Beijer Electronics BoX2 extreme Installation Manual

MAEN276, 2018-03

BoX2 extreme

Installation Manual

English

Installation manual for BoX2 extreme

Foreword

All operator panels are developed to satisfy the demands of human-machine communication. Built-in functions such as displaying and controlling text, dynamic indication, time channels, alarm and recipe handling are included.

The operator panel works primarily in an object-oriented way, making it easy to understand and use. Configuration is carried out on a PC using iX Developer software. The project can then be transferred and stored in the operator panel itself.

Various types of automation equipment such as PLCs, servos or drives can be connected to the operator panels. In this manual, the term “the controller” refers to the connected equipment.

This manual explains how to install the operator panel. Please refer to the iX Developer reference manual for further information.

Foreword

Order no: MAEN276

Copyright © 2018-03 Beijer Electronics AB. All rights reserved.

The information in this document is subject to change without notice and is provided as available at the time of printing. Beijer Electronics AB, including all its group companies, reserves the right to change any information without updating this publication. Beijer Electronics AB, including all its group companies, assumes no responsibility for any errors that may appear in this document. Read the entire installation manual prior to installing and using this equipment. Only qualified personnel may install, operate or repair this equipment. Beijer Electronics AB, including all its group companies, are not responsible for modified, altered or renovated equipment. Because the equipment has a wide range of applications, users must acquire the appropriate knowledge to use the equipment properly in their specific applications. Persons responsible for the application and the equipment must themselves ensure that each application is in compliance with all relevant requirements, standards and legislation in respect to configuration and safety. Only parts and accessories manufactured according to specifications set by Beijer Electronics AB, including all its group companies, may be used.

BEIJER ELECTRONICS AB, INCLUDING ALL ITS GROUP

COMPANIES, SHALL NOT BE LIABLE TO ANYONE FOR ANY

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL

DAMAGES RESULTING FROM THE INSTALLATION, USE OR

REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT,

CONTRACT, OR OTHERWISE. BUYER'S SOLE REMEDY SHALL

BE THE REPAIR, REPLACEMENT, OR REFUND OF PURCHASE

PRICE, AND THE CHOICE OF THE APPLICABLE REMEDY SHALL

BE AT THE SOLE DISCRETION OF BEIJER ELECTRONICS AB,

INCLUDING ALL ITS GROUP COMPANIES.

Beijer Electronics, MAEN276

Foreword

Beijer Electronics, MAEN276

Contents

Contents

1 Safety Precautions ....................................................... 7

1.1

General ........................................................... 7

1.2

Hazardous Materials ............................................. 7

1.3

Disposal Requirements Under WEEE Regulations ........... 8

1.4

UL and cUL Installation ......................................... 8

1.5

IECEx/ATEX Certificate and Dust Rating .................... 9

1.6

Conditions of Safe Use for Zone 2/22 ATEX/IECEx .......... 9

1.7

During Installation .............................................. 9

1.8

During Use ....................................................... 10

1.9

Service and Maintenance ........................................ 10

1.10

Dismantling and Scrapping ..................................... 10

2 Installation ............................................................... 11

2.1

Installation Process .............................................. 11

2.1.1

Protective Connector Shield Installation Process . . . . . . . . . . . . . . .13

2.1.2

Connections to the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.1.3

Other Connections and Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

3 Technical Data ........................................................... 15

4 Chemical Resistance .................................................... 17

4.1

Metal Casing ..................................................... 17

5 Operator Panel Drawings .............................................. 19

5.1

Connectors ....................................................... 19

5.1.1

5.1.2

5.1.3

5.1.4

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

COM A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

USB 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

LAN A / LAN B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.1.5

COM B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.2

BoX2 extreme Outline .......................................... 21

6 Additional Installation Tips ............................................ 23

6.1

Grounding the operator panel .................................. 23

6.2

To Achieve Better EMC Protection ............................. 23

6.3

Safety ............................................................. 25

6.4

Galvanic Isolation ................................................ 26

6.5

Cable and Bus Termination RS-485 ............................ 27

Beijer Electronics, MAEN276

Contents

Beijer Electronics, MAEN276

Safety Precautions

1 Safety Precautions

Both the installer and the owner and/or operator of the operator panel must read and understand this installation manual.

