again triggered. Thus, it may not be possible for the circuit to turn-on or conduct full load current for very light loads. In these instances, a load resistor called a bleeder resistor may be connected to the output to provide the minimum load. In some equipment special circuitry is provided to overcome this problem. Application Guidelines 3.1 General Application Precautions 3.1.1 Circuit Considerations The consequences of some malfunctions such as those caused by shorted output devices, alteration, loss of memory, or failure of isolation within components or logic devices, require that the user be concerned with the safety of personnel and the protection of the electronics. It is recommended that circuits which the user considers to be critical to personnel safety, such as “end of travel” circuits and “emergency stop” circuits, should directly control their appropriate functions through an electromechanical device independent of the solid state logic. Such circuits should initiate the stop function through deenergization rather than energization of the control device. This provides a means of circuit control that is independent of system failure. 6 C.3.1.1 Circuit Considerations The predominant failure mode of solid state devices is in the ON condition. This failure mode and the other types of failures mentioned in the NEMA Standard are the reasons for the precautions that are recommended for safety-critical circuits on systems that control potentially hazardous processes or machine operations. Alternatively, if solid-state is used for circuits designated as safety-critical, the circuits should be designed to provide safety equivalent to the recommended “hard-wired” electromechanical circuits. In such cases consideration should be given to techniques such as: redundancy, feedback loops, diagnostics, interlocking and read-only memory for critical parts of a program. De-energization rather than energization of the control device should be specified for STOP circuits so broken wires or corroded contacts do not go undetected. Estop push buttons or pull cords should be installed at appropriate locations on a machine to provide operators with a rapid and convenient means for removing power from devices which control machine motion. Alternate methods of stopping such as dynamic braking and regenerative braking may be available. In order to accomplish the dynamic braking and regenerative braking function, the control circuit, or part of it, in the equipment must remain energized during the stopping mode. However, operator interface components such as stop push buttons or pull cords, must still be connected through normally closed contacts so broken wires or corroded contacts do not go undetected. Also, if dynamic or regenerative braking is used for emergency stopping, provision should be made to interrupt the power circuit as soon as the machine comes to a stop. © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.1.2 Power Up/Power Down Considerations C.3.1.2 Power Up/Power Down Considerations Consideration should be given to system design so that unsafe operation does not occur under these conditions since solid state outputs may operate erratically for a short period of time after applying or removing power. Response of a system during power up/power down can create hazards not encountered during normal operation. Erratic operation of solid state outputs due to the changing voltage of DC power supplies during start up is one example. To avoid unpredictable outputs, many power supplies incorporate a power turn-on time delay circuit. This allows power supply output voltage to reach its specified value before being applied to solid state logic and output circuits. If this protection is not part of the DC supplies for a system, a timing circuit external to the power supply can be added to delay the application of power to output devices. Removing all power or losing all power from a system simultaneously usually does not result in a hazard since the power for machine operation is also being removed. However, when power other than electrical power is being controlled, a power interlock circuit may be required to protect against unexpected machine motion. Power interlocks with automatic shutdown should be included if erratic or hazardous operation results due to loss of one power supply in a system with multiple supplies. Automatic power supply sequencing should be employed in systems that require the application or removal of power in a specific sequence. If the STOP or E-STOP sequence normally employs dynamic braking, alternative safeguards, such as automatic mechanical braking upon loss of power, should be provided if coasting stops are hazardous. If hazardous operation can result from unexpected restoration of power during a power outage or a system shutdown, the system should include a feature which requires a deliberate operator action before power is reapplied to the system. www.rosscontrols.com 7 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.1.3 Redundancy and Monitoring C.3.1.3 Redundancy and Monitoring When solid state devices are being used to control operations, which the user determines to be critical, it is strongly recommended that redundancy and some form of checking be included in the system. Monitoring circuits should check that actual machine or process operation is identical to controller commands; and in the event of failure in the machine, process, or the monitoring system, the monitoring circuits should initiate a safe shutdown sequence. The normal operating mechanism for solid state components depends upon a deliberate electrical signal input altering the internal molecular structure of the semiconductor material. Unfortunately, spurious input signals may also alter the internal molecular structure without any means for external detection that this has happened. Therefore, solid state devices are subject to malfunction due to random causes that are undetectable. Because of this, redundancy and monitoring are the most highly recommended means for counteracting this situation. When redundancy is used, dissimilar components not susceptible to common cause failure should be used for the redundant elements if a common cause could produce simultaneous failure of those elements in a dangerous mode. A “safe shutdown sequence” can involve much more than disconnecting electrical power for some machinery and processes. Examples include machines with high inertia and hazardous access points; processes that become unstable at shutdown unless a specific sequence is followed; etc. The control system for such applications should be configured to deal with the particular hazard(s) through use of special features such as automatic transfer of control functions to redundant devices in the event of failure of primary controls; alarm circuits and diagnostics to signal and identify failures that require repair in order to maintain redundancy; emergency power sources with automatic transfer upon loss of primary power source; or other appropriate features. 3.1.4 Overcurrent Protection C.3.1.4 Overcurrent Protection To protect triacs and transistors from shorted loads, a closely matched short circuit protective device (SCPD) is often incorporated. These SCPDs should be replaced only with devices recommended by the manufacturer. Even a closely matched short circuit protective device (SCPD) will generally protect a solid state device only against shorted loads, an accidental short to ground or a phase to phase short. Depending upon the application, additional protective measures may be needed to protect the solid state devices against small to moderate overcurrents. Consult with the manufacturer if necessary. 3.1.5 Overvoltage Protection To protect triacs, SCRs and transistors from overvoltages, it may be advisable to consider incorporating peak voltage clamping devices such as varistors, zener diodes, or snubber networks in circuits incorporating these devices. 8 C.3.1.5 Overvoltage Protection See section 2.7. © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.2 Circuit Isolation Requirements C.3.2.1 Separating Voltages 3.2.1 Separating Voltages For specifications of Class 2 circuitry, refer to Article 725 of the National Electrical Code, NFPA 70. Solid state logic uses low level voltage (e.g., less than 32 volts DC) circuits. In contrast, the inputs and outputs are often high level (e.g., 120 volts AC) voltages. Proper design of the interface protects against an unwanted interaction between the low level and high level circuits; such an interaction can result in a failure of the low voltage circuitry. This is potentially dangerous. An input and output circuitry incorporating effective isolation techniques (which may include limiting impedance or Class 2 supplied circuitry) should be selected. C.3.2.2 Isolation Techniques Isolation transformers, pulse transformers, reed relays, or optical couplers are typical means to transmit low level logic signals to power devices in the high level circuit. Isolation impedance means also are used to transmit logic signals to power devices. In addition to utilizing the various components discussed in the left column, specific wiring techniques should be applied to assure separation of power circuit wires from logic circuit wires. If at all possible, logic wires should be run in a conduit that is segregated for that purpose only. Multiple conductors in a shielded cable is an appropriate substitute for separate conduits. Another common practice is to run the logic signals through twisted pairs of wire. Regardless of the circumstances, wires carrying logic signals should never be wrapped in the same bundle with wires that carry power signals. 