Month: August 2025

Product specifications

Normal operating voltage: 15-32 VDC

Standby current: 1.45 mA

Alarm current: 32 mA (assuming all six relays have switched once and all six LEDs are continuously on)

Temperature range:

ULC application: 32 ° F to 120 ° F (0 ° C to 49 ° C)

EN54 application: -10 ° C to 55 ° C

Humidity:

ULC application: 10% to 95%, non condensing

EN54 application: 10% to 93%, non condensing

Size: 6.8 inches high x 5.8 inches wide x 1.0 inches deep (173mm high x 147mm wide x 25mm deep)

Maximum IDC wiring resistance: 40 ohms

Accessories: BB-2A cabinet, BB-6A cabinet, CH-6A chassis, or appropriately grounded metal cabinet

Wire gauge: 12-18 AWG (0.9mm ² -3.25mm ²)

Relay current: 30 mA/relay pulse (15.6ms pulse duration, under panel control)

Preparation before installation

This information is only provided as a quick reference installation guide. If modules are installed in the existing operating system, operators and local authorities should be notified that the system will be temporarily suspended.

Disconnect the power supply of the control panel before installing the module.

This system contains static sensitive components. Before handling any circuit, it is necessary to ground it with a suitable wrist strap to eliminate static charges on the body.

The enclosure cabinet should be made of metal material and properly grounded.

This manual should be left to the owner/user of this device.

Product overview

Purpose: Suitable for intelligent alarm systems, used for Form-C switching applications, load circuits do not require wiring monitoring.

Structure: Each module provides a set of independent dry-type relay contacts, which can be wired as normally open or normally closed; Each module has its own address, and the address of the first module is set to 01 to 94 through a pair of rotary encoding switches. The remaining modules are automatically assigned to the next five higher addresses; Disable up to three unused modules to release addresses for use elsewhere; Each CR-6A module also has a green LED indicator light controlled by the panel, which can make the LED flash, lock on or lock off.

Includes: 6 1 × 3 terminal blocks, 1 1 × 4 terminal block, 2 1.25-inch (32mm) supports, 3 mechanical screws, 1 splitter (note: in the disabled position, a maximum of one splitter can be installed at the same time)

Compatibility requirements

To ensure normal operation, this module should only be connected to compatible control panels.

Component

Installation options:

Up to six CR-6A modules can be installed on the CH-6A of the BB-6A cabinet

One or two CR-6A modules can be installed in the BB-2A cabinet

Chassis: CH-6A chassis is used to install CR-6A modules in the BB-6A cabinet. It can accommodate up to six CR-6A modules in a single cabinet row, three modules wide and two modules deep; The BB-2A cabinet has a built-in chassis that can accommodate one or two CR-6A modules. The front CR-6A module position of each chassis is lower than the rear CR-6A module position, so that all status indicators are visible.

Cabinet: BB-6A cabinet can accommodate CH-6A chassis with up to six CR-6A modules installed; The BB-2A cabinet accommodates one or two CR-6A modules on its internal chassis, and the cabinet dimensions refer to the cabinet installation document.

Installation steps

Cabinet installation: Install the bottom box using the four holes provided on the back of the cabinet in a clean and dry area.

Chassis installation: The CH-6A chassis is installed in the BB-6A cabinet and secured to the two PEM bolts on the rear wall of the cabinet with two 8-32 hex nuts, which are provided with the chassis; The BB-2A cabinet comes with an installed chassis and does not require additional installation.

Module installation: There are two methods to install modules at the rear of the chassis.

Method 1: Install only the rear module and do not install any modules in front of it.

Method 2: Install the rear module, and another module will be installed in front of it. All necessary screws and supports are provided with the module.

Wiring requirements

All wiring must comply with applicable local codes, regulations, and laws.

Install module wiring according to the engineering drawings and corresponding wiring diagrams.

When making electrical connections, strip approximately 0.25 inches (6.35mm) of insulation from the end of the wire, slide the exposed end of the wire under the clamp, and then tighten the clamp screws.

Set the address on the module according to the engineering drawing, use the rotary encoding switch to set the address of the first module (between 01 and 94), and the remaining modules will be automatically assigned to the next five higher addresses. For example, if the base address switch is set to 28, the next five modules will be addressed as 29, 30, 31, 32, and 33. The minimum address cannot be set to 94 or above, otherwise other modules will be assigned to non-existent addresses.

Provide a splitter to disable up to three unused modules. The module is disabled starting from the highest address and moving downwards. For example, if the shunt with “address disabled” is placed on “2” and the base address switch is set to 28, the module will be assigned to 28, 29, 30, and 31.

Precautions for Relay Connection

The relay contacts on CR-6A can be connected to power limited or non power limited power sources, but the wiring must be kept at least 0.25 inches (6.35mm) away from all power limited wiring.

The power limiting circuit must use FPL, FPLR, or FPLP type cables as required by NEC Article 760.

For ease of wiring, allocate all power limiting wiring to one side instead of alternating with non power limiting wiring.

