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MAEN810C, 2008-05

EXTER™ K30m

Installation manual

English

Installation manual for the EXTER series operator panels

Foreword

Foreword

The EXTER operator panel is developed to satisfy the demands of humanmachine communication. Built-in functions such as displaying and controlling text, dynamic indication, time channels, alarm and recipe handling are included.

The operator panel work, for the most part, in an object-oriented way, making it easy to understand and use. The configuration operation of the panel is made in a personal computer, using the configuration tool Information Designer. The project is then transferred and stored in the operator panel.

The operator panel can be connected to many types of automation equipment, such as PLCs, servos or drives. In this manual the expression “the controller“ is used as a general term for the connected equipment.

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

©

Beijer Electronics AB, MAEN810C, 2008-05

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, MAEN810C

Table of Contents

Table of Contents

1 Safety Precautions................................................................................. 5

1.1 UL and cUL Installation ................................................................... 5

1.2 General ............................................................................................. 6

1.3 During Installation............................................................................ 6

1.4 During Use ....................................................................................... 7

1.5 Service and Maintenance................................................................... 7

1.6 Dismantling and Scrapping............................................................... 7

2 Installation ........................................................................................... 9

2.1 Space Requirements .......................................................................... 9

2.2 Installation Process............................................................................ 9

2.2.1 Mode Switches ................................................................................................ 11

2.2.2 Connections to the Controller ......................................................................... 11

2.2.3 Other Connections and Peripherals ................................................................. 11

3 Technical Data ................................................................................... 13

4 Chemical Resistance ........................................................................... 15

4.1 Metal Casing................................................................................... 15

4.2 Touch Screen and Overlay .............................................................. 15

4.2.1 Autotex F157/F207 ......................................................................................... 15

4.2.2 Touch Screen Surface ...................................................................................... 16

4.2.3 Autoflex EB ..................................................................................................... 16

5 Operator Panel Drawings ................................................................... 17

5.1 Communication Ports..................................................................... 17

5.2 EXTER K30m Outline ................................................................... 18

5.3 EXTER K30m Text Strip ............................................................... 19

6 Additional Installation Tips................................................................ 21

6.1 Grounding the Operator Panel ....................................................... 21

6.2 Ethernet Connection in the Panel ................................................... 22

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

6.4 Ambient Temperature..................................................................... 24

6.5 Safety .............................................................................................. 25

6.7 Cable and Bus Termination RS485................................................. 27

Beijer Electronics, MAEN810C

Table of Contents

Beijer Electronics, MAEN810C

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 UL and cUL Installation

– This equipment is suitable for use in Class I, Division 2, Groups A, B, C and D

OR 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.]

– Maximum ambient temperature 40 °C when mounted horizontal or 50 °C when mounted vertical.

– WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless power has been removed or the area is known to be non-hazardous.

– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE

DECONNECTER L’EQUIPEMENT, COUPER LE COURANT OU

S’ASSURER QUE L‘EMPLACEMENT EST DESIGNE NON DANGEREUX.

– WARNING – EXPLOSION HAZARD - Substitution of components may impair suitability for Class I, Division 2.

– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – LA

SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATERIEL

INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I,

DIVISION 2.

– WARNING – EXPLOSION HAZARD – 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.

– WARNING – EXPLOSION HAZARD - Do not replace expansion unit unless power has been switched off or the area is known to be non-hazardous.

– This product contains battery, this must only be changed in an area known to be non-hazardous. Permitted types are shown in the section

Technical Data

.

– For use on a flat surface of a type 4X enclosure indoor use only.

– To make wiring connections to the power supply connector, use an AWG 28-12 cable and a tightening torque of min. 0.5 Nm.

Beijer Electronics, MAEN810C

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6

Safety Precautions

1.2 General

– 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.

– 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.

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.

Beijer Electronics, MAEN810C

Safety Precautions

1.4 During Use

– Keep the operator panel clean.

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

– Do not use too much force or sharp objects when touching the keys, touch screen etc.

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.

1.6 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.

Beijer Electronics, MAEN810C

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Safety Precautions

8

Beijer Electronics, MAEN810C

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)

187 mm

(7.36 inch)

50 mm

(2.0 inch)

50 mm

(2.0 inch)

100 mm

(4.0 inch)

100 mm

(4.0 inch)

202 mm

(7.95 inch)

57 mm

(2.24 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

.