3.3 Special Application Considerations C.3.3.1 Converting Ladder Diagrams 3.3.1 Converting Ladder Diagrams The example cited in this section of the NEMA Standard illustrates only one of a number of reasons for special care in converting an electromechanical (relay) ladder diagram to a programmable controller (PC) program. Some other basic considerations are: 3.2.2 Isolation Techniques The most important function of isolation components is to separate high level circuits from low level circuits in order to protect against the transfer of a fault from one level to the other. Converting a ladder diagram originally designed for electromechanical systems to one using solid state control must account for the differences between electromechanical and solid state devices. Simply replacing each contact in the ladder diagram with a corresponding solid state “contact” will not always produce the desired logic functions or fault detection and response. For example, in electromechanical systems, a relay having a mechanically linked normally open (NO) and normally closed (NC) contact can be wired to check itself. Solid state components do not have a mutually exclusive NO-NC arrangement. However, external circuitry can be employed to sample the input and “contact” state and compare to determine if the system is functioning properly. • A PC program is an instruction to the PC's central processing unit to enable it to perform the logic functions and sequences for a particular application. Typically, the PC's logic level components are electrically isolated from the actual input, sensor and actuator devices, as contrasted with electromechanical controls which usually include contacts and coils of the actual plant floor devices in the control schematic. Therefore a PC program normally functions as open-loop control, unless feedback loops from the plant floor devices to separate inputs of the PC are provided and programmed to cause corrective action if inconsistencies are detected. Programmers of PC systems should evaluate functional and safety implications of all control paths and provide appropriate feedback arrangements as needed. (continued) www.rosscontrols.com 9 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls C.3.3.1 (continued) • In an electromechanical implementation of a ladder diagram, power is available to every rung at all times, so that the logic of the various rungs is executed continually and simultaneously, limited of course by the operating delays inherent in the electromechanical devices. By contrast, a typical PC examines the status of input devices (I/O scan), then executes the user program in sequence (program scan), then changes outputs accordingly in the next I/O scan. Therefore, the sequential order of a PC program can be of more importance and significance than in its electromechanical counterpart, particularly when special instructions such as “immediate” inputs or outputs are programmed as some PCs permit. Also, differences in response characteristics of components, differences in system architecture, and the scan time associates with a PC system can combine to change timing characteristics of a circuit significantly. In particular, care must be taken in handling momentary or rapidly changing inputs to a PC system which might be missed between scans. Simple transfer of a ladder diagram without consideration of these characteristics of PCs may produce unintended and possibly hazardous results. Programmers should consult the user’s manual in order to understand the characteristics of the particular PC being used, and provide appropriate features in the program to accommodate them. • Another concern is the operating mode of devices connected to input terminals. Input signals must be arranged so loss of signal due to a broken wire or corroded contact does not go undetected and create a hazardous condition. In particular, stop functions should be initiated by opening a normally closed external circuit rather than closing a normally open circuit even though the system is capable of being programmed to accept either type of input. The considerations described in this section apply to the creation of “new” programs as well as conversion of existing ladder diagrams. 3.3.2 Polarity and Phase Sequence C.3.3.2 Polarity and Phase Sequence Input power and control signals should be applied with polarity and phase sequence as specified by the manufacturer. Solid state devices can be damaged by the application of reverse polarity or incorrect phase sequence. Additionally, incorrect polarity or phase sequence connection may cause erratic response by solid state controls, with potential hazards to personnel. Frequently, such a system contains a detection circuit that illuminates an indicator when incorrect phase sequence is applied. Phase sequence may be corrected by interchanging any two system input power leads. It is advisable to check rotation of motors whenever input power leads are disconnected and reconnected in a system. 10 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.4 Planning Electrical Noise Rejection The low energy levels of solid state controls may cause them to be vulnerable to electrical noise. This should be considered in the planning stages. 3.4.1 Assessing Electrical Environment C.3.4.1 Assessing Electrical Environment Sources of noise are those pieces of equipment that have large, fast changing voltages or currents when they are energized or de-energized, such as motor starters, welding equipment, SCR type, adjustable speed devices and other inductive devices. These devices, as well as the more common control relays and their associated wiring, all have the capability of inducing serious current and voltage transients on their respective power lines. It is these transients which nearby solid state controls must withstand and for which noise immunity should be provided. Noise can also occur in the form of electromagnetic radiation, or due to improper grounding practices. Section C.3.4.3 explains these forms of noise and precautionary measures that should be taken for protection against them. An examination of the proposed installation site of the solid state control should identify equipment that could contaminate power lines. All power lines that will be tapped by the proposed solid state control should be examined for the presence, severity, and frequency of noise occurrences. If found, system plans should provide for the control of such noise. In many instances a system may begin to malfunction some time after it has been installed and is working properly. This may be due to recent installation of new equipment capable of inducing noise into presently operating systems. Thus, it is not sufficient to merely evaluate a system at the time of installation. Periodic rechecks should be made, especially as other equipment is moved, modified, or newly installed. When installing a solid state system, it is wise to assume various noise sources exist and install the system to guard against possible interference. 3.4.2 Selecting Devices to Provide Noise Immunity C.3.4.2 Selecting Devices to Provide Noise Immunity Installation planning is not complete without examination of the noise immunity characteristics of the system devices under consideration. Results of tests to determine relative immunity to electrical noise may be requested from the manufacturer. Two such standardized tests are the ANSI (C37.90a-1974) Surge Withstand Capability Test and the NEMA (ICS.1-1983) noise test referred to as The Showering Arc Test. These are applied where direct connection of solid state control to other electromechanical control circuits is intended. Circuits involving analog regulating systems or high speed logic are generally more sensitive to electrical noise; therefore, isolation and separation of these circuits is more critical. Inductive devices are capable of generating high voltage transients when switched off. In addition to possibly causing damage to solid state devices by exceeding the semiconductor voltage rating, the high voltage transient can be coupled to other portions of a system where it appears as noise. Fortunately, it is fairly easy to limit the effects of this type of noise with some form of suppression device. When necessary, in addition to suppression devices often provided in solid state equipment, an external suppressor should be connected as close as possible to the source of the transient for maximum attenuation. NOTE: A surge suppressor increases drop-out time of an electromechanical device. Further information on electrical noise and evaluation of the severity of noise may be found in ANSI/IEEE Publication No. 518-1982. Where severe power line transients are anticipated or noted, appropriate filters such as commercially available line filter, isolation transformers, or voltage limiting varistors, should be considered. All inductive components associated with the system should be examined for the need for noise suppression. www.rosscontrols.com 11 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.4.3 Design of Wiring for Maximum Protection C.3.4.3 Design of Wiring for Maximum Protection Once the installation site and power conductors have been examined, the system wiring plans that will provide noise suppression should be considered. Noise can also occur in the form of electromagnetic radiation. Examples include radio frequency (RF) energy emanating from portable transceivers (walkie-talkie) and fixed station transmitters of various types. Close coupling is not required; the various lines entering the system act as receiving antennas. Tests described in 3.4.2 may not be sufficient to demonstrate noise immunity to radio frequency signals. Variations in building construction and equipment installation make it impossible for equipment manufacturers to perform meaningful tests of radio frequency sources. RF fields are affected by concentrating masses of metal such as steel beams, piping, conduit, metal enclosures, and equipment used in production such as fork lift trucks and products being transported on conveyors. Conducted noise enters solid state control at the points where the control is connected to input lines, output lines, and power supply wires. Input circuits are the circuits most vulnerable to noise. Noise may be introduced capacitatively through wire to wire proximity, or magnetically from nearby lines carrying large currents. In most installations, signal lines and power lines should be separate. Further, signal lines should be appropriately routed and shielded according to manufacturer’s recommendations. When planning system layout, care must be given to appropriate grounding practice. Because design differences may call for different grounding, the control manufacturer’s recommendations should be followed. If the installation site will be subjected to this type of noise, thorough testing should be performed to assure that the solid state system has sufficient noise immunity for the expected levels of radio frequency energy. Corrective measures should be taken if necessary. These include shielding of solid state circuits and/or connected wiring and the establishment of restrictions to provide safe operating distances between the solid state equipment and the RF sources. Grounding practices in industry are frequently misunderstood and often ignored. Poor grounding can lead to many problems in solid state systems. Intentionally grounding one circuit conductor of any electrical supply system is widely accepted and is generally required by electrical codes. However, the non-current carrying parts of a system which enclose equipment and conductors must also be grounded. In addition to complying with various codes and standards, proper equipment grounding achieves several desirable objectives: 1. It reduces the potential difference between conductive surfaces to minimize electric shock hazard exposure for personnel. 2. It provides a path for passage of fault current to operate protective devices in the supply circuit. 3. It attenuates the electrical noise and transients which can reach enclosed equipment and also reduces the electrical noise which the equipment can contribute to its surroundings. 