Basic Overview

Honeywell’s C300 controller is PlantCruise by Expert ®  The platform provides powerful and robust control functions. Its core is the field validated Deterministic Control Execution Environment (CEE) core software, which uses the easy-to-use and intuitive engineering tool Control Builder to configure and load control strategies. The C300 controller hardware adopts an innovative Series 8 exterior design, which has unique advantages in space saving, installation, and maintenance, and can be configured with redundancy by adding an additional identical hardware module.

Main advantages

Improve engineering efficiency: With a rich library of features and a seamless and intuitive user environment, it facilitates the creation and implementation of control strategies.

Maximizing process runtime: With powerful diagnostic capabilities and complete hardware redundancy, it reduces maintenance work and minimizes downtime to the greatest extent possible.

Reduce production costs: By implementing flexible and efficient control strategies, online migration, and efficient hardware processing capabilities, production costs can be reduced.

Core functions

Control Execution Environment (CEE)

Support ISA S88.01 batch standard, integrate sequences with devices, enable devices to track sequence status and perform pre configured operations based on status, reducing the complexity of handling abnormal situations.

The execution cycle of the control strategy can be set within the range of 50 milliseconds to 2000 milliseconds. Users can modify or add new strategies to existing strategies without interrupting the execution of other control strategies by the controller, and can fully control the execution order of functional blocks within the control strategy and the execution order of multiple control strategies.

Function block support

The functional blocks that control the execution environment support continuous control, logic based control, sequential control, and model-based control. Each functional block contains rich predefined functions, such as alarm limits and priorities, various control algorithms, and maintenance statistics, all of which are configurable parameters. Function blocks are linked together in the control module to perform specific control tasks, providing a foundation for efficient control engineering.

Data communication

Parameters provide access to various information in the controller, which can be used throughout the entire Expert system. Each parameter is protected from accidental changes through a secure access level, and some parameters can only be changed offline. Communication is based on anomaly reporting and publish subscribe mode, accessing data only when needed to avoid data duplication and efficiently utilize communication bandwidth.

Engineering environment

Control Builder is a control engineering and maintenance tool that controls the execution environment, simplifying configuration through a graphical user interface and predefined functional blocks, and improving the work efficiency of control engineers. Control engineers do not need to build standard functional blocks from scratch to enable and modify these features, and can also use embedded objects such as text, documents, or web links to add document descriptions to control policies.

On-line monitor

After loading the control strategy into the C300 controller, engineers can use the same graphical interface to monitor the strategy online, which helps validate the control strategy or troubleshoot process issues. Control or maintenance engineers can directly modify parameters from the engineering environment without the need for an operator interface.

Controller based model predictive tuning (ProfitLoop)

ProfitLoop is a patented algorithm from Honeywell that provides single input/single output model prediction function blocks, which are included in the standard C300 controller function block library. It has the operational simplicity and computational efficiency of standard PID function blocks, while providing tight and robust control, which can improve process stability by up to 30%. A simple model for the creation process of ProfitLoop, which predicts the impact of control actions on process (controlled) variables, can predict future process behavior, and accurately determine the adjustment required to achieve the expected control objectives of the process.

Custom Algorithm Blocks (CABs)

Custom algorithm blocks are similar in purpose and structure to the native feature blocks included in Control Builder, but have user-defined algorithms and data structures. CABs are developed using Visual Basic integrated into Control Builder. The C300 controller supports executing CABs in the Expert LX, greatly reducing the workload required to create complex control strategies that require a robust control environment provided by the C300.

Product Introduction

Overview

This document provides expertise ®  Technical information on the configuration of Series C I/O and C300 controllers, which will be released starting from the Expert R300 version.

Range

The Series C I/O products covered include various types such as digital inputs, digital outputs, analog inputs, analog outputs, low-level multiplexers, pulse inputs, and general-purpose input/output.

definition

IOTA (Input Output Termination Assembly): A component that accommodates IOM and on-site wiring connections.

IOM (Input Output Module): A device that contains most of the electronic devices required to perform specific I/O functions and can be plugged into IOTA.

Product Features

Innovative design: Supports enhanced thermal management and significantly reduces size compared to similar products.

Integrated design: I/O modules and field terminals are combined in the same area, without the need for separate chassis to accommodate electronic components.

Detachable terminals: Two levels of “detachable” terminals, convenient for factory installation and maintenance.

Power supply: Provide on-site power through IOTA, without the need for additional power or manual wiring.

Redundancy support: Implement redundancy directly on IOTA without the need for external wiring or redundant control devices.

Installation design: Vertical installation facilitates wiring; The “information circle” provides quick visual prompts; The “tilted” design effectively manages the heat inside the cabinet.

Circuit protection: The input and output circuits have short-circuit protection, eliminating the need for circuit fuses and reducing installation and maintenance costs.

Series C I/O selection and size

Selection advantages

In almost all configurations, the C300 controller and Series C I/O provide practical and maintainable process equipment connections in a smaller space, helping to reduce overall installation costs.