Installation

Panel cut out 166 x 149 mm

(6.54 x 5.87 inch) x 7

Note:

Place the operator panel on a stable surface during installation.

Dropping it or letting it fall may cause damage.

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. If access to the text strips is needed, add extra space at the left side.

For text strip

14.0 mm

(0.55 inch)

7.0 mm

(0.28 inch)

Beijer Electronics, MAEN810C

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Installation

3. Secure the operator panel in position, using all the fastening holes and the provided brackets and screws: x 7

0.5 - 1.0 Nm

4. Connect the cables in the specified order.

A

Caution

Ensure that the operator panel and the controller system have the same electrical grounding (reference voltage level), otherwise errors in communication may occur.

B

Use an M5 screw and a grounding conductor (as short as possible) with a cross-section of minimum 2.5 mm

2

.

C

Caution

- Use only shielded communication cables.

- Separate high voltage cables from signal and supply cables.

D

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 voltage and polarity of the power source is correct.

B

Power

Controller

RS422/

RS485

RS232

24V DC

C

D

A

24V DC

10

Ethernet

5. Carefully remove the laminated film over the operator panel display, to avoid static electricity that could damage the panel.

Beijer Electronics, MAEN810C

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 personell.

Installation

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, MAEN810C

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Installation

12

Beijer Electronics, MAEN810C

Technical Data

3 Technical Data

Parameter EXTER K30m

Front panel,

W x H x D

Mounting depth

Front panel seal

Rear panel seal

202 x 187 x 6 mm

57 mm (157 mm including clearance)

IP 66

IP 20

Keyboard material

Reverse side material

Weight

Membrane switch keyboard with metal domes. Overlay film of Autotex

F157 * with print on reverse side. 1 million operations.

Powder-coated aluminum

Serial port

RS422/RS485

Serial port

RS232C

Ethernet

USB

0.95 kg

25-pin D-sub contact, chassis-mounted female with standard locking screws 4-40 UNC.

9-pin D-sub contact, male with standard locking screws 4-40 UNC.

Shielded RJ 45

Host type A (USB 1.1), max output current 500 mA

Flash memory for application

Real time clock

Real time clock battery

Power consumption at rated voltage

Display

12 MB (incl. fonts)

±20 PPM + error because of ambient temperature and supply voltage.

Total maximum error: 1 min/month at 25

°

C

Temperature coefficient: 0.004 ppm/

°

C

2

CR2450 (UL and cUL: Sanyo or Panasonic)

Minimum lifetime: 3 years

Normal: 0.15 A

Maximum: 0.35 A

FSTN-LCD. 240 x 64 pixels, monocrome transflective.

LED backlight lifetime at the ambient temperature of

+25

°

C: >35,000 h.

127.0 x 33.8 mm Active area of display,

W x H

Fuse Internal DC fuse, 2.0 AT, 5 x 20 mm

Power supply +24V DC (20 - 30V 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

Storage temperature

Vertical installation: 0

° to +50

°

C

Horizontal installation: 0

° to +40

°

C

-20

°

to +70

°

C

Relative humidity

5 - 85 % non-condensed

CE approvals Noise tested according to EN61000-6-3 emission and EN61000-6-2 immunity.

Beijer Electronics, MAEN810C

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Technical Data

Parameter EXTER K30m

UL, cUL approvals

(when product or packing is marked)

DNV

NEMA

UL 1604 Class I, Div 2 / UL 508 / UL 50 4x indoor use only

Yes

4x indoor use only

* See section

Chemical Resistance

for more information.

14

Beijer Electronics, MAEN810C

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

Phosphoric acid 4%

Phosphoric acid 10%

Sea water

Sodium chloride 2%

Edible oil

Fuel oil

Sodium chloride 20%

Sulphuric acid 20%

Hydrogen peroxide 3% Tap water

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

Butanol

Hydrochloric acid 5%

Isopropyl alcohol

Na-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 on an “invisble” 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 octan unleaded petrol

98 octan leaded petrol

4.2 Touch Screen and Overlay

4.2.1 Autotex F157/F207

Autotex F157 or F207 covers the overlay surrounding the touch screen.