12 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.5 Countering the Effects of Off-State Current C.3.5.1 Off-State Current 3.5.1 Off-State Current See section 2.3. Solid state components, such as triacs, transistors, and thyristors, inherently have in the off-state a small current flow called “off-state current”. Off-state current may also be contributed by devices used to protect these components, such as RC snubbers. 3.5.2 Off-State Current Precautions C.3.5.2 Off-State Current Precautions Off-state currents in a device in the off-state may present a hazard of electrical shock and the device should be disconnected from the power source before working on the circuit or load. The off-state current of a power switching device such as a solid state motor controller can be lethal. Simply switching off power via a stop push button in a control circuit is not a sufficient precaution, since off-state current will continue to flow through solid state devices which remain connected to the supply. Good practice requires disconnection of all power from equipment before working on or near exposed circuit parts. (See NFPA 70E, Part II.) It should not be assumed that a shock hazard does not exist simply because a solid state circuit operates at low voltage levels. Standing on a wet floor or working in a damp location can lower a person’s body impedance to the extent that offstate current from low voltage also presents an electrical shock hazard. If it is necessary to work on energized equipment, the guidelines detailed in section 5.2 for Preventive Maintenance should be followed. In addition to the specific procedures for personnel safety, care is needed when making measurements in energized systems. First, there is a possibility of damage to delicate instruments due to off-state current. Second, the off-state current can lead to false conclusions when using sensitive instruments to check for “contact continuity.” Precautions should be taken to prevent the off-state current of an output device which is in the off-state from energizing an input device. When a device (solid state or electromechanical) that can produce a leakage current in the off-state is used to provide the input to a solid state control, the precautions explained in section C.2.3 apply. www.rosscontrols.com 13 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.6 Avoiding Adverse Environmental Conditions 3.6.1 Temperature Solid state devices should only be operated within the temperature ranges specified by the manufacturer. Because such devices generate heat, care should be taken to see that the ambient temperature at the device does not exceed the temperature range specified by the manufacturer. The main source of heat in a solid state system is the energy dissipated in the power devices. Since the life of the equipment can be increased by reducing operating temperature, it is important to observe the manufacturer’s “maximum/minimum ambient temperature” guidelines, where ambient refers to the temperature of the air providing the cooling. The solid state equipment must be allowed to stabilize to within the manufacturer’s recommended operating temperature range before energizing control functions. When evaluating a system design, other sources of heat in the enclosure which might raise the ambient temperature should not be overlooked. For example, power supplies, transformers, radiated heat, sunlight, furnaces, incandescent lamps, and so forth should be evaluated. C.3.6.1 Temperature Operation above the maximum rated temperature will usually result in many failures in a short time. Nuisance type malfunctions can also be encountered as a result of elevated ambient temperature. These malfunctions, when they occur, are usually temporary and normal operation resumes when temperatures are lowered. Some solid state devices temporarily cease to function when ambient temperature is below their minimum rated operating temperature. Operation in cold environments should be avoided or heaters should be installed in the equipment enclosures to bring the system up to the minimum specified operating temperature before applying power to the system. Air circulating in a non-ventilated enclosure with equipment operating will be at a higher temperature than the room in which it is installed. A temperature differential of 10 to 20 degrees Celsius can be expected in a typical industrial installation. Also see section 2.1. In instances where a system will have to exist in a very hot ambient environment, special cooling methods may have to be employed. Techniques that are employed include cooling fans (with adequate filtering), vortex coolers, heat exchanges, and air conditioned rooms. Over-temperature sensors are recommended for systems where special cooling is employed. Use of air conditioning should include means for prevention of condensing moisture. 14 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 3.6.2 Contaminants C.3.6.2 Contaminants Moisture, corrosive gases and liquids, and conductive dust can all have adverse effects on a system that is not adequately protected against atmospheric contaminants. Modules for solid state systems usually consist of electronic devices mounted on printed circuit boards with relatively close spacing between conductors. Moisture in the form of humidity is one of the atmospheric contaminants which can cause failure. If moisture is allowed to condense on a printed circuit board, the board metallizations could “electroplate” across the conductor spacings when voltage is applied. In low impedance circuits, this conductive path would immediately burn open, then reform to be burned open again. This action can lead to erratic operation. In high impedance circuits, a short circuit may appear resulting in a permanent malfunction. Specifications for equipment often include a relative humidity exposure limit, but appropriate precautions should be taken to prevent condensation. Failures due to moisture are often accelerated in the presence of corrosive gases or vapors. These increase the conductivity of the moisture layer allowing electromigration to occur more rapidly and at lower potentials. If these contaminants are allowed to collect on printed circuit boards, bridging between the conductors may result in malfunction of the circuit. This could lead to noisy, erratic control operation, or at worst, a permanent malfunction. A thick coating of dust could also prevent adequate cooling on the board or heat sink, causing malfunction. A dust coating on heat sinks reduces their thermal efficiency. Preventive measures include a specially conditioned room or a properly specified enclosure for the system. 3.6.3 Shock and Vibration C.3.6.3 Shock and Vibration Excessive shock or vibration may cause damage to solid state equipment. Special mounting provisions may be required to minimize damage. Solid state systems usually have good resistance to shock and vibration since they contain no moving parts. However, at relatively high levels of shock or vibration, circuit boards may disengage from mating connectors if not restrained sufficiently. Circuit boards can crack, components can come out of sockets or component leads can break loose from a solder connection to the board. Mounting position is usually of little significance to solid state devices except in instances where air flow is required 3.7 The Need for Education – Knowledge Leads to Safety Planning for an effective solid state circuit requires enough knowledge to make basic decisions that will render the system safe as well as effective. Everyone who works with a solid state control should be educated in its capabilities and limitations. This includes in-plant installers, operators, service personnel, and system designers. www.rosscontrols.com 15 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls Section 4 Installation Guidelines 4.1 Installation and Wiring Practice 4.1.1 Proper installation and field wiring practices are of prime importance to the application of solid state controls. Proper wiring practice will minimize the influence of electrical noise, which may cause malfunction of equipment. User and installers should familiarize themselves with the follow installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. The manufacturer of the device or component in question should be consulted whenever conditions arise that are not covered by the manufacturer’s instructions. 4.1.2 C.4.1.2 Electrical noise is a very important consideration in any installation of solid state control. While wiring practices may vary from situation to situation, the following are basic to minimizing electrical noise: A great deal of effort goes into the design of solid state equipment to achieve a reasonable degree of noise immunity. Filters, shielding, and circuit design are all used. It is, however, impossible to design equipment which is impervious to every form of noise found in the industrial setting. 1. Sufficient physical separation should be maintained between electrical noise sources and sensitive equipment to assure that the noise will not cause malfunctioning or unintended actuation of the control. 2. Physical separation should be maintained between sensitive signal wires and electrical power and control conductors. This separation can be accomplished by conduits, wiring trays, or as otherwise recommended by the manufacturer. When installing a system using solid state technology it is wise to assume that electrical noise exists and install the equipment in accordance with the recommended guidelines to minimize problems. Also see section 3.4.1. 3. Twisted-pair wiring should be used in critical signal circuits and noise producing circuits to minimize magnetic interference. 4. Shielded wire should be used to reduce the magnitude of the noise coupled into the low level circuit by electrostatic or magnetic coupling. 1 5. Provisions of the 1984 National Electrical Code with respect to grounding should be followed. Additional grounding precautions may be required to minimize electrical noise. These precautions generally deal with ground loop currents arising from multiple ground paths. The manufacturer’s recommendations should be followed. 1 16 Available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 4.2 Enclosures (Cooling and Ventilating) C.4.2 Enclosures (Cooling and Ventilating) Suitable enclosures and control of the maximum operating temperature, both of which are environmental variables, may be needed to prevent malfunctions of solid state control. NEMA Standards Publication No. 250-1985, Rev. 2, May 1988, classifies enclosures by type number and specifies their design test requirements. The manufacturer’s recommendations should be followed for the selection of enclosures, ventilation, air filtering (if required), and ambient temperature. These recommendations may vary from installation to installation, even within the same facility. Also see section 2.1 and 3.6.1. 