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EXTER K10m
Installation Manual
MAEN851B, 2014-10
English
Foreword
Installation manual for EXTER K10m
Foreword
All EXTER 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 the configuration
tool. The project can then be transferred and stored in the operator panel itself.
Various types of automation equipment such PLCs, servos or drives can be
connected to the EXTER 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
reference manual for further information.
Order no: MAEN851B
Copyright © 2014-10 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 reserves the right to change any information without updating this
publication. Beijer Electronics AB 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 is 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 may be used.
BEIJER ELECTRONICS AB 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 .
Beijer Electronics, MAEN851B
Contents
Contents
1 Safety Precautions .......................................................
1.1
General ...........................................................
1.2
UL and cUL Installation .........................................
1.3
During Installation ..............................................
1.4
During Use .......................................................
1.5
Service and Maintenance ........................................
1.6
Dismantling and Scrapping .....................................
2 Installation ...............................................................
2.1
Space Requirements .............................................
2.2
Installation Process ..............................................
2.2.1
2.2.2
2.2.3
Mode Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Connections to the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Other Connections and Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Technical Data ...........................................................
4 Chemical Resistance ....................................................
4.1
Metal Casing .....................................................
4.2
Screen and Overlay Material ....................................
4.2.1
4.2.2
4.2.3
4
4
4
6
6
6
6
7
7
7
11
12
12
12
Autotex F157/207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Screen Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Screen and Keyboard Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Operator Panel Drawings ..............................................
5.1
Communication Ports ...........................................
5.2
EXTER K10m Outline ..........................................
5.3
EXTER K10m Text Strip ........................................
6 Additional Installation Tips ............................................
6.1
Grounding the Operator Panel .................................
6.2
Ethernet Connection in the Panel ..............................
6.3
To Achieve Better EMC Protection .............................
6.4
Ambient Temperature ...........................................
6.5
Safety .............................................................
6.6
Galvanic Isolation ................................................
6.7
Cable and Bus Termination RS485 .............................
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15
16
17
18
18
19
20
21
22
23
24
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
Read the safety precautions carefully.
Check the delivery for transportation damage. If damage is found, notify the
supplier as soon as possible.
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.
Storing the operator panel where the temperature is lower/higher than
recommended in this manual can cause the LCD display liquid to
congeal/become isotopic.
The LCD display liquid contains a powerful irritant. In case of skin contact,
wash immediately with plenty of water. In case of eye contact, hold the eye
open, flush with plenty of water and get medical attention.
The figures in this manual serves 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, like for example serial devices.
1.2
UL and cUL Installation
Caution:
This section is only valid for UL labeled EXTER K10m panels.
•
•
This equipment is suitable for use in non-hazardous locations only.
[Combinations of equipment in your system are subject to investigation by
the local authority having jurisdiction at the time of installation].
All devices have to be supplied by a Class 2 power supply.
Beijer Electronics, MAEN851B
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Safety Precautions
Warning:
Do not disconnect equipment unless power has been removed or the area is
known to be non-hazardous
AVANT DE DECONNECTER L’EQUIPEMENT, COUPER LE COURANT
OUS’ASSURER QUE L‘EMPLACEMENT EST DESIGNE NON DANGEREUX.
Warning:
Only UL and cUL approved expansion units are allowed to be connected to
the port designated “EXPANSION”. At the moment there are no such units
evaluated or allowed.
SEULES LES UNITÉS D'EXTENSION CERTIFIÉES UL ET
cUL PEUVENT ÊTRE RACCORDÉES AU PORT DÉSIGNÉ « EXPANSION ».
À L'HEURE ACTUELLE, AUCUNE UNITÉ DE CE TYPE N'A ÉTÉ TESTÉE
OU AUTORISÉE.
Warning:
Do not replace expansion unit unless power has been switched off or the area
is known to be non-hazardous.
NE REMPLACEZ L'UNITÉ D'EXTENSION QUE SI LE
COURANT A ÉTÉ COUPÉ OU SI LA ZONE EST JUGÉE NON DANGEREUSE.