1.1 General

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•

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•

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•

•

•

•

Read the safety precautions carefully.

Check the delivery for transportation damage. If damage is found, notify the supplier as soon as possible.

Do not use the operator panel in an environment with high explosive hazards.

The supplier is not responsible for modified, altered or reconstructed equipment.

Use only parts and accessories manufactured according to specifications of the supplier.

Read the installation and operating instructions carefully before installing, using or repairing the operator panel.

Never allow fluids, metal filings or wiring debris to enter any openings in the operator panel. This may cause fire or electrical shock.

Only qualified personnel may operate the operator panel.

The figures in this manual serve an illustrative purpose. Because of the many variables associated with any particular installation, the supplier cannot assume responsibility for actual use based on the figures.

The supplier neither guarantees that the operator panel is suitable for your particular application, nor assumes responsibility for your product design, installation or operation.

It is recommended to turn on and shut down the operator panel at least once before installing any components/cards or before connecting the operator

– panel to external devices; for example serial devices.

–

For Marine panels only:

The operator panel must be installed and operated as described in this document to meet this certification.

Observe precautions for handling electrostatic discharge sensitive devices

1.2 Hazardous Materials

Part description

零件描述

Pb

Toxic and hazardous materials or elements

有毒和有害的材料或元素

Hg Cd Cr6+ PBB PBDE

PCB and electronic components

PCB 和电子元件

X O O O O O

O: Indicates that this toxic or hazardous substance contained in all of the homogenous materials for this part is below the limit requirement in SJ/T 11363–2014.

O ： 表示该有害物质在该部件所有均质材料中的含量均在 SJ/T 11363–2014 规定的限

量要求以下。

X: Indicates that this toxic or hazardous substance contained in at least one of the homogenous materials for this part is above the limit requirement in SJ/T 11363–2014.

Beijer Electronics, MAEN276 7

8

Safety Precautions

X: 表明该有害物质至少在部件的某一均质材料中的含量超出 SJ/T 11363–2014 规定

的限量要求。

1.3 Disposal Requirements Under

WEEE Regulations

For professional users in the European Union: If you wish to discard electrical and electronic equipment (EEE), please contact your dealer or supplier for further information.

For disposal in countries outside of the European Union: If you wish to discard this product please contact your local authorities or dealer and ask for the correct method of disposal.

1.4 UL and cUL Installation

• All devices have to be supplied by a Class 2 power supply.

Warning:

Do not separate when energized.

AVERTISSEMENT, NE PAS SEPARER SOUS TENSION.

Warning:

Do not open when an explosive atmosphere is present.

NE PAS OUVRIR SI UNE ATMOSPHERE EXPLOSIVE EST PRÉSENT.

Warning:

Battery may explode if mistreated. Do not recharge, disassemble or dispose of in fire.

This product contains a battery that is not user replaceable.

LA BATTERIE PEUT EXPLOSER EN CAS DE MAUVAISE MANIPULATION.

NE LA RECHARGEZ PAS, NE LA DÉMONTEZ PAS ET NE LA JETEZ

PAS DANS LE FEU.

CE PRODUIT CONTIENT UNE PILE QUI NE PEUT PAS ÊTRE

REMPLACÉE PAR L'UTILISATEUR.

Warning:

Potential electrostatic charging hazard, see instrucions.

To avoid electrostatic charge build-up, it must not be rubbed or cleaned with solvents or a dry cloth when installed/used within a potentially explosive atmosphere.

POTENTIEL ÉLECTROSTATIQUE RISQUE DE CHARGEMENT,

VOIR INSTRUCTIONS.

Beijer Electronics, MAEN276

Safety Precautions

Warning:

Explosion hazard! Substitution of components may impair suitability for

Class I, Division 2.