4.3 Special Handling of Electrostatic Sensitive Devices C.4.3 Special Handling of Electrostatic Sensitive Devices Some devises may be damaged by electrostatic charges. These devices are identified and should be handled in the special manner specified by the manufacturer. Many problems due to electrostatic discharge (ESD) occur due to handling of modules during installation or maintenance. NOTE: Plastic wrapping material used to ship these devices may be conductive and should not be used as insulating material. In addition to specific guidelines provided by an equipment supplier, the following general guidelines can help reduce damage due to ESD. 1. Use a grounding bracelet if possible to minimize charge build-up on personnel. 2. Handle a module by the edges without touching components or printed circuit paths. 3. Store modules with ESD sensitive components in the conductive packaging used for shipping the modules. Also, use conductive packaging when returning static sensitive modules for repair. 4.4 Compatibility of Devices with Applied Voltages and Frequencies Prior to energization, users and installers should verify that the applied voltage and frequency agree with the rated voltage and frequency specified by the manufacturer. NOTE: Incorrect voltage or frequency may cause a malfunction of, or damage to, the control. C.4.5 Testing Precautions 4.5 Testing Precautions When testing solid state control, the procedures and recommendations set forth by the manufacturer should be followed. When applicable, instrumentation and test equipment should be electrically equivalent to that recommended by the manufacturer for the test procedure. A low impedance voltage tester should not be used. High voltage insulation tests and dielectric tests should never be used to test solid state devices. If high voltage insulation of field wiring is required, solid state devices should be disconnected. Ohmmeters should only be used when and as recommended by the equipment manufacturer. Testing equipment should be grounded; if it is not, special Make-do test devices such as incandescent lamps or neon lamps should not be used for checking voltages in solid state systems. Incandescent lamps have low impedance; the low impedance of these devices can effectively change a voltage level from a logic “1” condition to a logic “0” condition when attempting to make a measurement. Unexpected machine motion can result if an output to a controlled device is energized as a result. Neon lamps do not respond to voltages typically used in logic circuits (e.g., 32 volts DC or less). Use of a neon lamp tester could lead to false conclusions about the voltage level present in a circuit. High input impedance meters are required to obtain accurate voltage measurements in high impedance circuits. Unless otherwise specified by the manufacturer, a meter with an input impedance of ten megohms or greater is recommended for making voltage measurements. The meter must also have sufficient sensitivity to measure logic level voltages; some meters do not respond to low voltages. www.rosscontrols.com 17 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 4.6 Startup Procedures C.4.6 Startup Procedures Checks and tests prior to startup and startup procedures recommended by the manufacturer should be followed. Startup procedures can provide important benefits for safety with new installation, or after modifications or repairs. A “dry run” under controlled conditions can verify proper installation and functioning of the control system before it is turned over to operating personnel. Many programmable solid state systems have the capability for simulating operation in a mode known as “test” mode or “dry run” mode. These modes allow a user to check a program and correct obvious programming errors with outputs disabled. Unexpected machine motion and possible damage to workpieces and equipment is thus avoided. These modes can also be used to verify proper system operation after a repair. Many programmable systems provide capability for “force on” and “force off” of inputs and outputs. Use of these functions can reduce troubleshooting and maintenance time by enabling personnel to bypass certain operations without physically operating switches on a machine. Care must be taken when using “force” functions to avoid exposing personnel to hazardous machine motions or process operations. For controllers operating a machine tool or robot, running a part program at a fraction of the programmed operating speed with a workpiece of soft material is considered “good practice”. This allows an operator to observe possible interference of tooling with the part and make corrections to the program. A workpiece of soft material such as wood, plastic, or machinable wax will minimize risk of tool damage if there is a tool crash with the workpiece. 18 © 2007 ROSS CONTROLS®. All Rights Reserved. Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls Section 5 Preventive Maintenance and Repair Guidelines 5.1 General A well-planned and executed maintenance program is essential to the satisfactory operation of solid state electrical equipment. The kind and frequency of the maintenance operation will vary with the kind and complexity of the equipment as well as with the nature of the operating conditions. Maintenance recommendations of the manufacturer or appropriate product standards should be followed. Useful reference publications for setting up a maintenance program are NFPA 70B-1983, Maintenance of Electrical Equipment, and NFPA 70E-1983, Electrical Safety Requirements for Employee Workplaces. 5.2 Preventive Maintenance C.5.2 Preventive Maintenance The following factors should be considered when formulating a maintenance program: Lithium batteries are frequently used for memory backup in solid state equipment due to their excellent shelf life and high energy to weight ratio. Lithium is a highly reactive metal that can cause burns if there is contact with skin. The batteries are sealed so there is seldom a problem of contact with lithium as long as reasonable care is exercised when handling them. They should only be used in their intended application and not subjected to rough handling. When batteries are replaced in equipment, the batteries removed should be disposed of in accordance with supplier’s instructions. 1. Maintenance must be performed by qualified personnel familiar with the construction, operation, and hazards involved with the control. 2. Maintenance should be performed with the control out of operation and disconnected from all sources of power. If maintenance must be performed while the control is energized, the safety related practices of NFPA 70E should be followed. 3. Care should be taken when servicing electrostatic sensitive components. The manufacturer’s recommendations for these components should be followed. 4. Ventilation passages should be kept open. If the equipment depends upon auxiliary cooling, e.g., air, water, or oil, periodic inspection (with filter replacement when necessary) should be made of these systems. 5. The means employed for grounding or insulating the equipment from ground should be checked to assure its integrity (see 4.5). The Department of Transportation has certain regulations that prohibit shipment of equipment with batteries installed if the batteries contain 0.5 gram or greater of lithium. The batteries must be removed from equipment and shipped separately in a container approved by the Department of Transportation. Additional Department of Transportation restrictions apply to the shipment of lithium batteries. NEMA Standards Publication No. ICS 1.3 – 1986, Preventive Maintenance of Industrial Control and System Equipment, is recommended for personnel responsible for maintenance of equipment. 6. Accumulations of dust and dirt on all parts, including on semiconductor heat sinks, should be removed according to the manufacturer’s instructions, if provided; otherwise, the manufacturer should be consulted. Care must be taken to avoid damaging any delicate components and to avoid displacing dust, dirt, or debris in a way that permits it to enter or settle into parts of the control equipment. (continued) www.rosscontrols.com 19 Safety Guidelines for the Application, Installation, and Maintenance of Solid State Controls 5.2 Preventive Maintenance (continued) 7. Enclosures should be inspected for evidence of deterioration. Accumulated dust and dirt should be removed from the top of the enclosures before opening doors or removing covers. 8. Certain hazardous materials removed as part of maintenance or repair procedure (e.g., polychlorinated biphenyls (PCB) found in some liquid filled capacitors) must be disposed of as described in Federal regulations. C.5.3 Repair 5.3 Repair If equipment condition indicates repair or replacement, the manufacturer’s instruction manual should be followed carefully. Diagnostic information within such a manual should be used to identify the probable source of the problem, and to formulate a repair plan. The level of field repair recommended by the manufacturer should be followed. When solid state equipment is repaired, it is important that any replacement part be in accordance with the recommendations of the equipment manufacturer. Care should be taken to avoid the use of parts which are no longer compatible with other changes in the equipment. Also, replacement parts should be inspected for deterioration due to “shelf life” and for signs of rework or wear which may involve factors critical to safety. After repair, proper start-up procedures should be followed. Special precautions should be taken to protect personnel from hazards during start-up. Follow manufacturer’s instructions exactly when replacing power semiconductors mounted on heatsinks since improper installation may become the source of further difficulties. Torque semiconductors or bolts retaining semiconductors to the value specified using a torque wrench. Too much pressure against a heatsink can damage a semiconductor while too little can restrict the amount of heat transferred from the semiconductor to the heatsink and result in operation at higher temperature with decreased reliability. Exercise care when removing modules from a system during maintenance. Failed modules are frequently returned to the manufacturer for repair. Any physical damage sustained during removal may result in more expensive repair or render the module unrepairable if damage is too great. Modules with electrostatic sensitive components should be handled by the edges without touching components or printed circuit conductors. Use packaging material supplied with the replacement module when shipping the module to the manufacturer for repair. When the scope of repairs exceeds the manufacturer’s recommendations for field repair, the module(s) should be returned to the manufacturer for repair. Doing so will help to ensure that only properly selected components are used, and that all necessary hardware and firmware revisions are incorporated into the repair. Failure to make necessary updates may result in safety, compatibility or performance problems which may not become apparent for some time after the repaired module has been placed back in service. When firmware is protected by copyright law, updates can be provided legally only by the manufacturer or licensee. Also see section 4.3. 