•
•
This product contains a rechargeable battery; this must only be changed in
an area known to be non-hazardous.
Replace the battery with a MS614S battery. Use of another type of battery
may present a risk of fire or explosion.
Warning:
Battery may explode if mistreated. Do not recharge, disassemble or dispose
of in fire.
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.
•
•
•
•
For use on a flat surface of a type 4X enclosure indoor use only.
Use minimum 75°C copper conductors only.
To make wiring connections to the power supply connector, follow the table
with cable and torque specifications below:
Terminal Block Connector
Wire Size
TQ Lb.In.
X1/X100 Phoenix connectors
AWG 30–12
5–7
X1/X100 Anytek connectors
AWG 24–12
3.5
These devices are Class 2 supplied programmable controllers (industrial PCs)
for the use in industrial control equipment and are intended to be (front)
panel mounted (Type 1 and 4x for indoor use only).
Beijer Electronics, MAEN851B
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Safety Precautions
Caution:
The enclosure provides a degree of protection of at least IP20, but when installed in an
apparatus, it should meet IP54.
LE BOÎTIER OFFRE UN DEGRÉ DE PROTECTION D'AU MOINS IP20, MAIS
LORSQU'IL EST INSTALLÉ DANS UN APPAREIL, IL DOIT ÊTRE DE CLASSE IP54.
1.3
During Installation
•
The operator panel is designed for stationary installation on a plane surface,
where the following conditions are fulfilled:
–
no high explosive risks
–
no strong magnetic fields
–
no direct sunlight
–
no large, sudden temperature changes
•
•
•
•
•
Install the product according to the accompanying installation instructions.
Ground the product 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 product to the power outlet.
Peripheral equipment must be appropriate for the application and location.
•
1.4
•
•
•
Keep the operator panel clean.
Emergency stop and other safety functions may not be controlled from the
operator panel.
Do not use excessive force or sharp objects
1.5
•
•
•
•
•
•
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.
Clean the display and surrounding front cover with a soft cloth and mild
detergent.
Replacing the battery incorrectly may result in explosion. Only use batteries
recommended by the supplier. During the warranty period, the battery needs
to be replaced by an authorized Beijer Electronics service center.
1.6
•
During Use
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, electrolytic capacitor and
display.
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Installation
2
Installation
2.1
Space Requirements
•
•
Installation plate thickness: 1.5 - 7.5 mm (0.06 - 0.3 inch)
Space requirements when installing the operator panel:
100 mm
(4.0 inch)
114 mm
(4.49 inch)
50 mm
(2.0 inch)
50 mm
(2.0 inch)
100 mm
(4.0 inch)
100 mm
(4.0 inch)
46.4 mm
(1.83 inch)
155 mm
(6.10 inch)
Caution:
The openings on the enclosure are for air convection. Do not cover these openings.
2.2
Installation Process
1. Unpack and check the delivery. If damage is found, notify the supplier.
Panel cut out 121 x 80 mm
(4.76 x 3.15 inch)
x4
Note:
Place the operator panel on a stable surface during installation.
Dropping it or letting it fall may cause damage.
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Installation
2. Place the panel cut out where the operator panel is to be situated, draw along
the outer sides of the holes and cut according to the markings.
For text strip
12.0 mm
(0.48 inch)
8.0 mm
(0.31 inch)
3. Secure the operator panel in position, using all the fastening holes and the
provided brackets and screws:
x4
0.5 - 1.0 Nm
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Installation
4. Connect the cables in the specified order, according to the drawing and steps
below.
Caution:
•
The operator panel must be brought to ambient temperature before it is started
up. If condensation forms, ensure that the operator panel is dry before connecting
it to the power outlet.
•
Ensure that the operator panel and the controller system have the same electrical
grounding (reference voltage level), otherwise errors in communication may
occur.
•
Ensure that the voltage and polarity of the power source is correct.
•
Separate high voltage cables from signal and supply cables.