RISQUE D'EXPLOSION! LA SUBSTITUTION DE COMPOSANTS PEUT

NUIRE À LA CONFORMITÉ DE CLASSE I, DIVISION 2.

II 3 G Ex nA nC IIC T4 Gc

II 3 D EX tc IIIC T85 °C Dc

IECEx UL 17.0058X

DEMKO 17 ATEX 1900X

•

•

•

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•

•

•

•

•

•

In a Zone 2 environment, this equipment shall be installed in an enclosure that provides a degree of protection not less than IP54 or greater than IP65 in accordance with IEC/EN 60079-0. The IP rating of the equipment is limited to the IP rating of the enclosure it is to be installed into.

In a Zone 22 environment, this equipment shall be installed in an enclosure that provides a degree of protection not less than IP64 or greater than IP65 in accordance with IEC/EN 60079-0. The IP rating of the equipment is limited to the IP rating of the enclosure it is to be installed into.

To avoid electrostatic charge build-up, it must not be rubbed or cleaned with solvents or a dry cloth when installed/used within a potentially explosive atmosphere.

The inside of the enclosure the device is mounted in shall not be more than pollution degree 2, as defined in IEC/EN 60664-1.

Only install in locations without UV light exposure.

1.7 During Installation

Install the operator panel according to the accompanying installation instructions.

Ground the operator panel according to the accompanying installation instructions.

Only qualified personnel may install the operator panel.

Separate the high voltage, signal, and supply cables.

Make sure that the voltage and polarity of the power source is correct before connecting the operator panel to the power outlet.

Peripheral equipment must be appropriate for the application and location.

Use only UL certified and approved M12 cables according to the accompanying installation instructions.

Beijer Electronics, MAEN276 9

Safety Precautions

1.8 During Use

•

•

Keep the operator panel clean.

Emergency stop and other safety functions may not be controlled from the operator panel.

1.9 Service and Maintenance

•

•

•

•

Only qualified personnel should carry out repairs.

The agreed warranty applies.

Before carrying out any cleaning or maintenance operations, disconnect the equipment from the electrical supply.

The battery must be replaced by an authorized Beijer Electronics service center.

1.10 Dismantling and Scrapping

•

•

The operator panel or parts thereof shall be recycled according to local regulations.

The following components contain substances that might be hazardous to health and the environment: lithium battery and electrolytic capacitor.

10 Beijer Electronics, MAEN276

Installation

2 Installation

2.1 Installation Process

178.4

163.2

71.7

C

D

M3 x 0.5

20

6 mm min. (4x)

M4 x 0.7

6 mm min. (4x)

34

•

•

•

The following is needed:

A Phillips screwdriver for installation of the M12 protection bracket

Four M5 × 0.8 screws conforming to the table above

Installation tool for mounting screws

1. Unpack and check the delivery. If damage is found, notify the supplier.

Note:

Place the operator panel on a stable surface during installation.

Dropping the operator panel or letting it fall may cause damage.

2. Attach UL certified and approved cables to the operator panel. Approved cables include:

–

–

–

900-1616-01 cable TxBR-2 M12 female 4p to blank 3 meter (pwr) [EX]

900-1618-01 cable TxBR-2 M12 male 4p to blank 3 meter (lan) [EX]

900-1621-01 cable TxBR-2 M12 male 8p to blank 3 meter (com) [EX]

Other lengths may also be available; please contact Beijer Electronics for details.

Beijer Electronics, MAEN276 11

Installation

3. Drill the correct hole pattern in panel outlined above or install unit on VESA compliant mounting bracket.

–

Connect cable A to the terminal, using 14-20 AWG (2.08–0.52 mm 2 ),

180–220 N-cm torque.

Note:

Use minimum 85°C copper conductors only.

12 Beijer Electronics, MAEN276

2.1.1

1. Install the protective connector shield as shown.

Installation

2. Secure the cables to the protective connector shield using the included cable ties

Beijer Electronics, MAEN276 13

Installation

Note:

The protective connector shield is required to be used on all applications.