MODULE SIZE

Simulation modules typically have 16 points, with 6-inch (152mm) IOTA used for non redundant applications and 12 inch (304mm) IOTA used for redundant applications.

The discrete module has 32 points, with 9-inch (228mm) IOTA used for non redundant applications and 12 inch (304mm) IOTA used for redundant applications.

I/O module functionality

Including various functional modules such as high-level analog input/with HART input, high-level analog input/without HART, analog output/with HART output, etc., each module has different functions and characteristics.

Specific module specifications

Analog Input Module

CC-PAIH01/02 (with HART): Supports high-level current or voltage input, 16 channels, multiple input ranges, and features extensive self diagnosis and optional redundancy.

CC-PAIH51 (with HART): accepts high-level current input from transmitters and sensing devices, 16 channels, supports only 4-20mA input.

CC-PAIX01/02 (without HART): Similar in function to CC-PAIH01/02, but does not support HART.

CC-PAIN01 (without HART): accepts high-level current input from sensing devices, with 16 channels.

Low level analog (temperature) input module

CC-PAIM01 (LLMUX): Supports up to 64 channels of temperature input, uses Honeywell PMIO LLMUX FTA, supports thermocouple (TC) and thermistor (RTD) inputs.

CC-PAIL51: Supports up to 16 channels of temperature input, each channel can be configured as a thermocouple or thermistor input, without the need for an external Process Manager FTA.

Pulse input module (CC-PPIX01)

Provide the ability to monitor various pulse input field values for the Expert C300 controller, support the “quick cut-off” function, suitable for metering and trade handover applications, with 8 input channels and 2 output channels.

Analog output module

CC-PAOH01 (with HART): Provides high-level constant current to actuators and recording/indicating devices, with 16 output channels and multiple features.

CC-PAOH51 (with HART): Similar in function to CC-PAOH01, supports HART status and configuration.

CC-PAOX01 (without HART): Provides standard 4-20mA DC output with 16 channels.

CC-PAON01 (without HART): Similar in function to CC-PAOX01.

Digital Input Module

CC-PDIL01 (24VDC): accepts 24VDC signals as discrete inputs, with 32 channels and multiple features.

CC-PDIL51 (24VDC): Similar in function to CC-PDIL01, without open circuit detection.

CC-PBIS01 (Event Sequence): accepts 24VDC discrete signals, can be time stamped to support event sequences with 1ms resolution, and has 32 channels.

CC-PDIH01 (high voltage): accepts signals such as 120VAC/125VDC, 220VAC as discrete inputs, with 32 channels.

Digital Output Module

CC-PDOB01 (Bus based 24VDC): Provides reliable 24V digital output signals, 32 channels, and multiple features.

Relay IOTA (using CC-PDOB01 IOM): Provides dry contacts for isolated low voltage/low current or high voltage/high current discrete output applications, with 32 output channels.

CC-PDOD51 (drain type 24VDC): switchable reliable 24V digital output signal, 32 channels.

Universal Input/Output Module

CC-PUIO01: Interface with field devices for analog input, analog output, digital input, and digital output, with 32 channels, each channel can be configured for multiple types.

CC-PUIO31: Similar in functionality to CC-PUIO01, it supports more features such as event sequences.

Functional matrix

Provides a table to assist in selecting I/O modules and IOTA with similar functional characteristics, including AI, AO, DI, DO function matrices, to facilitate users in selecting suitable modules and IOTA based on their needs.

Brand background

Honeywell is a Fortune Global 500 high-tech enterprise with businesses covering aviation, building and industrial control technology, specialty materials, and the Internet of Things. In China, all four of its major business groups have settled down, with Shanghai as the Asia Pacific headquarters and over 50 wholly-owned and joint ventures in more than 30 cities, employing approximately 11000 people, of whom 20% are research and development personnel.

Honeywell Intelligent Building Technologies (BA) has over 30000 employees worldwide, with products, software, and technology applied to more than 10 million buildings worldwide. Its business units include building automation, fire protection, security, intelligent living solutions, and building intelligent systems.

WIN-PAK access control system

System Overview

The WIN-PAK access control system has complete functions, high cost-effectiveness and reliability, and is widely used in government, government agencies, banks, residential areas and other fields, meeting the needs of small and medium-sized projects with high security performance requirements and relatively complex applications. It has high reliability and is used by hundreds of thousands of users worldwide; Easy to use, with features such as quick launch guide, electronic map, and dynamic icons; Powerful functionality, supporting unlimited number of cardholders and doors, compatible with multiple controllers.

The system adopts a unified interface, which can integrate and manage functions such as access control, video surveillance, and anti-theft alarm. It provides an intuitive browser based interface that can perform common access control operations from almost anywhere. It can also be easily extended from a single site to a multi regional enterprise level solution, supporting the integration of multiple biometric technologies, and has API interfaces for customized integration.