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

Ajax / Vim in solution

Alkalicarbonate solution

1

Ammonia (<40%)

1

Diesel Downey / Lenor

1

Ethanol

Glycerine

Glycol

Phosphoric acid (<30%)

Potassium ferricyanide

Potassium hydroxide (<30%)

Pure Turpentine

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Chemical Resistance

Acetic acid (<50%)

Ariel powder in solution

1

Bleach

1

Castor oil

Caustic soda (<40%)

1

Cutting oil

Gumption

1

Hydrochloric acid (<36%)

Linseed oil

Methanol

Nitric acid (<10%)

Paraffin oil

Cyclohexanol

Diacetone alcohol

Persil powder in solution

1

Petroleum spirit

1

1

Extremely faint glossing of the texture was noted.

SBP 60/95

1

Sulfuric acid (<10%)

Tomato ketchup

Trichloroacetic acid (<50%)

White Spirit

Windex

1

Wisk

-

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

Concentrated caustic solution

Benzyl alcohol

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 Touch Screen Surface

The touch screen surface on the panel withstands exposure to the following solvents without visible change:

Solvents Time

Acetone

Isopropanol

Toluene

10 minutes

10 minutes

5 hours

4.2.3 Autoflex EB

It is recommended to use the Autoflex EB touch display protection film, that can be ordered from Beijer Electronics.

Solvent Resistance

Autoflex EB withstands exposure to the same chemicals as Autotex F157 or F207 according to section

Autotex F157/F207

.

Outdoor Use

In common with all polyester based films Autoflex EB is not suitable for use in conditions of long term exposure to direct sunlight.

Beijer Electronics, MAEN810C

5 Operator Panel Drawings

5.1 Communication Ports

RS-232

Operator Panel Drawings

RS-422 RS-485

RS-422/485

USB

Ethernet

Drawing No. S-05005, Date 2004-10-27

Beijer Electronics, MAEN810C

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Operator Panel Drawings

5.2 EXTER K30m Outline

18

Drawing No. P-06629, Date 2005-10-05

Beijer Electronics, MAEN810C

5.3 EXTER K30m Text Strip

Text max 17,0x8,0

Text max 18,5x8,0

Operator Panel Drawings

4,5

9

Drawing No. S-06627, Date 2005-07-19

Beijer Electronics, MAEN810C

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Operator Panel Drawings

20

Beijer Electronics, MAEN810C

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

Door

Mounting plate in the cabinet

Operator panel

3

2

Power supply

1

24 V DC

Ferrite core

5

6

4

1. The operator panel’s mounting clamps do not provide a secure grounding connection between the panel and the device cabinet.

2. Connect a 2.5 mm

2

wire between the operator panel’s quick-connect plinth and the panel chassis.

3. Connect a 6 or 4 mm

2

wire or grounding braid between the panel’s chassis and the closest grounding point on the door.

4. Connect a strong but short grounding braid between the door and the device cabinet.

5. Twist the cables onto the 24 V DC feed.

6. A ferrite core suppresses disturbances to the 24 V feed.

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.

Remember:

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, MAEN810C 21

22

Additional Installation Tips

6.2 Ethernet Connection in the Panel

Industrial Ethernet

RJ45

RJ45

1

RJ45

RJ45

Operator panel

RJ45

2

3

Operator panel

RJ45

Shielded

4

1-1

2-2

3-3

8-8

Short and unshielded

Operator panel

RJ45

5

Operator panel

RJ45

0.1 uF

250 V

5351

1. In some industrial units for Ethernet, the RJ45 contact’s shield is connected to the chassis via a capacitor.

2. The operator panel’s Ethernet shield is directly connected to the chassis.

Check whether the other Ethernet unit has its shield directly grounded or grounded via a capacitor.

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.

3. One option is to break the shield.

4. A more elegant method is to expand the shielded Ethernet cabling with a piece of unshielded Ethernet cable.

5. You can ground the shield via an external 0.1 uF/250 V plastic capacitor. This will connect the HF transients to the ground.

Beijer Electronics, MAEN810C

Additional Installation Tips

6.3 To Achieve Better EMC Protection

– Initially, use the original cabling from Beijer Electronics primarily.

– 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 + braided shield.