2.1.2

Connections to the Controller

For information about the cables to be used when connecting the operator panel to the controller, please refer to the help file for the driver in question.

2.1.3

Other Connections and Peripherals

Cables, peripheral equipment and accessories must be suitable for the application and its environment. For further details or recommendations, please refer to the supplier.

14 Beijer Electronics, MAEN276

Technical Data

3 Technical Data

Parameter

Dimensions, W × H × D 234 × 183 × 62 mm

BoX2 extreme

Sealing

Frame material

Weight

CPU

Serial port COM A

Serial port COM B

IP65

Powder-coated aluminum

1.5 kg i.MX 6Quad

Quad ARM Cortex-A9 Core

1.0 GHz

1 MB L2 cache

M12 (8 pin, male)

1×RS-232 Rx/Tx with RTS (no CTS) and 1×RS-422, or

2×RS-485 or 1×CAN 2.0B

M12 (8 pin, female)

1×RS-485 with isolated +5V/5mA out for bias resistor network, or 1×CAN 2.0B with termination

Ethernet LAN A

Ethernet LAN B

USB

External storage media

Flash memory

(application memory)

Memory RAM

NVRAM

M12 (4 Pin, female, D-coded according to EN/IEC

61076-2-101) 10/100 Mbit via RMII

M12 (4 Pin, female, D-coded according to EN/IEC

61076-2-101) 10/100 Mbit via RMII

Supports up to USB 2.0 High Speed

1 × SD card

3.5 GB SSD (eMMC)

2 GB DDR3

64 kB

Real time clock

Battery

Yes

BR 2477A/GAN lithium battery, non replaceable

8 W Power consumption at rated voltage

Fuse

Power supply

Internal DC fuse, 4 AT SMT

+24 V DC

CE: The power supply must conform with the requirements according to EN/IEC 60950 and EN/IEC 61558-2-4.

UL and cUL: The power supply must conform with the requirements for class 2 power supplies.

-30°C to +70°C Operating temperature

Storage temperature -40°C to +80°C

Relative humidity in operation

5% – 95% non-condensation

Vibration

Mechanical shock

4g, according to EN/IEC 60068-2-6, Test Fc

40g, half-sine, 11ms according to EN/IEC60068-2-27

Beijer Electronics, MAEN276 15

Technical Data

Parameter

Approvals and certifications

UL approval

Marine certificates

BoX2 extreme

CE / FCC / KC

Information is available on www.beijerelectronics.com

Information is available on www.beijerelectronics.com

Information is available on www.beijerelectronics.com

16 Beijer Electronics, MAEN276

Chemical Resistance

4 Chemical Resistance

4.1 Metal Casing

The frame and casing material is powder-coated aluminum. This powder paint withstands exposure to the following chemicals without visible change:

Acetic acid 10%

Citric acid 10%

Diesel

Distilled water

Edible oil

Fuel oil

Hydrogen peroxide 3%

Phosphoric acid 4%

Phosphoric acid 10%

Sea water

Sodium chloride 2%

Sodium chloride 20%

Sulphuric acid 20%

Tap water

The powder paint shows limited resistance to the following chemicals at room temperature:

Butanol

Hydrochloric acid 5%

Isopropyl alcohol

Sodium hypochlorite 10%

Nitric acid 3%

Nitric acid 10%

Phosphoric acid 43%

Turpentine

Note:

If exposure to any of the above chemicals is demanded, it is recommended to first test the chemical in a hidden spot of the metal casing.

The powder paint shows little or no resistance to the following chemicals at room temperature:

Acetic acid, conc.

Acetone

Ammonia 5%

Ammonia, conc.