5.4 Safety Recommendations for Maintenance Personnel All maintenance work should be done by qualified personnel familiar with the construction, operation, and hazards involved with the equipment. The appropriate work practices of NFPA 70E should be followed. Printed in U.S.A -1007 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10325 Installation & Service Instructions A10329 W66 Size 0 & W66 Size 00 Interposed Regulators ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. The valves exhaust (coming out of its inlet passage) is directed to manifold or subbase exhaust port “5”. ! CAUTION: The reverse valve porting utilized with Dual Interposed Regulation will reverse the function of 4-Way, 3-Position cylinder to exhaust and 4-Way, 3-Position inlet to cylinder valves. Utilize the opposite function valve for normal operation. The interposed regulator should be installed with reasonable accessibility for service whenever possible. Repair service kits are available. Keep pipe or tubing lengths to a minimum with inside clean and free of dirt and chips. Pipe joint compound should be used sparingly and applied only to the male pipe, never into the female port. Do not use PTFE tape to seal pipe joints. Pieces have a tendency to break off and lodge inside the unit, possibly causing malfunction. Air applied to the interposed regulator must be filtered to realize maximum component life. Lubrication Factory pre-lubed. If lubricating in service, use paraffin based mineral oil with 150 to 200 SSU viscosity @100°F. ! CAUTION: Do not use oils that are synthetic, reconstituted, have an alcohol content or a detergent additive. Application Limits These products are intended for use in general purpose compressed air systems only. Operating Pressure Range: Maximum 145 PSIG (1000 kPa) Ambient Temperature Range: -15°C to 49°C (5°F to 120°F) ANSI Symbol Independent Dual Port Regulator with 4-Way, 3-Position, Closed Center Common Port Regulator with 4-Way, 2-Position Valve 4 2 14 4 2 5 1 3 5 1 3 Independent Dual Port Regulator with 4-Way, 3-Position, Inlet to Cylinder Function 4 Independent Single Port Regulator with 4-Way, 3-Position, Closed Center 4 2 2 12 14 12 14 12 14 12 5 1 3 5 1 3 ! CAUTION: Requires 4-Way, 3-Position, Cylinder to Exhaust Valve Introduction Installation: Follow these instructions when installing, operating, or servicing the product. (See Figure 1, Size 00 Interposed Regulator shown as example) Installation & Operating Instructions: An interposed regulator is used to provide regulated pressure to individual valves in a manifolded valve arrangement. Two basic modes of regulation are available as follows: Single Interposed Regulation - Provides adjustable regulated air pressure to the valve inlet. Dual Interposed Regulation - Provides (2) separately adjustable regulated air pressures, one to each of the valves exhaust passages. ! Warning: Not following these instruction may result in Interposed Regulator damage or inadequate thread engagement, which may lead to personal injury, property damage, or economic loss. Important: • Remove pressure and electrical connections before installation. • All threads on tie rods and screws must be free of rust, water or other debris, which could prevent finger thread engagement. W66 Size 0 & W66 Size 00 Interposed Regulators Step 1: Install Tie Rods 1. Install two Tie Rods (6) to the base, torque finger tight. 2. Adjust tie rod height to 28.5/28.0 mm (1.12/1.10 inch) as figure shows. 3. If finger tight height exceeds 28.5 mm (1.12 inch), use mechanical tightening as necessary to get the proper height. Max: 28.5 mm (1.12 Inch) Min: 28.0 mm (1.10 Inch) 2 lowering the secondary pressure from 550 kPa (80 PSIG) to 410 kPa (60 PSIG) is best accomplished by dropping the secondary pressure to 345 kPa (50 PSIG), then adjusting upward to 410 kPa (60 PSIG). Service Instructions: 4 Note: “Base” could be a manifold, sub-base or interposed flow control. Step 2: Install Interposed Regulator 1. Lay the Interposed Regulator Gasket (5) on the Base. Make sure the two rubber projections are face up and the orientation of the gasket is correct. 2. Engage both Tie Rods (6) into mounting holes on Regulator Body, lower the Regulator Body. 3. Carefully engage the Electrical Plug into the Base. 4. Continue to lower the Regulator Body by carefully engaging the two rubber projections on the gasket into the appropriate holes on the Regulator Body. 5. Press the Regulator Body by hand firmly. To confirm the gasket is indeed attached to the Regulator Body, lift the Regulator Body by about one half inch. Both rubber projections should remain in the holes. 6. Lay the Regulator Body back on the Base. Step 3: Install Valve 1. Locate Valve Gasket (7) on bottom of Valve Body. 2. Install valve onto Regulator. 3. Carefully engage the Valve Electrical Plug. 4. Using hex wrench, tighten two Screws (8) – torque 1.5 to 1.7 Nm (13 to 15 in-lb) for Size 0, 0.9 to 1.1 Nm (8 to 10 in-lb) for Size 00. Step 4: Leakage Check 1. Apply pressure to base and check for audible leakage at various joints. If any are present, do not not operate the valve, repeat the assembly procedure until satisfied. 1. Disconnect air supply and depressurize the unit. 2. Loosen nut on adjusting screw. Turn adjusting screw counterclockwise until all downstream air is exhausted. 3. For Size 00 Regulator, remove Regulator Cartridge from block and replace with a new unit. For Size 0 Regulator, remove Regulator from base and replace with a new unit per installation procedure. 4. Reapply pressure to unit and check for audible leakage at joints or out bleed holes. If any are present, do not operate the valve. Repeat assembly procedure until satisfied. 5. Adjust outlet pressure per Outlet Pressure Adjustment procedure. 8 Valve Electrical Plug 2 Valve Body 3 7 4 1 Regulator Electrical Plug 5 6 Note: If both a Interposed Flow Control and Interposed Regulator is to be installed, the Flow Control should be installed between the Regulator and the Base. Refer to Interposed Flow Control Installation & Service Instructions (A10327) for Interposed Flow Control installation. 2 Base Figure 1 2 1 Size 00 Common Port Interposed Regulator (Valve & Base shown for reference only) 2 Component List Regulator Electrical Plug 5 6 Size 0 Independent Port Interposed Regulator Outlet Pressure Adjustment: 1. Before turning on the air supply, turn the adjusting knob counterclockwise until compression is released from the pressure control spring then turn on air supply. Proceed to adjust the desired downstream pressure by turning adjusting knob clockwise. This permits pressure to build up slowly in the downstream line. 2. To decrease regulated pressure setting, always reset from a pressure lower than the final setting required. For e xample, The components listed below are for identification purposes only, some of these components are available in various Interposed Regulator Kits, some are not available due to special factory assembly. Individual components are not sold separately since all kit components should be installed when serviced. Item 1 2 3* 4 5 6 7 8 Description Regulator Body Assembly Gauge Adapter Fitting Cartridge Regulator Flow Control / Regulator Gasket Tie Rods Valve Gasket Mounting Screws * Alternating Fittings must be used in order to fit two Size 00 regulators to each other. For all Instruction Sheets, go to www.rosscontrols.com A10326 - W66 Size 0 (26mm) & W66 Size 00 (18mm) ISO 15407 Valve Service A10327 - W66 Size 0 & W66 Size 00 ISO 15407-2 Interposed Flow Controls A10329 - W66 Size 0 & W66 Size 00 Interposed Regulators Printed in U.S.A -0807 A10330 - W66 Size 0 & W66 Size 00 ISO 15407-1 Subbbase & Manifold Installation A10331 - W65 Size 1, 2 & 3, ISO 5599-1, 5599-2 Subbase & Manifold Installation © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. Form A10329 Installation & Service Instructions A10324 Industrial Automation Wiring and Grounding Guidelines ISSUED: August, 2007 Supersedes: None ! WARNING To avoid unpredictable system behavior that can cause personal injury and property damage: • Disconnect electrical supply (when necessary) before installation, servicing, or conversion. • Disconnect air supply and depressurize all air lines connected to this product before installation, servicing, or conversion. • Operate within the manufacturer’s specified pressure, temperature, and other conditions listed in these instructions. • Medium must be moisture-free if ambient temperature is below freezing. • Service according to procedures listed in these instructions. • Installation, service, and conversion of these products must be performed by knowledgeable personnel who understand how pneumatic products are to be applied. • After installation, servicing, or conversion, air and electrical supplies (when necessary) should be connected and the product tested for proper function and leakage. If audible leakage is present, or the product does not operate properly, do not put into use. • Warnings and specifications on the product should not be covered by paint, etc. If masking is not possible, contact your local representative for replacement labels. Purpose This publication gives you general guidelines for installing an industrial automation system that may include programmable controllers, industrial computers, operatorinterface terminals, display devices, and communication networks. While these guidelines apply to the majority of installations, certain electrically harsh environments may require additional precautions. Use these guidelines as a tool for helping avoid potential electromagnetic interference (EMI) and transient EMI that could cause problems such as “adapter faults, rack faults, communication faults,” etc. These guidelines are not intended to supersede local electrical codes. This publication is organized into the following sections: • Raceway Layout Considerations Safety Guide For more complete information on recommended application guidelines, see the Installation Safety Guidelines section of Bulletin 600 (Form A10309) or you can download the Installation Safety Guidelines at: www.rosscontrols.com/rosslit.htm. • Mounting, Bonding, and Grounding • Power Distribution • Surge-Suppression • Ferrite Beads • Enclosure Lighting • Avoiding Unintentional Momentary Turn-On of Outputs • Related Publications ! WARNING FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from ROSS