Specification parameters

Different versions of WIN-PAK access control management software have differences in web browser support, system workstation/user count, anti-theft alarm integration, video integration, account/sub account, Suprema biometric, attendance (web module), API interface integration, and other aspects.

The system supports multiple access control systems, video systems, and alarm systems, and is compatible with operating systems SQL、 Browsers, VMWARE, etc. have specific requirements, support multiple languages, and have software support agreements (SSAs) to provide different levels of services.

The access controller

PRO4000 intelligent access control controller: suitable for medium to large entrance and exit management solutions, equipped with WIN-PAK access control platform, using 32-bit CPU structure and embedded Linux operating system. Cardholder and event data are stored in onboard flash memory and can be saved for a long time after power failure. Provide complete logic for multiple doors, support offline operation, can be connected to the main computer through TCP/IP network, supports both full network architecture and master-slave architecture for door management expansion, supports passive and active electric lock control methods, provides pre installed access control chassis, and has two door control controller models to choose from.

PRO42 modular access control controller: connected to WIN-PAK integrated security management server through network, providing various advanced functions. The PRO42IC intelligent controller supports hanging multiple input/output or card reading modules. The PRO42R2/PRO42R2B dual card reader module supports bidirectional encrypted OSDP communication protocol and Wiegand card reader interface. The PRO42OUT and PRO42IN provide multiple relay outputs and monitored alarm inputs, respectively, and have multiple chassis suitable for different installation methods.

Fingerprint scanner and card reader

The JT-MCR series intelligent card reader can enhance the flexibility, scalability, and security of access control systems. It can read multiple standard smart cards, and different models have different specifications in terms of maximum card reading distance, working frequency, supported ISO standards, card reading content, keyboard signal output, working temperature, working humidity, power supply, output interface, certification, size, weight, and other aspects.

Intelligent Quick Pass Door Series

HASE-1000 indoor/outdoor wing gate: equipped with 16 pairs of high-density infrared precise detection of traffic status, LED lights indicating direction for entry and exit, safety anti pinch and other functions, widely used in various places. There are different models of side roads and middle roads, with rich supporting accessories and detailed parameters in terms of structure, specifications, etc.

HASE-2000 Indoor Double Swing Lock: With 20 pairs of high-density infrared detection, LED light indication for entry and exit, safety anti pinch and anti impact functions, it has a wide range of application scenarios, including side and middle channels, various supporting accessories, and clear structural and specification parameters.

Electromagnetic lock and accessories

The HL series electromagnetic lock products come in various specifications to meet the installation needs of different door types, and there are also multiple waterproof models suitable for outdoor environments. Including magnetic locks with different tensile strengths such as 300 pounds, 600 pounds, 1200 pounds, and 1500 pounds, as well as anode locks, cathode locks, and various installation brackets, switch buttons, emergency release buttons, and other accessories. Each product has detailed specifications and ordering information.

HOCP One Card System

System Overview

The HOCP series is a Honeywell one card management system, which includes various functions such as basic platform, access control, attendance management, consumption system, visitor management, etc. It realizes universal use of one card and is widely used in various places. It seamlessly integrates with the WIN-PAK access control management system, integrating security and flexibility.

The HOCP one card server uses Linux operating system, pre installed database and platform software, supports web and desktop clients, and can be extended through server cascading.

FUNCTION

The basic platform includes holiday management, personnel information management, electronic maps, operator management, log management, etc; The access control module integrates the WIN-PAK access control system; Visitor management has a complete process; Attendance management supports multiple attendance methods and related configurations; Consumer management is a system that combines online and offline methods; Ladder control management supports two deployment methods; Patrol management supports multiple patrol methods and task formulation; Parking management supports multi site management, entrance and exit control management, parking space detection, parking guidance, reverse car search, etc. The platform has clear device access restrictions and also supports various other functions and API interfaces.

Related equipment

This includes various devices such as the HOCP-BPSVR one card server, HOCP-BPMRW IC card issuer, HARB-FR6700 7-inch facial recognition all-in-one machine, HARB-FR3400 4-inch facial recognition all-in-one machine, HARB-FP2000 fingerprint recognition machine, HOCP-VSPIM person card comparison visitor machine, etc. Each device has its own functional characteristics, specification parameters, and ordering information.

Basic information

Product Name: Sieger System 57 Modbus Interface Module Kit

Model: RS422/485 (05701-A-0312), RS232 (05701-A-0313)

Document Number: MAN0502.PM6 Issue 04 October 99 05701M5006

Manufacturer: Honeywell (formerly Zellweger Analytics Limited)

Safety Warning and Precautions

Warn

This device is not designed or certified for use in hazardous areas.

Suitable for indoor use only.

Avoid exposure to rain or moisture.

Precautions

Only use components and accessories approved by the System 57 control system.

To maintain safety standards, qualified personnel must regularly maintain, calibrate, and operate the System 57 control system.

Important Statement

Zellweger Analytics Limited shall not be liable for any failure to install and/or use the equipment in accordance with the corresponding version and revision of this manual.