Ethyl acetate

Methyl-ethyl ketone

Nitric acid 30%

Phenol

Sodium hydroxide 5%

Sodium hydroxide 30%

Toluene

Trichlorethylene

Xylene

97 octane unleaded petrol

98 octane leaded petrol

Beijer Electronics, MAEN276 17

Chemical Resistance

18 Beijer Electronics, MAEN276

Operator Panel Drawings

5 Operator Panel Drawings

5.1 Connectors

1 2 3 4 5 6

2

3

4

5

6

Pos

1

Connector

Power supply

COM B

USB 1 + USB 2

LAN A

LAN B

COM A

Description

+24 V DC

Serial communication port

USB Host 2.0, max output current 500 mA

1 × 10/100 Base-T

1 × 10/100 Base-T

Serial communication port

2

3

4

Pin

1

5.1.1

Power Supply

Description

V in

+

V in

-

V in

-

V in

+

M12. 4 pin male

2

3

4

5

6

5.1.2

7

8

Pin

1

COM 1

RS232_RxD

RS232_TxD

GND

RS232_RTS

COM A

COM 2

RS422 Tx+

RS485 Tx+/Rx+

-

-

RS422_Rx+

GND

RS422 Tx-

RS485 Tx-/Rx-

-

RS422_Rx-

COM 3

CAN-H

M12, 8 pin male

-

CAN-L

-

-

-

-

-

Beijer Electronics, MAEN276 19

Operator Panel Drawings

5.1.3

3

4

5

6

7

8

Pin

1

2

USB 1/2

V cc

USB 2 D-

USB 2 D+

GND

V cc

USB 1 D-

USB 1 D+

GND

USB 1/2

5.1.4

2

3

4

Pin

1

LAN A / LAN B

LAN A

Tx+

Rx+

Tx-

Rx-

LAN B

5.1.5

2

3

4

Pin

1

7

8

5

6

COM B

COM 3

RS-485 Tx+/Rx+

TERM+

-

-

GND

RS-485 Tx-/Rx-

TERM-

V cc

CAN

CAN-H

TERM+

-

-

GND

CAN-L

TERM-

V cc

M12, 8 pin male

M12, 4pin male

M12, 8 pin male

20 Beijer Electronics, MAEN276

5.2 BoX2 extreme Outline

Operator Panel Drawings

234

75

71.7

75

169

178.4

163.2

34.2

144

40

62

3.80

20

34

Note:

A Step CAD file is available on the web site www.beijerelectronics.com

Beijer Electronics, MAEN276 21

Operator Panel Drawings

22 Beijer Electronics, MAEN276

Additional Installation Tips

6 Additional Installation Tips

When experiencing communication problems in noisy environments or when operating close to temperature limits, the following recommendations are to be noticed.

6.1 Grounding the operator panel

The VESA mounting of the operator panel does not provide a secure grounding connection between the panel and the device cabinet, see drawing above.

Connect a wire or grounding braid, that is sized correctly according to local electrical codes, between the chassis of the operator panel and the closest grounding point.

Note:

The grounding wires should be short and the conductor should have a large area.

A long, thin grounding wire has a very high impedance (resistance) at high frequencies and does not guide disturbances to the ground.

Multi-wire conductors are better than single wire conductors with the same area.

A braided conductor wire with the same area is even better. The best is a short, thick grounding braid.

6.2 To Achieve Better EMC Protection

•

•

Initially, use the original cabling from Beijer Electronics primarily.

Use shielded M12 cables.

Beijer Electronics, MAEN276 23

Additional Installation Tips

• Place the 24 V DC and communications cabling in one cable trunk/cable duct and 230/380 V AC in another. If the cables need to be crossed, cross them at

90° only. Avoid combining the cabling for stronger 24 V DC outputs with the communication cabling.

Ferrite cores that are snapped onto the shielded cabling may remove minor disturbances. Large ferrite pieces that are snapped onto unshielded cabling and where the wires go 2-4 times around the cores are approximately 5-25 times more efficient.

24 Beijer Electronics, MAEN276

Additional Installation Tips

6.3 Safety

1

2

Power supply

230 V AC to 24 V DC

+24 V

0 V

Power supply

230 V AC to 24 V DC

4

+24 V

0 V

4

Distance?

Operator panel

Operator panel

3

Power supply

230 V AC to 24 V DC

4

+24 V

0 V

230 V AC

Operator panel

COM1

Small controller with expansion unit

Ch0

Ch1

COM100 Ch100

Ch101

5355

If a power supply that meets safety standards is used and only powers the operator panel, there is no problem. See 1 in drawing above.