– D-sub covers should be shielded, and the shield should be connected to the cover

360 ° where the cable comes in.

– Connect the shield at both ends.

Shielded cable

0.1 uF/250 V

Ground plane 1

Terminal or connector

Ground plane 2

Not same potential

Ground plate

5352

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 uF/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

Cable clamp in steel

EMC cable gland

Plastic cable gland

Shielded cable Shielded cable

5353

– 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.

– 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.

Beijer Electronics, MAEN810C 23

24

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.

Operator panel

Top

50

° inside

Power

30

°

C outside

Power

Middle

45 ° inside

Power

Axial fan

120x120 mm

Airflow

Bottom

40 ° 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 ° increase in temperature. A 15-20 ° 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/m

2

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 will blow cold air against the operator panel. If the fan is mounted at the top and sucks air upwards, the fan’s ambient temperature will be higher = 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 needs to come on 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.

The operator panel’s loss effect = supply voltage x current. Virtually no power goes to external users and no loss effects due to inputs.

Beijer Electronics, MAEN810C

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

1

+24 V

0 V

Power supply

230 V AC to 24 V DC

4

Operator panel

2

+24 V

0 V

4

Distance?

Power supply

230 V AC to 24 V DC

3

+24 V

0 V

Operator panel

4

230 V AC

COM1

Small controller with expansion unit

Ch0

Ch1

COM100

Ch100

Ch101

5355

1. If you use a power supply that meets safety standards and only feeds the operator panel, there is no problem.

2. However, if you have a 24 V unit that also feeds other units, there is reason to be cautious.

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.

Example:

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.

3. 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.

4. Connect 0 V on the 24 V feed to the ground. 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.

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26

Additional Installation Tips

6.6 Galvanic Isolation

Internal electronic

Ethernet

Filter

DC/DC galvanic isolation

+24 V DC

0 V

VCC

0 V (GND)

DC/AC

CFL

1.5 m

RS422/485 RS232 USB USB

5356

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

Printer

Power CPU COM COM2

*

RS422 RS232 USB

* *

* * *

PC

*

PC

*

Not same ground potential

* = Internal 0 V (GND) connection

*

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, MAEN810C

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 mm

2

(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 uF/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).

+5 V

1 2

Inside operator panel

+5 V

3

1K

1K

120 ohm

1K

120 ohm

0 V 1K

(120 ohm)

0 V

0 V

4

CAB8

Operator panel

RS422

CAB8

Bus

RS485

Shield

0 V

0 V

+5 V

0 V

0 V

VCC

2.65 V

VCC

1K

120 ohm

2.35 V

1K

Bus termination

5358

1. Some (older) operator panels had pull-up and pull-down resistance except for the actual bus termination at 120 ohm, similar to Westermo and Profibus.

2. Newer panels have another type of recipient, so-called built-in “Fail Safe”, where simple bus termination resistance is sufficient.

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:

3. Connect two 1k/0.25 W resistors in the 25-pole D-sub contact. Set jumper pins

6-19.

4. 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.

Beijer Electronics, MAEN810C 27

HEAD OFFICE

SWEDEN

Beijer Electronics Products AB

Box 426

SE-201 24 Malmö, Sweden

Tel: +46 40 35 86 00

Fax: +46 40 93 23 01 [email protected]

SUBSIDIARIES

GERMANY

Elektronik-Systeme Lauer GmbH & Co. KG

Kelterstraße 59

72669 Unterensingen, GERMANY

Tel: +49 7022 9660 0

Fax: +49 7022 9660 103 [email protected]

TAIWAN

Hitech Electronics Corp.

7 & 8 F, No. 108 Min-Quan Road

Shin-Tien, Taipei Shien, TAIWAN, R.O.C. 231

Tel: +886-2-2218-3600

Fax: +886-2-2218-9547 [email protected]

USA

Beijer Electronics Inc.

939 N. Plum Grove Road, Suite F

Schaumburg, IL 601 73, USA

Tel: +1 847 619 6068

Fax: +1 847 619 6674 [email protected]

CHINA

Beijer Electronics Co. Ltd

Room 201, Buildning B, No. 1618,

Yishan Road, Shanghai 201103, CHINA

Tel: +86 21 6145 0400

Fax: +86 21 6145 0499 [email protected]

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