The user of the manual should ensure that its content is completely consistent with the equipment to be installed and/or operated. If there are any questions, they should contact the company for consultation.

The company reserves the right to modify the information in this document without notifying any individual or organization.

Glossary

A1: Low or warning alarm level.

A2: Second warning alarm level.

A3: High or primary warning level.

LED: Light Emitting Diode.

LTEL: Long term exposure limit (8-hour time weighted average).

RFI: Radio Frequency Interference.

RH: Relative humidity.

STEL: Short term exposure limit (10 minute time weighted average).

TWA: Time weighted average.

Main functions and overview

Function: Provides digital communication between the System 57 control system and external computer systems, supports reading configuration, alarm status, and executing calibration programs.

Compatibility: Compatible with 5701, 5704, and 5704F control cards.

Communication standards: Supports RS485, RS422, and RS232 electrical standards.

Protocol: Operates as a Modbus RTU and supports the 02, 03, 04, 06, and 16 functions of the Modbus protocol.

Data isolation: The data signal is isolated from the System 57 power supply.

Configuration flexibility: Asynchronous serial links can be configured with baud rate, parity, and stop bits.

Way of working

System 57, as a Modbus Remote Terminal Unit (RTU), only transmits data in response to requests from the master device.

The host system (usually a PLC, DCS, or SCADA graphic package) serves as the main device to control the operation of the communication system.

Installation instructions

Preparation before installation

Confirm the type of engineering card, Modbus interface kit can only be installed on Mk 2 engineering cards.

Unpack and inspect the contents of the kit to ensure completeness and no transportation damage.

Installation steps

Cut off all power to the System 57 rack.

Remove the engineering card, insert the software upgrade EPROM integrated circuit into the IC2 socket of the engineering card, and insert the RAM expansion integrated circuit into the IC12 socket.

Replace the short-circuit link LK1 of the engineering card.

For RS485/422 modules, set the terminal resistance as needed.

Insert the Modbus interface module into the J1 and J2 sockets of the engineering card and reinstall the engineering card.

On site connection

RS485/422 interface: Connect through the auxiliary terminal block TB2 on the DC input card, use shielded twisted pair cable, pay attention to correctly terminating the transmission line, and avoid signal interference.

RS232 interface: also connected through TB2 of DC input card, using high-quality multi-core shielded cable, following the connection specifications of RS232 standard.

Configure Modbus functionality

Host configuration

It is recommended to configure the host to retry at least twice when communication frames are lost.

System 57 configuration

Communication parameters: configurable modes (RS422, RS485, RS232), baud rate, stop bit, parity check, etc.

Address setting: Each rack needs to specify a unique Modbus master address, and when using RS485 half duplex communication and enabling the secondary bus, a secondary address also needs to be set.

Debugging and Maintenance Instructions

Start program

Ensure that the system power is turned off, reconnect the power, and verify that the LED on the front panel of the engineering card flashes normally and the green POWER ON indicator light remains on.

After the power on suppression time, ensure that the gas detection system operates normally.

Turn on the host system and initiate Modbus master operation.

Simulate alarm conditions, check if the host can correctly detect and take corresponding actions, repeat the test and clear the simulated alarm.

maintenance

The Modbus interface functionality should be regularly tested according to the maintenance procedures in the control system user manual.

Operating instructions

Mainly used to connect gas detection systems to factory control systems, providing centralized monitoring of system status, usually with graphical displays.

The host system needs to be programmed to interpret the signals and status data provided by the System 57 control system.

It is recommended that the host system be programmed to use Function 02 to collect alarm and status data from all channels. If the alarm function needs to be reset, Function 06 or 16 should also be implemented.

Modbus Function Reference

Supported Features

Function 02: Read input status, can read channel status bits, each sub channel has 11 status bits.

Function 03: Read the hold register. The host can read the contents of the hold register and can read up to 35 registers per frame.

Function 04: Read input registers, with two types of input registers: analog signal value and animation value. A maximum of 64 registers can be read per frame.

Function 06: Preset a single hold register.

Function 16: Preset multiple hold registers, up to 35 registers can be set per frame.

Specification parameters

Environmental parameters

Working temperature: -5 ° C to+55 ° C.

Storage temperature: -25 ° C to+55 ° C.

Humidity: 0 to 90% RH (non condensing).

EMC/RFI compliance

Compliant with EN50081 Part 1 and Part 2 (EMC/RFI Generic Emission) and EN50082 Part 1 and Part 2 (EMC/RFI Generic Immunity).

Serial communication

Format: Asynchronous serial data.

Data bit: 8.

Speed: 19200, 9600, 4800, 2400 baud.

Stop position: 1 or 2.

Parity check: odd, even, or none.

Mode: Half duplex.

Modbus protocol

Mode: RTU.

Supported functions: 02, 03, 04, 06, and 16.

RS485/422 interface module

Power supply: Powered by the engineering card.

Power consumption: maximum 1.5W.

Weight: 30g.

On site terminal: 2.5mm ² (14 AWG), located on the DC input card.