However, if a 24 V unit that also powers other units is used, there is reason to be cautious, see 2 in drawing above. The operator panel does not have insulation that meets safety requirements in the event of a potential short circuit between

230 V AC and 24 V DC. It is assumed that the 24 V power supply is secure, for example, SELV according to EN 60950 (protection against electric shock) and

UL 950.

Note:

Here is an example that explains why a secure 24 V DC power supply can be ruined by mixing 24 V relay contacts with 230 V AC relay contacts in a smaller controller. Check that the clearances and creepage distances between 24 V DC and 230 V AC fulfill

EN 60950 or UL 950. If not, input a separate 24 V unit into the operator panel.

•

•

•

If there is a substantial distance between the relay contacts for 24 V DC and

230 V AC, it is OK to use the same 24 V devices for all feeds. See 3 in drawing above.

Connect 0 V on the 24 V power supply to the ground, see 4 in drawing above. This offers three advantages:

Safety is increased. The 24 V power supply is not live in the event of a faulty connection or short circuit between 0 V (24 V) and 230 V phase.

Transients on the 24 V feed are connected to the ground.

No risk that the 24 V feed is at a high level in relationship to the ground. This is not unusual since there is high static electricity.

Beijer Electronics, MAEN276 25

Additional Installation Tips

6.4 Galvanic Isolation

26

The operator panel has galvanic isolation against the 24 V DC power supply but no galvanic isolation between the communication ports for RS-232,

RS-422/RS-485 and USB. Only the Ethernet- and RS-485 connection have galvanic isolation.

PC

*

Operator panel Modular controller

Power CPU COM COM2

RS422

*

RS232

*

USB

* * *

*

Different ground potential

*

= Internal 0 V (GND) connection

Printer

*

PC

*

When a PC is connected to the operator panel, the internal 0 V (GND) of the panel is connected to the protective ground via the PC.

A number of USB devices can have the shield connected together with the protective ground. Here, the 0 V (GND) of the operator panel is connected to the protective ground when, for example, a USB memory stick, keyboard, or similar device is plugged in.

If a number of units are connected that have a 0 V and a ground connection, and these are connected to various grounding points, there is a substantial risk of problems. Grounding currents go through communication cables, the rear plate of the controller, internally in the operator panel, and can cause errors.

Use external units to improve communication and achieve galvanic isolation.

Westermo has good industry-standard insulators that are also insulated from the

24 V DC feed.

Note:

It is very important to make sure that the 24 V feed in the external insulation unit is not connected to one of the communication outlets. If it does not have 100% insulation against the 24 V feed, disturbances and grounding currents from the 0 V on the 24 V side disrupt the communication.

Using this type of unit solves one problem but creates a larger problem! A substandard installation may work now, but problems may arise when other devices are connected.

Beijer Electronics, MAEN276

Additional Installation Tips

6.5 Cable and Bus Termination RS-485

•

•

•

If maximum transfer distance and maximum transfer speed is needed, shielded and twisted pair cable should be used. The mutual capacitance may not exceed 52.5 pF/m, and the cable area should be at least 0.25 mm 2

(AWG 24).

0 V, the reference voltage for communication should be included in the cabling. With two-way communication use two pairs; one pair for communication and one pair for 0 V.

The shield must be grounded at one end. The other end is usually grounded, but with longer distances or when there is a difference in the ground potential, the shield should be connected to the ground via 0.1 μF/250 V film capacitor to prevent ground current in the braided shield. A number of manufacturers recommend that the shield be grounded at each node. Various manufacturers have different systems for bus termination.

Depending on the recipients’ design, the bus wires may be on the same level or require pull-up or pull-down to ensure that no faulty signals are detected when the bus is in resting mode (all transmitters are disconnected).

Beijer Electronics, MAEN276 27

Head office

Beijer Electronics AB

Box 426

201 24 Malmö, Sweden www.beijerelectronics.com / +46 40 358600