•
Shielded communication cables are recommended.
Power
B
Controller
24V DC
RS422/
RS485
RS232
24V DC
C
D
A
Connect cable A.
Connect cable B, using an M5 screw and a grounding conductor (as short
as possible), that is sized correctly according to local electrical codes.
–
Connect cable C.
–
Connect cable D.
5. Carefully remove the laminated film over the operator panel display, to avoid
static electricity that could damage the panel.
–
–
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Installation
2.2.1
Mode Switches
All mode switches must be in OFF position during operator panel use.
The mode switches should not be touched unless by qualified personnel.
ON DIP
1 2 3 4
2.2.2
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.
2.2.3
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.
Beijer Electronics, MAEN851B
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Technical Data
3
Technical Data
Parameter
EXTER K10m
Front panel, W x H x D
155 x 114 x 6 mm
Mounting depth
46.4 mm
Front panel seal
IP 66
Rear panel seal
IP 20
Keyboard material
Membrane switch keyboard with metal domes. Overlay
film of Autotex F207* with print on reverse side. 1 million
operations.
Reverse side
material
Powder-coated aluminum
Weight
0.45 kg
Serial port
RS422/RS485
25-pin D-sub contact, chassis-mounted female with
standard locking screws 4-40 UNC
Serial port RS232C
9-pin D-sub contact, male with standard locking screws 4-40
UNC
Flash memory for
application
512 kB
Real time clock
±20 PPM + error because of ambient temperature. Total
maximum error: 1 minute/month at 25 °C.
Temperature coefficient: -0.034±0.006 ppm/°C2
Real time
clock battery
(rechargeable)
MS614S (UL and cUL: SII Micro Parts Ltd)
Power consumption
at rated voltage
Normal: 0.1 A
Maximum: 0.3 A
Display
FSTN-LCD, 160 x 32 pixels, monochrome transmissive
negative.
LED backlight lifetime at the ambient temperature of
+25 °C: >47,000 h.
Active area of
display, W x H
89.6 x 17.9 mm
Fuse
Internal DC fuse, 1.0 AT, 5 x 20 mm
Power supply
+24 V DC (20 - 30 V DC). Power supply connector.
CE: The power supply must conform with the requirements
according to IEC 60950 and IEC 61558-2-4.
UL and cUL: The power supply must conform with the
requirements for class II power supplies.
Ambient
temperature
Vertical installation: 0 ° to +50 °C
Horizontal installation: 0 ° to +40 °C
Storage temperature
-20 ° to +70 °C
Relative humidity
5 - 85 % non-condensed
Approvals and
certifications
Information is available on the web site
www.beijerelectronics.com
* See section Chemical Resistance for more information.
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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%
Phosphoric acid 4%
Citric acid 10%
Phosphoric acid 10%
Diesel
Sea water
Distilled water
Sodium chloride 2%
Edible oil
Sodium chloride 20%
Fuel oil
Sulphuric acid 20%
Hydrogen peroxide 3%
Tap water
The powder paint shows limited resistance to the following chemicals at room
temperature:
Butanol
Nitric acid 3%
Hydrochloric acid 5%
Nitric acid 10%
Isopropyl alcohol
Phosphoric acid 43%
Na-hypochlorite 10%
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.
Methyl-ethyl ketone
Toluene
Acetone
Nitric acid 30%
Trichlorethylene
Ammonia 5%
Phenol
Xylene
Ammonia, conc.
Sodium hydroxide 5%
97 octan unleaded petrol
Ethyl acetate
Sodium hydroxide 30%
98 octan leaded petrol
4.2
4.2.1
Screen and Overlay Material
Autotex F157/207
Autotex F157 or F207 covers the overlay surrounding the screen.