Cable type: It is recommended to use shielded twisted pair cables with separate grounding wires.

Input/Output: Two RS485 transceivers (Channel 1, Channel 2).

Working mode: single RS485 highway, dual RS485 highway (primary and secondary) RS422 highway。

Multi node capability: up to 31 nodes (RS485) or up to 10 nodes (RS422).

Maximum cable length: 1200m (3900ft).

Maximum data rate: 19.2k baud.

RS232 module

Power supply: Powered by the engineering card.

Power consumption: Maximum 0.75W.

Weight: 30g.

On site terminal: 2.5mm ² (14 AWG), located on the DC input card.

Cable type: It is recommended to use shielded multi-core wires.

Input/Output: Two data sets (RXD, TXD) and two handshakes (DTR, DSR).

Maximum cable length: 15m (49ft).

Maximum data rate: 9600 bits per second.

Product specifications

Normal operating voltage: 15 to 32 VDC

Maximum current consumption: 6.5 mA (when LED lights up)

Average working current: directly polling 230 μ A; Group polling 255 μ A

Terminal Resistance (EOL): Not used

Temperature range: 32 ° F to 120 ° F (0 ° C to 49 ° C)

Humidity: 10% to 93%, non condensing

Size: 4.5 inches high x 4 inches wide x 1.25 inches deep (can be installed on a box measuring 4 inches square and 2.125 inches deep)

Accessories: SMB500 Electrical Box

Product overview

Purpose: Suitable for intelligent two-wire systems, each module’s independent address can be selected through a built-in rotary switch, allowing compatible control panels to switch discrete contacts through code commands.

Structure: Contains two sets of isolated Form-C contacts, used as DPDT switches, with rated values in accordance with the table in the manual; The module does not monitor the circuit connections of relay contacts; The module also has an LED indicator controlled by a panel.

Compatibility requirements

Need to connect to a compatible Silent Knight system control panel (specific list can be obtained from Silent Knight).

Preparation before installation

This information is only for a quick reference installation guide. For detailed system information, please refer to the corresponding Silent Knight control panel installation manual.

To install modules in existing operating systems, operators and local authorities need to be notified that the system will be temporarily suspended.

Disconnect the power supply of the control panel before installing the module.

This manual should be left to the owner/user of this device.

Installation method

SK Relay is directly installed on a 4-inch square electrical box (see Figure 2A), and the minimum depth of the box must be 2 inches.

Silent Knight provides surface mounted electrical boxes (SMB500).

Wiring requirements

All wiring must comply with applicable local codes, regulations, and laws.

When using control modules in non power limiting applications, CB500 module barriers must be used to meet UL’s requirements for power limiting and non power limiting terminal and wiring separation. The barrier must be inserted into a junction box, and the control module must be placed in the barrier and connected to the junction box (Figure 2A). The power limiting wiring must be placed in the isolation quadrant of the module barrier (Figure 2B).

Install module wiring according to the engineering drawings and corresponding wiring diagrams.

Set the address on the module according to the engineering drawing.

Fix the module to the electrical box as shown in Figure 2A (provided by the installer).

Warning message

All relay switch contacts are in standby state (open) at the factory, but may have been switched to active state (closed) during transportation. To ensure that the switch contacts are in the correct state, the module must communicate with the panel before connecting the circuit controlled by the module.

Product basic information

The manual begins by introducing the basic overview of the Ndrive HL series digital servo drive, including the product’s functional positioning as a high-performance discrete drive option for the Automation 3200 motion system. It can drive various types of motors (brushless motor, brushed DC motor, and stepper motor) and perform current loop and servo loop closure to ensure positioning performance and speed stability. At the same time, basic information such as the version of the manual (Revision: 1.08b), release date (October 31, 2007), and related product number (P/N EDU176) were clarified.

System installation and configuration

This section is an important component of the manual, detailing the specific steps and requirements for product installation and configuration. Including safety operating procedures, emphasizing precautions such as preventing electric shock and mechanical injury that must be followed during installation; The power connection method explains the wiring method, required wire specifications, and related protective measures for the motor power supply and control power supply (- AUXPWR option); Detailed wiring diagrams and phase adjustment methods are provided for different types of motors such as brushed DC motors, brushless motors, and stepper motors, including motor and feedback connections; Encoder feedback connection, introducing the phase adjustment and signal wiring of the encoder; And network configuration related content such as communication channel settings and multi drive connections.

Technical Details Explanation

Deeply analyzed the technical details of the Ndrive HL series products. Covering the pin allocation and functionality of the auxiliary I/O interface (J205), including analog input/output, digital input/output, and secondary encoder channels; Position synchronization output (PSO)/laser triggering function, explaining the working principle, triggering method, supported number of axes, and related parameter configuration of PSO; The pin definition of the motor feedback interface (J207) involves encoder signals, Hall effect signals, limit switch signals, etc; Communication protocol and pin allocation between RS-232/RS-422 ports and FireWire bus; It also includes parameter settings, hardware configuration, and fault handling for voltage current mode operation.