CONTROLS, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure and review the information concerning the product or systems in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by ROSS CONTROLS and its subsidiaries at any time without notice. EXTRA COPIES OF THESE INSTRUCTIONS ARE AVAILABLE FOR INCLUSION IN EQUIPMENT / MAINTENANCE MANUALS THAT UTILIZE THESE PRODUCTS. CONTACT YOUR LOCAL REPRESENTATIVE. Industrial Automation Wiring and Grounding Guidelines Raceway Layout Considerations The raceway layout of a system is reflective of where the different types of I/O modules are placed in I/O chassis. Therefore, you should determine I/O-module placement prior to any layout and routing of wires. However, when planning your I/O-module placement, segregate the modules based upon the conductor categories published for each I/O module so that you can follow these guidelines. Also, all conductors (AC or DC) in the same raceway must be insulated for the highest voltage applied to any one of the conductors in the raceway. These guidelines coincide with the guidelines for “the installation of electrical equipment to minimize electrical noise inputs to controllers from external sources” in IEEE standard 518-1982. Categorize Conductors Segregate all wires and cables into the following three categories (Table A). Refer to the publication for each specific I/O module or block for individual conductorcategory classification of each I/O line. Table A Follow these Guidelines for Grouping Conductors with Respect to Noise Group conductor cables fitting this description Control and AC Power — high-power conductors that are more tolerant of electrical noise than category 2 conductors and may also cause more noise to be picked up by adjacent conductors Into this category: Category 1 • AC power lines for power supplies and I/O circuits. • High-power digital AC I/O lines — to connect AC I/O modules rated for high power and high noise immunity. • High-power digital DC I/O lines — to connect DC I/O modules rated for high power or with input circuits with long time-constant filters for high noise rejection. They typically connect devices such as hard-contact switches, relays, and solenoids. Category 2 • Analog I/O lines and DC power lines for analog circuits. • Low-power digital AC/DC I/O lines — to connect to I/O modules that are rated for low power such as low-power contact-output modules. • Low-power digital DC I/O lines — to connect to DC I/O modules that are rated for low power and have input circuits with short time-constant filters to detect short pulses. They typically connect to devices such as proximity switches, photo-electric sensors, TTL devices, and encoders. • Communication cables (ControlNet, DeviceNet, RS-232-C cables) — to connect between processors or to I/O adapter modules, programming terminals, computers, or data terminals. Category 3 • Low-voltage DC power cables — provide backplane power to the system components. • Corresponds to IEEE levels 3 (low susceptibility) and 4 (power) Signal and Communication — low-power conductors that are less tolerant of electrical noise than category-1 conductors and should also cause less noise to be picked up by adjacent conductors (they connect to sensors and actuators relatively close to the I/O modules) • Corresponds to IEEE levels 1 (high susceptibility) and 2 (medium susceptibility) Intra-enclosure — interconnect the system components within an enclosure • Corresponds to IEEE levels 1 (high susceptibility) and 2 (medium susceptibility) 2 Examples: • Communication cables — to connect between system components within the same enclosure. © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Route Conductors To guard against coupling noise from one conductor to another, follow these general guidelines (Table B) when routing wires and cables (both inside and outside of an enclosure). Use the spacing given in these general guidelines with the following exceptions: • Where connection points (for conductors of different categories) on a device are closer together than the specified spacing. • Application-specific configurations for which the spacing is described in a publication for that specific application. These guidelines are for noise immunity only. Follow all local codes for safety requirements. Table B Follow these Guidelines for Routing Cables to Guard Against Noise Route this category of conductor cables: According to these guidelines: Category 1 These conductors can be routed in the same cable tray or raceway with machine power conductors of up to 600VAC (feeding up to 100 hp devices). Category 2 • If it must cross power feed lines, it should do so at right angles. • Route at least 5 ft from high-voltage enclosures, or sources of rf/microwave radiation. • If the conductor is in a metal wireway or conduit, each segment of that wireway or conduit must be bonded to each adjacent segment so that it has electrical continuity along its entire length, and must be bonded to the enclosure at the entry point. • Properly shield (where applicable) and route in a raceway separate from category-1 conductors. • If in a contiguous metallic wireway or conduit, route at least 0.08m (3 in) from category-1 conductors of less than 20A; 0.15m (6 in) from AC power lines of 20A or more, but only up to 100 kVA; 0.3m (1 ft) from AC power lines of greater than 100 kVA. • If not in a contiguous metallic wireway or conduit, route at least 0.15m (6 in) from category-1 conductors of less than 20A; 0.3m (1 ft) from AC power lines of 20A or more, but only up to 100 kVA; 0.6m (2 ft) from AC power lines of greater than 100 kVA. Category 3 Route conductors external to all raceways in the enclosure or in a raceway separate from any category-1 conductors with the same spacing listed for category-2 conductors, where possible. Important: These guidelines assume that you follow the Surge-Suppression guidelines (page 15). While these guidelines apply to the majority of installations, certain electrically harsh environments may require additional precautions. The use of the guidelines in Table B are illustrated in Figure 1. www.rosscontrols.com 3 Industrial Automation Wiring and Grounding Guidelines Figure 1 – Mounting Assembly Details Category-1 Conductors (AC Power Lines) Category-2 Conductors Conduit Tighter spacing allowed with conduit Enclosure Wall Conduit Use greater spacing without conduit Transformer Tighter spacing allowed where forced by spacing of connection points Category-2 Conductors I/O Block 1771 I/O Chassis Place modules to comply with spacing guidelines if possible Mounting, Bonding, and Grounding After establishing all layouts, you can begin mounting, bonding, and grounding each chassis. Bonding is the connecting together of metal parts of chassis, assemblies, frames, shields, and enclosures to reduce the effects of EMI and ground noise. Grounding is the connection to the grounding-electrode system to place equipment at earth ground potential. 4 © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Mounting and Bonding the Chassis You can mount the chassis with either bolts or welded studs. Figure 2 shows details for: • Stud-mounting a ground bus or chassis to the back panel of the enclosure. • Stud-mounting a back panel to the enclosure. • Bolt-mounting a ground bus or chassis to the back panel of the enclosure. If the mounting brackets of a chassis do not lay flat before the nuts are tightened, use additional washers as shims so that the chassis does not bend when you tighten the nuts. IMPORTANT Do not bend the chassis. Bending the chassis might damage the backplane and result in poor connections. Figure 2 – Mounting Assembly Details Back Panel Mounting Bracket or Ground Bus Back Wall of Enclosure Back Panel Welded Stud Flat Washer Scrape Paint Nut Welded Stud Nut Flat Washer Use a wire brush to remove paint from threads to allow a ground connection. If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole. Star Washer Stud Mounting of a Ground Bus or Chassis to the Back Panel Back Panel Tapped Hole Ground Bus or Mounting Bracket Scrape paint on panel and use a star washer. Stud Mounting of the Back Panel to the Enclosure Back Wall Back Panel Mounting Bracket Bolt Tapped Hole Flat Washer Nut Star Washer Flat Washer Nut Flat Washer Star Washer Scrape Paint Scrape paint on panel and use star washers. Bolt If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole. Bolt Mounting of a Ground Bus or Chassis to the Back Panel Flat Washer If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole. Alternative Bolt Mounting of Chassis to the Back Panel www.rosscontrols.com 5 Industrial Automation Wiring and Grounding Guidelines Figure 4 – Details of Ground Connection at Enclosure Wall Make good electrical connection between each chassis, back-panel, and enclosure through each mounting bolt or stud. Wherever contact is made, remove paint or other non-conductive finish from around studs or tapped holes. Enclosure Wall Scrape Paint Bolt Bonding and Grounding the Chassis With solid-state controls, proper bonding and grounding helps reduce the effects of EMI and ground noise. Also, since bonding and grounding are important for safety in electrical installations, local codes and ordinances dictate which bonding and grounding methods are permissible. Ground Lug For example, for U.S. installations, the National Electrical Code (NEC) gives you the requirements for safe bonding and grounding, such as information about the size and types of conductors and methods of safely grounding electrical components. Equipment-Grounding Conductor — In addition to making good connections through each bolt or stud, use either 1-inch copper braid or 8 AWG minimum stranded copper wire to connect each chassis, enclosure and central ground bus mounted on the back-panel. Figure 3 shows ground-bus connection details. Figure 3 – Ground Bus Connection Details Ground Bus Mounting Scrape paint on enclosure wall and use a star washer. Nut EquipmentGrounding Conductor Star Washer Connect an equipment grounding conductor directly from each chassis to an individual bolt on the ground bus. For a chassis with no ground stud, use a mounting bolt (Figure 5). For those chassis with a ground stud, use the ground stud for this connection (Figure 6). Figure 5 – Details of Ground Connection at Mounting Bracket of Chassis with No Ground Stud Back Panel Mounting Bracket Ground Bus Equipmentgrounding Conductors Welded Stud Ground Lug Ground Lug Scrape Paint Tapped Hole Flat Washer Nut Bolt Star Washer Grounding-electrode conductor to grounding-electrode system. Star Washer Figure 4 shows enclosure-wall ground connection details. Use a steel enclosure to guard against EMI. If the enclosure door has a viewing window, it should be a laminated screen or a conductive optical substrate to block EMI. Do not rely on the hinge for electrical contact between the door and the enclosure; install a bonding wire. 6 Flat