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Chemical Resistance
Solvent Resistance
Autotex F157/F207 withstands exposure of more than 24 hours duration under
DIN 42 115 Part 2 to the following chemicals without visible change:
Acetonitrile
Diesel Downey / Lenor1
Phosphoric acid (<30%)
Ajax / Vim in solution
Ethanol
Potassium ferricyanide
Alkalicarbonate solution1
Glycerine
Potassium hydroxide
(<30%)
Ammonia (<40%)1
Glycol
Pure Turpentine
Acetic acid (<50%)
Gumption1
SBP 60/951
Ariel powder in solution1
Hydrochloric acid (<36%)
Sulfuric acid (<10%)
Bleach1
Linseed oil
Tomato ketchup
Castor oil
Methanol
Trichloroacetic acid
(<50%)
Caustic soda (<40%)1
Nitric acid (<10%)
White Spirit
Cutting oil
Paraffin oil
Windex1
Cyclohexanol
Persil powder in solution1
Wisk
Diacetone alcohol
Petroleum spirit1
-
1 Extremely faint glossing of the texture was noted.
Autotex withstands DIN 42 115 Part 2 exposure of up to 1 hour duration to glacial
acetic acid without visible change.
Autotex is not resistant to high pressure steam at over 100 °C or the following
chemicals:
Concentrated mineral acids
Benzyl alcohol
Concentrated caustic solution
Methylene chloride
Outdoor Use
In common with all polyester based films Autotex F157/F207 is not suitable for
use in conditions of long term exposure to direct sunlight.
4.2.2
Screen Surface
The screen surface on the operator panel withstands exposure to the following
solvents without visible change:
Solvents
Time
Acetone
10 minutes
Isopropanol
10 minutes
Toluene
5 hours
Beijer Electronics, MAEN851B
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Chemical Resistance
4.2.3
Screen and Keyboard Protector
For harsh environments and exposure to outdoor conditions, it is recommended
to use a protective film to guard the screen and the keyboard from damage. These
optional parts can be ordered from Beijer Electronics.
Beijer Electronics, MAEN851B
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Operator Panel Drawings
5
Operator Panel Drawings
5.1
Communication Ports
RS-232
RS-422
RS-485
RS-422/485
Beijer Electronics, MAEN851B
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Operator Panel Drawings
5.2
EXTER K10m Outline
Beijer Electronics, MAEN851B
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Operator Panel Drawings
5.3
EXTER K10m Text Strip
(unit: mm)
9.0
4.5
11.25
19.0
20.5
20.5
138.0
20.5
19.0
Text max 18.5x7.5
Text max 15.5x7.5
R1 (4x)
Beijer Electronics, MAEN851B
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Additional Installation Tips
6
Additional Installation Tips
When experiencing communication problems in for example noisy environments
or when operating close to temperature limits, the following recommendations
are to be noticed.
6.1
Grounding the Operator Panel
Mounting plate in the cabinet
Door
Operator panel
3
2
Power supply
1
Ferrite core
24 V DC
5
6
4
5350
The operator panel’s mounting clamps do not provide a secure grounding
connection between the panel and the device cabinet, see 1 in drawing above.
1. Connect a wire that is sized correctly according to local electrical codes
between the operator panel’s quick-connect plinth and the panel’s chassis, see
2 in drawing above.
2. Connect a 6 or 4 mm2 wire or grounding braid between the panel’s chassis and
the closest grounding point on the door, see 3 in drawing above.
3. Connect a strong but short grounding braid between the door and the device
cabinet, see 4 in drawing above.
4. Twist the cables onto the 24 V DC feed, see 5 in drawing above.
2 turns around the ferrite core provide 4 times the suppression of 1 turn.
3 turns around the ferrite core provide 9 times the suppression of 1 turn.
A ferrite core suppresses disturbances to the 24 V feed, see 6 in drawing above.
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 will 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.
Beijer Electronics, MAEN851B
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Additional Installation Tips
6.2
Ethernet Connection in the Panel
Industrial Ethernet
RJ45
RJ45
1
RJ45
RJ45
Operator panel
RJ45
3
2
Operator panel
RJ45
4
Shielded
1-1
2-2
3-3
Short and
unshielded
Operator panel
RJ45
8-8
5
Operator panel
RJ45
0.1 uF
250 V
5351
In some industrial units for Ethernet, the RJ45 contact’s shield is connected to the
chassis via a capacitor, see 1 in drawing above.