Optional Features and Accessories

Introduced the optional options and related accessories of the product. The optional options include – IOPSO and – IOPSOH expansion boards, – DUALPSO and – TRIPLEPSO laser triggering options, – ENET (Ethernet) options, – RDP rotary transformer input options, etc. The functions, hardware composition, and configuration methods of each option are described in detail. The attachment section lists the models, descriptions, and applicable scenarios of standard interconnect cables, as well as the connection methods for joystick and handwheel interfaces.

Troubleshooting and Maintenance

Provided diagnosis and solutions for common faults, listed in table form the possible causes and countermeasures for faults such as motor loss of control, amplifier alarm, overcurrent, overtemperature, etc; Introduced the testing points, jumper settings, and fuse information for key components such as the control board, motor power board, and power supply board; Explained the meaning of LED indicator lights, helping users determine the operating status of the device through the status of the indicator lights; It also includes recommendations for preventive maintenance, such as regularly checking cable connections, cleaning equipment, etc.

Product Overview

Functional Features

Suitable for brushless motors, brushed DC motors, and stepper motors, supporting full digital control of current loop, speed loop, and position loop, with a sampling rate of up to 20kHz.

Equipped with flexible redundancy design, supporting simplex, duplex, and triple module redundancy (TMR) systems, different levels of redundancy can be selected according to application requirements.

Provide rich I/O interfaces, including analog input/output, digital input/output, encoder feedback interface, etc., supporting high-speed user input (with a delay of about 50 nanoseconds).

Supports Position Synchronized Output (PSO)/laser triggering function, with a single axis triggering delay of 200 nanoseconds and a dual/three-axis triggering delay of 275 nanoseconds, enabling high-precision synchronous control.

Adopting IEEE-1394 (FireWire) ®） Communication bus, with a data transmission rate of 400Mbps, supports multi drive networking control, and can connect up to 32 axes.

Model and specifications

It includes three models: Ndrive HP10, HP20, and HP30, with peak output currents of 10A, 20A, and 30A respectively, and continuous output currents of 5A, 10A, and 15A respectively.

The power input supports single-phase or three-phase AC, with a voltage range of 85-240VAC, a frequency of 50/60Hz, and a bus voltage range of 100-320VDC (optional 40-80VDC).

The working environment temperature is 0-50 ° C, the storage temperature is -20-70 ° C, the humidity is 5-95% (non condensing), and the highest altitude is 2000 meters.

Installation and Configuration

Safety regulations: Emphasize electrical safety during installation, including precautions such as power-off operation, electric shock prevention, and mechanical injury prevention. Use cables and connectors that meet specifications.

Wiring and Grounding: Provide detailed instructions on the methods of power wiring (main power supply, control power supply), motor wiring, and feedback wiring (encoder, Hall sensor, etc.), emphasizing shielding and grounding techniques to reduce electromagnetic interference (EMI).

Motor configuration: Supports wiring and phase adjustment for brushed DC motors (torque mode, with speed feedback), brushless motors (Hall effect feedback, encoder feedback), and stepper motors, providing steps and methods for determining motor phase.

Communication settings: Set the communication channel number (1-32) of the drive through switch S2, supporting Daisy Chain or star topology of FireWire bus, and can connect up to 16 drives.

Technical Details

Auxiliary I/O interface (J205): Provides 4 optical isolated outputs, 6 optical isolated inputs (including 2 high-speed inputs), analog input/output, secondary encoder channels, supports RS-422 differential signals, and can be used for master-slave control or dual feedback systems.

Position Synchronization Output (PSO): Supports single axis, dual axis, and three-axis laser triggering, and can generate synchronization pulses based on encoder signals, external triggers, or software instructions. It has high triggering accuracy and is suitable for high-precision synchronization applications such as laser processing.

Motor feedback interface (J207): Supports differential line driven encoder, Hall effect sensor, limit switch, motor overheat thermistor input, encoder supports up to 8MHz signal (32MHz after fourth harmonic).

Communication interfaces: including RS-232/RS-422 (for firmware upgrade), FireWire (main communication bus), optional Ethernet interface (- ENET option), supporting ModBus TCP protocol.

Voltage current mode: supports independent operation mode, controls motor current through analog input (± 10V), suitable for use with external controllers, requires configuration of relevant parameters and saving to flash memory.

Optional Features

-IOPSO and – IOPSOH Options Board: Extended I/O interfaces, including 8 optically isolated inputs/outputs, 2 18 bit analog outputs, 2 16 bit differential analog inputs, SSI network interfaces, absolute encoder interfaces, and brake relays. – IOPSOH supports higher output currents (1A/channel).

-DUALPSO and TRIPLEPSO options: Supports dual axis/three-axis laser triggering, requiring the transmission of encoder signals from other axes through SSI network or auxiliary encoder channels, with a maximum tracking rate of 5MHz.

-ENET option: Provides 10/100BASE-T Ethernet ports, supports ModBus TCP protocol, and is used to connect third-party I/O modules.