Washer If the mounting bracket is coated with a non-conductive material (anodized, painted, etc.), scrape the material around the mounting hole. For a power supply without a groundable power supply chassis (such as a power-supply module or mini-processor with an integral power supply), or a power supply with a chassis that is not internally connected to its GND terminal, use a 14 AWG copper wire to connect its GND terminal to the ground stud or mounting bolt connected to the ground bus. This will ensure an adequate ground for noise immunity. © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Figure 6 – Typical Grounding Configuration Enclosure Wall See Figure 4 Ground Bus GroundingElectrode Conductor See Figure 3 To GroundingElectrode System PLC with Power Supply Equipment-Grounding Conductors 8AWG Equipment-Grounding Conductors 14AWG I/O Modules DIN Rail Power Supply Chassis with Power Supply I/O Chassis Wall 14 AWG Mini-processor with built-in power supply Ground Lug Power-Supply Module Nut Star Washers Chassis with 2 Power Supplies Ground Lug Star Washer 14 AWG Ground Bus Do not lay one ground lug directly on top of the other. This type of connection can become loose due to compression of the metal lugs. Sandwich the first lug between a star washer and a nut with a captive star washer. After tightening the nut, sandwich the second lug between the first nut and a second nut with a captive star washer. www.rosscontrols.com 7 Industrial Automation Wiring and Grounding Guidelines Some products have no visible groundable chassis and no ground lug or ground terminal, but mount on a DIN rail. The chassis of these products are grounded only through the DIN rail. For these products, connect an equipmentgrounding conductor directly from the mounting bolt on the DIN rail to an individual bolt on the ground bus. Grounding-Electrode Conductor — Connect the ground bus to the grounding-electrode system through a grounding-electrode conductor. The grounding-electrode system is at earth-ground potential and is the central ground for all electrical equipment and AC power within any facility. Use 8 AWG copper wire minimum for the grounding-electrode conductor to help guard against EMI. The National Electrical Code specifies safety requirements for the grounding-electrode conductor. Shielded Cables — Certain I/O connections require shielded cables to help reduce the effects of electrical noise coupling. Ground each shield at one end only. A shield grounded at both ends forms a ground loop which can cause a processor to fault. Ground each shield at the end specified in the appropriate publication for the product. Never connect a shield to the common side of a logic circuit (this would introduce noise into the logic circuit). Connect each shield directly to a chassis ground. For some communication network cables, the shield connections are unique to the particular cabling system. In some such cases, a DC short to ground is not needed because a low-impedance AC path to ground and a high-impedance DC path to ground are provided internally at each node. Follow the specific instructions in the publication provided for the specific communication network cabling system. Avoid breaking shields at junction boxes. Many types of connectors for shielded conductors are available from various manufacturers. If you do break a shield at a junction box, do the following: • Connect only category-2 conductors in the junction box. • Do not strip the shield back any further than necessary to make a connection. • Connect the shields of the two cable segments to ensure continuity along the entire length of the cable. 8 © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Power Distribution You can connect the power supply directly to the secondary of a transformer (Figures 7 and 8). The transformer provides DC isolation from other equipment not connected to that transformer secondary. Connect the transformer primary to the AC source; connect the high side of the transformer secondary to the L1 terminal of the power supply; connect the low side of the transformer secondary to the neutral (common) terminal of the power supply. Figure 7 – Grounded AC Power-Distribution System with Master-Control Relay Disc. L1 Suppressor1 1FU L1 2FU Incoming L2 AC L2 3FU L3 To Motor Starters Enclosure Wall L3 H4 H1 H3 H2 Back-Panel Ground Bus Step-Down2 Transformer Grounded Conductor FUSE X1 Multiple E-Stop Switches X2 Start CRM EquipmentGrounding Conductors Grounding-Electrode Conductor to Grounding-Electrode System Suppressor1 CRM The I/O circuits form a net inductive load switched by the CRM contacts. Therefore, a suppressor is needed across the line at the load side of the CRM contacts. Connect When Applicable GND Controller Power Supply L1 N or L2 User DC Supply CRM Suppressor3 Input Module Wiring Arm Output Actuator Output Module Wiring Arm Input Sensor CRM + – To DC I/O Actuators/ Sensors Notes: 1 To minimize EMI generation, connect a suppressor across an inductive load. 2 In many applications, a second transformer provides power to the input circuits and power supplies for isolation from the output circuits. 3 Connect a suppressor here to minimize EMI generation from the net inductive load switched by the CRM contacts. In some installations, a 1μf 220Ω suppressor or 2μf 100Ω suppressor has been effective. www.rosscontrols.com 9 Industrial Automation Wiring and Grounding Guidelines Connect one input directly to the L1 side of the line, on the load side of the CRM contacts, to detect whether the CRM contacts are closed. In the ladder logic, use this input to hold off all outputs anytime the CRM contacts are open. (Refer to your programming manual.) If you fail to do this, closing the CRM contacts could generate transient EMI because outputs are already turned on. To have outputs turned on when CRM contacts are closing would be analogous to squeezing the trigger on a hand tool as you’re plugging it in. Figure 8 – Ungrounded AC Power-Distribution System with Master-Control Relay Disc. Suppressor1 1FU L1 L1 2FU Incoming L2 AC L2 3FU L3 To Motor Starters L3 Enclosure Wall H4 H1 H3 H2 2 Step-Down Transformer Back-Panel Ground Bus FUSE X1 X2 1LT FUSE 2LT Multiple E-Stop Switches EquipmentGrounding Conductors Grounding-Electrode Conductor to Grounding-Electrode System Start CRM Suppressor1 The I/O circuits form a net inductive load switched by the CRM contacts. Therefore, a suppressor is needed across the line at the load side of the CRM contacts. CRM Controller Connect When Applicable GND L1 Power Supply N or L2 CRM User DC Supply CRM Suppressor3 Input Module Wiring Arm Output Actuator Output Module Wiring Arm Input Sensor CRM + Notes: 1 To minimize EMI generation, connect a suppressor across an inductive load. 2 In many applications, a second transformer provides power to the input circuits and power supplies for isolation from the output circuits. 3 Connect a suppressor here to minimize EMI generation from the net inductive load switched by the CRM contacts. In some installations, a 1μf 220Ω suppressor or 2μf 100Ω suppressor has been effective. 10 – To DC I/O Actuators/ Sensors © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Common Power Source for I/O Second Transformer Unless each I/O of a module or block is individually isolated, multiple I/O within the block or module share a common terminal for one side of the power source. All I/O sharing a common terminal must share a common power source (i.e., from the same pole of a disconnect or from the same transformer tap). Certain manufacturer's power supplies have circuits that suppress electromagnetic interference from other equipment. However, isolate output circuits from power supplies and input circuits to help prevent output transients from being induced into inputs and power supplies. In many applications, power is provided to the input circuits and power supplies through a second transformer (Figure 9). If a module or block has multiple commons, each common and its I/O may be isolated from the other commons. In that case, each common and its I/O can have a separate power source. If each I/O is individually isolated, each I/O can have a separate power source. If a module or block has individually isolated I/O or multiple isolated commons and multiple power sources are used, be certain that the difference in potential between any two power sources does not exceed the specified maximum continuous voltage that can be applied between the channels. Figure 9 – Power Supplies and Input Circuits Receiving Power Through a Separate Transformer Disc. L1 L1 2FU Incoming L2 AC Under-Voltage Shutdown Suppressor1 1FU L2 3FU L3 L3 H4 H1 Each power supply with under-voltage shut-down protection generates a shut-down signal on the backplane when the AC line voltage drops below its lower voltage limit. The power supply removes the shut-down signal when the line voltage comes back above the lower voltage limit. This shut-down is to guard against invalid data being stored in memory. To Motor Starters H3 H2 Step-Down Transformer X1 Because a capacitive-input power supply converting AC to DC draws power only from the peak of the AC voltage wave-form, the external transformer load (in VA) of each power supply is 2.5 times its real power dissipation (in Watts). If the transformer is too small, the peaks of the sine wave are clipped. Even if the voltage is still above the lower voltage limit, the power supply senses the clipped wave as low voltage and sends the shut-down signal. H1 X2 H4 H3 H2 Isolation/ Constant-Voltage Transformer X1 X2 To Power Supplies and Input Circuits To Output Circuits Sizing the Transformer To determine the required rating of the transformer add the external-transformer load of the power supply and all other power requirements (input circuits, output circuits). The power requirements must take into consideration the surge currents of devices controlled by the processor. Choose a transformer with the closest standard transformer rating above the calculated requirements. Notes: 1 To minimize transient EMI generation when power is interrupted by the interrupt switch, connect a suppressor across the primary of the transformer. For example, the external-transformer load of a powersupply module at maximum backplane load current is 140VA (2.5 x 56W = 140). A 140VA transformer could be used if a power-supply module were the only load. A 500VA transformer should be used if there were 360VA of load in addition to that of the power-supply module. www.rosscontrols.com 11 Industrial Automation Wiring and Grounding Guidelines Isolation Transformer — For applications near excessive electrical noise generators, an isolation transformer (for the second transformer) provides further suppression of electromagnetic interference from other equipment. The output actuators being controlled should draw power from the same AC source as the isolation transformer, but not from the secondary