The operator panel’s Ethernet shield is directly connected to the chassis, see 2 in
drawing above.
1. Check whether the other Ethernet unit has its shield directly grounded or
grounded via a capacitor.
Note:
In many cases, connecting the shielded Ethernet cabling to the chassis at both ends is
inappropriate. Hum or grounding loops can occur. Unshielded cabling may even result
in fewer communication errors.
A good solution may be to use a shielded Ethernet cable, but to connect the shield
at one end only.
One option is to break the shield, see 3 in drawing above.
A more elegant method is to expand the shielded Ethernet cabling with a piece of
unshielded Ethernet cable, see 4 in drawing above.
You can ground the shield via an external 0.1 µF/250 V plastic capacitor, see 5 in
drawing above. This will connect the HF transients to the ground.
Beijer Electronics, MAEN851B
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Additional Installation Tips
6.3
•
•
•
•
•
•
•
To Achieve Better EMC Protection
Use shielded cables for RS232 communication.
Use twisted pair and shielded cabling for RS422 and RS485.
Use the cabling intended for the bus type; Ethernet, Profibus, CC-Link,
CAN, Device Net etc.
Install and connect according to applicable specifications for the relevant bus
standard.
Use shielded cabling for Ethernet, preferably with foil and a braided shield.
D-sub covers should be shielded, and the shield should be connected to the
cover 360° where the cable enters.
Connect the shield at both ends.
Shielded cable
0.1 uF/250 V
Ground plane 1
Ground plane 2
Not same potential
5352
Ground plate
Ground plate
in another building
With longer distances, there is a risk that the ground potential may be different.
In that case, the shield should only be connected at one end. A good alternative
is to connect the other end of the shield to the ground via a 0.1 µF/250 V plastic
capacitor. Both ends are then connected to the ground in terms of HF, but only
connected to the ground at one end in terms of LF, thus avoiding the 50 Hz
grounding loops.
Metal cabinet
Metal cabinet
Terminal or connector
Short distance
Terminal or connector
EMC cable gland
Shielded cable
Cable clamp
in steel
Plastic cable gland
Shielded cable
5353
1. Use an EMC cable gland or regular plastic cable gland, remove the outer jacket
and connect the shield to the installation plate with a 360 ° metal cable clamp.
2. 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.
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Additional Installation Tips
6.4
Ambient Temperature
The maximum ambient temperature for the operator panel is provided in the
specifications. The ambient temperature refers to the temperature in the device
cabinet which cools the panel’s electronics.
Top
50 °C inside
Operator
panel
Power
Power
30 °C outside
Axial fan
120 x 120 mm
Middle
45 °C inside
Airflow
Power
Bottom
40 °C inside
5354
In most cases, the ambient temperature for the operator panel is significantly
higher than the device cabinet’s ambient temperature.
If the cabinet is tall and there are a number of heat-generating devices, the
temperature at the top of the cabinet will be considerably higher than the
theoretical temperature increase that would be expected. All electronics are
sensitive to heat. The lifespan of an electrolytic capacitor is cut in half with an
8-10 °C increase in temperature. A 15-20 °C temperature increase results in a
quarter of the lifespan etc.
Rittal has a good program for estimating the anticipated average temperature in
the cabinet as well as a large program for controlling the temperature in the device
cabinet.
An enamel-coated steel cabinet has a radiant heat value of 5.5 W/m2 and degrees
C.
Installing a fan inside the cabinet will even out the temperature, while moving air
provides considerably better cooling than still air. A suitable fan is a 120 x 120 mm
axial fan, available in 24 V DC, 115 and 230 V AC.
Install the fan so that it sits in the cooler area and blows cold air against the operator
panel. If the fan is mounted at the top and sucks warm air upwards, the fan’s
ambient temperature will be higher, resulting in a shorter lifespan.
A good fan with a ball-bearing mounting has an expected lifespan of at least
40,000 hours (not a guaranteed lifespan) at 40 °C. This corresponds to at least 4
years of continuous use. If a thermostat is installed, the fan only operates when
needed.
Large graphic terminals draw only one fifth of the current when the background
lighting is off. The loss effect drops from e.g. 25 W to only 5 W.
An approximate value of the net power consumption for the operator panel can
be calculated by multiplying the supply voltage with the current drawn by the
operator panel. This is assuming that all supplied power is transformed to heat.
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Additional Installation Tips
6.5
Safety
Most of the operator panels are fed with 24 V DC.
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
1
0V
4
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
2
0V
4
Distance?
Power supply
230 V AC to 24 V DC
Operator panel
+24 V
3
0V
4
COM1
Small controller with expansion unit
Ch0
Ch1
230 V AC
COM100
Ch100
Ch101
5355
If a power supply that meets safety standards is used and only feeds the operator
panel, there is no problem. See 1 in drawing above.
However, if a 24 V unit that also feeds 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 feed 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 feed 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 feed to the ground, see 4 in drawing above. This offers
three advantages:
•
Safety is increased. The 24 V feed will not be 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, MAEN851B
22
Additional Installation Tips
6.6
Galvanic Isolation
Internal electronic
Filter
Ethernet
DC/DC
galvanic isolation
DC/AC
VCC
+24 V DC
CFL
0 V (GND)
0V
1.5 m
RS422/485
RS232
USB
5356
USB
The operator panel has galvanic isolation against the 24 V DC feed but no galvanic
isolation between the communication ports for RS232, RS422/485 and USB.
Only the Ethernet connection has galvanic isolation.
Operator panel
Modular controller
Power CPU
RS422
*
RS232
*
* * *
USB
*
PC
*
Not same ground potential
* = Internal 0 V (GND) connection
Printer
COM COM2
*
PC
*
5357
When a PC is connected to the panel, the panel’s internal 0 V (GND) will be
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 panel’s 0 V (GND) 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, and 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 will disrupt 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, MAEN851B
23
Additional Installation Tips
6.7
•
Cable and Bus Termination RS485
Use shielded and twisted pair cable. The pair capacitance may not exceed 52.5
pF/m and area at least 0.25 mm2 (AWG 24), if you want to use the maximum
transfer distance and maximum transfer speed.
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 plastic
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. The RS485
standard does not describe how the “Fail Safe” function would be carried out,
just that the system should be able to handle the error.
•
•
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).
Inside operator panel
+5 V
1
+5 V
2
14
3
1K
1K
120 ohm
2
15
120 ohm
6
19
(120 ohm)
1K
0V
1K
7
8
4
CAB8
Operator
panel
RS422
55
1 2 3 4 5 6 7 8
17
50
+5 V
0V
0V
0V
0V
CAB8
Bus
RS485
2
15
1
2
3
16
3
4
17
4
5
6
14
8
7
VCC
VCC
1K
120 ohm
1K
0V
0V
Shield
7
8
Bus termination
5358
Some (older) operator panels had pull-up and pull-down resistance except for
the actual bus termination at 120 Ω, similar to Westermo and Profibus. See 1 in
drawing above.
Newer panels have another type of recipient, so-called built-in “Fail Safe”, where
simple bus termination resistance is sufficient. See 2 in drawing above.
If other nodes on the RS485 network require pull-up and pull-down and the
operator panel is at one end of the loop, one of the following procedures can be
carried out:
• Connect two 1 kΩ / 0.25 W resistors in the 25-pole D-sub contact. See 3 in
drawing above. Set jumper pins 6-19.
• Use CAB8. It offers the option of bus termination with pull-up/-down. It
is also easy to connect the bus cable via the screw terminal block. See 4 in
drawing above.
Beijer Electronics, MAEN851B
24
Head office
Beijer Electronics AB
Box 426
201 24 Malmö, Sweden
www.beijerelectronics.com / +46 40 358600

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