of the isolation transformer (Figure 9). Constant-Voltage Transformer — In applications where the AC power source is especially “soft” and subject to unusual variations, a constant-voltage transformer can stabilize the AC power source to the processor and minimize shutdowns. The constant-voltage transformer must be of the harmonic neutralizing type. If the power supply receives its AC power through a constant-voltage transformer, the input sensors connected to the I/O chassis should also receive their AC power from the same constant-voltage transformer. If the inputs receive their AC power through another transformer, the AC source voltage could go low enough that erroneous input data enters memory while the constant-voltage transformer prevents the power supply from shutting down the processor. The output actuators being controlled should draw power form the same AC sources as the constant-voltage transformer, but not from the secondary of the constant-voltage transformer (9). Ground Connection When AC power is supplied as a separately derived system through an isolation/step-down transformer, you can connect it as a grounded AC system or an ungrounded AC system. For a grounded AC system, connect one side of the transformer secondary to the ground bus as in Figure 7. For an ungrounded AC system, connect one side of each test switch for the ground-fault-detector lights to the ground bus as in Figure 8. We do not recommend an ungrounded system. Follow local codes in determining whether to use a grounded system. When bringing AC power into the enclosure, do not ground its raceway to the ground bus on the back-panel. Connecting the raceway to the ground bus may cause the processor to fault by introducing EMI into the grounding circuit. Local codes may provide an exception for permitting isolation from the raceway. For example, article 250-75 of the National Electrical Code has an exception that explains the conditions under which this isolation from the raceway is permitted. 12 Surge-Suppression Transient EMI can be generated whenever inductive loads such as relays, solenoids, motor starters, or motors are operated by “hard contacts” such as pushbutton or selector switches. The wiring guidelines are based on the assumption that you guard your system against the effects of transient EMI by using surge-suppressors to suppress transient EMI at its source. Inductive loads switched by solid-state output devices alone do not require surge-suppression. However, inductive loads of AC output modules that are in series or parallel with hard contacts require surge-suppression to protect the module output circuits as well as to suppress transient EMI. Figure 10 shows three Examples of where to use suppressors. In Example 1, although the motor-starter coil is an inductive load, it does not need a suppressor because it is switched by a solid-state device alone. In Example 2, the relay coil needs a suppressor because a hard-contact switch is in series with the solid-state switch. However, in both Examples 1 and 2, we show a suppressor on the motor and solenoid because it is an inductive load switched by the hard contacts of the motor starter or relay. Even if they have no interaction with the control system, regularly cycled loads of this type need suppression if conductors connecting to these loads are: 1) connected to the same separately derived system as that of the control system; 2) or routed in proximity with conductors of the control system as per the routing guidelines. In Example 3, the pilot light has a built-in step-down transformer that needs a suppressor because it is an inductive load being switched by the hard contacts of a contact output module; without suppression, the transient EMI would be generated inside the I/O chassis. Lights with built-in step-down transformers that are switched by hard contacts external to any I/O chassis may not need to be suppressed because the noise spike they can generate may be only approximately one tenth that of a relay or motor starter. In all cases, the AC power coming into the I/O modules must be switched by the CRM contacts. Therefore, a suppressor is needed across the line at the load side of the CRM contacts as shown in Figures 7 and 8. The application (voltage, net load of I/O circuits) dictates the specific suppressor needed across the line at the load side of the CRM contacts. © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines Figure 10 – Examples of Where to Use Suppression L1 1MS Solid-State Switch 1MS Suppressor 1MS Suppressor Suppressor AC Output Module 1MS L2 L1 L2 1M Example 1: An AC output module controls a motor starter whose contacts control the motor. L1 Although the motor starter is an inductive load, it does not need a suppressor because it is switched by a solid-state device. AC Output Module L1 L2 The motor needs supressors because it is an inductive load switched by hard contacts. L1 L2 1CR 1S Solid-State Switch 1CR Suppressor Suppressor The solenoid needs a supressor because it is an inductive load switched by hard contacts. The interposing relay needs a supressor because it is an inductive load switched by hard contacts. Contact Output Module L1 Pilot Light With Built-In Step-Down Transformer Suppressor Example 2: An AC output module controls an interposing relay, but the circuit can be opened by hard contacts. The relay contacts control a solenoid. Example 3: A contact output module controls an inductive load. L2 The pilot light needs a supressor because it is an inductive load switched by hard contacts. Figure 11 shows typical suppression circuitry for different types of loads. Figure 11 – Typical Suppression Applications 230/460VAC Electrocube 1676-13 120VAC 3-Phase Motor Cat. No. 700-N24 For Small Apparatus (Relays, Solenoids, and Motor Starters up to Size 1) For 3-Phase Apparatus, a Suppressor is Needed Across Each Phase + 120/240VAC – VDC Cat. No. 599-K04 or 599-KA04 or ITW Paktron 104M06QC100 700-Nx For Large Apparatus (Contacts up to Size 5) For DC Relays www.rosscontrols.com 13 Industrial Automation Wiring and Grounding Guidelines Surge-suppressors are usually most effective when connected at the inductive loads. They are still usable when connected at the switching devices; however, this may be less effective because the wires connecting the switching devices to the inductive loads act as antennas that radiate EMI. You can see the effectiveness of a particular suppressor by using an oscilloscope to observe the voltage waveform on the line. Ferrite Beads Ferrite beads can provide additional suppression of transient EMI. Fair-Rite Products Corporation manufactures a ferrite bead (part number 2643626502) which can be slipped over category-2 and -3 conductors. You can secure them with heat-shrink tubing or tie-wraps. With a ferrite bead located near the end of a cable (or cable segment in the case of a daisy-chain or dropline configuration) transient EMI induced onto the cable can be suppressed by the bead before it enters the equipment connected to the end of the cable. Avoiding Unintentional Momentary Turn-On of Outputs Unintentional turn-on of outputs as the power source is connected or disconnected, even if momentary, can result in injury to personnel as well as damage to equipment. The danger is greater with fast-response actuators. You can help minimize the probability of unintentional momentary turn-on of AC and DC circuits by following each of these guidelines according to your specific application: • Follow the surge-suppression guidelines in this publication • Follow the bonding and grounding guidelines in this publication • Do not unnecessarily disconnect the power source from output circuits • Where possible, turn off all outputs before using CRM contacts to interrupt the output circuit power source • Hold off all outputs anytime the CRM contacts are open to be certain that they are off as power is reconnected Even if unintentional momentary turn-on does occur, the effects can be minimized if: Enclosure Lighting Fluorescent lamps are also sources of EMI. If you must use fluorescent lamps inside an enclosure, the following precautions may help guard against EMI problems from this source as shown in Figure 12: • Install a shielding grid over the lamp • Use shielded cable between the lamp and its switch • Use a metal-encased switch • Install a filter between the switch and the power line, or shield the power-line cable Figure 12 – Installation Requirements for Suppressing Noise From Fluorescent Lamps Inside an Enclosure • Actuators have a home position, i.e. defined by a spring return • For latching actuators, in the ladder logic, use nonretentive energize (OTE) instructions with hold-in (sealin) paths to maintain the established position until power turn-off and leave outputs off initially at power turn-on • Each input or other load device connected to an output has an input-filter time constant no lower than necessary for the application After designing and installing your system following these guidelines to minimize unintentional momentary turn-on and any effects thereof, test the system by de-energizing and then re-energizing the CRM relay (Figures 7 and 8). Related Publications Filter Shielding-Grid Over Lamp 14 Shielded Cable Metal-Encased Switch AC Power Line-Filter or Shielded Power Line For additional information regarding wiring and grounding guidelines, refer to: • Application Considerations for Solid-State Controls (publication A10325) — this is an aid to the user of solid-state controls who has considerable familiarity with relay-type controls but may have limited electronic experience and knowledge. © 2007 ROSS CONTROLS®. All Rights Reserved. Industrial Automation Wiring and Grounding Guidelines • National Electrical Code (ANSI/NFPA 70) — Article 250 of this code provides information about the types and sizes of conductors and methods for safely grounding electrical equipment and components. Articles 725-5, 725-15, 725-52, and 800-52 restrict the placement of different types of conductors in a composite cable, a raceway, or a cable tray. • IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems (IEEE Std 142-1991) • Grounding for the Control of EMI (by Hugh W. Denny — publisher, Don White Consultants Inc., 1973) • Electromagnetic Interference and Compatibility, Volume 3 (by R. J. White — publisher, Don White Consultants, Inc., 1981) • Military Handbook 419, “Grounding, Bonding, and Shielding for Electronic Equipment and Facilities” • IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise Inputs to Controllers from External Sources (IEEE Std 518-1982) • IEEE Recommended Practice for Powering and Grounding Sensitive Electronic Equipment (IEEE Std 1100-1992) www.rosscontrols.com 15 Industrial Automation Wiring and Grounding Guidelines NOTES Printed in U.S.A -0807 © Copyright 2007, ROSS CONTROLS®. All Rights Reserved. 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