-RDP Rotary Transformer Input Options: Supports 1-2 ways of rotary transformer or induction synchronizer input, with optional carrier frequencies of 10kHz, 7.5kHz, and 5kHz. Phase and gain parameters need to be configured.

-MXH option: Encoder resolution multiplier, supporting up to x2048 multiplication (up to x8192 when combined with fourth harmonic), suitable for high-precision positioning, with a maximum input frequency of 200kHz.

Accessories and Troubleshooting

Standard cables: Provide models and specifications of motor cables, feedback cables, SSI network cables, etc., supporting different lengths and connector types.

Interface between joystick and handwheel: Instructions on how to connect single/dual axis joystick and handwheel for manual positioning, requiring calibration of analog input range.

Troubleshooting: List the causes and solutions of common faults (such as motor loss of control, driver alarm, overcurrent, overheating, etc.), provide information on the meaning of LED indicator lights, test point locations, fuse replacement, etc.

Preventive maintenance: It is recommended to check cable connections, cooling and ventilation, clean equipment every month to prevent liquids and conductive substances from entering the drive and ensure the normal operation of the equipment.

Series Overview

The Ndrive series digital servo drive is a high-performance discrete drive option for the Automation 3200 motion system, featuring the following features:

Driving capability: It can drive brushless motors, brushed DC motors, and stepper motors, execute current loop and servo loop closure, and ensure high-level positioning performance and speed stability.

Processing capability: Equipped with a high-performance digital signal processor (DSP), it can perform complex calculations in real-time. The sampling rate of the digital current loop and servo loop can reach 20kHz, and it can also handle digital and analog I/O, laser triggering, and encoder multiplication.

Network and Expansion: Some models (such as HP and HL) have optional dedicated Ethernet ports that can communicate with I/O modules from third-party vendors; Support on FireWire ®  Combine usage online and customize the system as needed.

General options: including onboard encoder multiplier, three-axis position synchronous output (PSO), brake relay, additional I/O, absolute encoder interface, and independent logic power input for “keep alive” operation.

Power input: HP, HL, CP, and CL models accept AC input power, while MP models accept DC input power.

Special model: HL is a linear power amplifier suitable for low noise and ultra-high performance applications, meeting high bandwidth requirements, with excellent linearity and no cross distortion; CP is a high-performance PWM amplifier designed for cost sensitive applications; CL is a high-performance linear amplifier designed for cost sensitive applications, while CP and CL retain complex control architectures but eliminate support for optional features; MP is the smallest amplifier in the series, suitable for applications with ultra compact space requirements.

Comparison of Parameters for Various Models

Model Current Output (Peak/Continuous) Power Input Amplifier Type Motor Type Basic I/O Additional I/O (Beyond Basic I/O) Multi axis PSO Supports Third Party I/O Ethernet Capability “Keep Active” Function

Ndrive HP 10-150A/5-75A 2 or 3-phase AC PWM with brushed, brushless, stepper 4-channel digital output/6-channel digital input, 1-channel analog output/1-channel analog input, 8-channel digital output/8-channel digital input, 1-channel analog output/1-channel analog input supports single axis, dual axis, and three-axis

Ndrive HL 10-20A/5-10A 2-phase AC linear brushed, brushless, stepper 4-channel digital output/6-channel digital input, 1-channel analog output/1-channel analog input, 8-channel digital output/8-channel digital input, 1-channel analog output/1-channel analog input supports single axis, dual axis, and three-axis

Ndrive CP 10-30A/5-15A 2-phase AC PWM with brushed, brushless, and stepper 4-channel digital output/6-channel digital input, 1-channel analog output/1-channel analog input 16 channel digital output/16 channel digital input, 1-channel analog output/1-channel analog input only supports single axis absence

Ndrive CL 10A/5A 2-phase AC linear brushed, brushless, stepper 4-channel digital output/6-channel digital input, 1-channel analog output/1-channel analog input 16 channel digital output/16 channel digital input, 1-channel analog output/1-channel analog input only supports single axis none

Ndrive MP 10A/5A DC PWM with brushed, brushless, and stepper (no clear basic I/O data) 8-way digital output/8-way digital input, 1-way analog output/1-way analog input only supports single axis without any input

Detailed specifications for each model

Ndrive HP: Output voltage 100-320VDC, PWM switching frequency 20kHz, operating temperature 0-50 ° C, supports 1-3 phase AC input (50-60Hz, 115-240VAC), encoder input frequency can reach 200kHz (with onboard multiplier) or 40MHz LTT square wave, current loop and servo loop update rates are 20kHz and 1-20kHz respectively, options include “keep active”/auxiliary power supply, brake output, position synchronization output, etc. Different sub models have differences in peak and continuous current, weight and other parameters.

Ndrive HL: Output voltage ± 40VDC or ± 80VDC, operating temperature 0-50 ° C, storage temperature -30-85 ° C, supports single-phase AC input (50-60Hz, 115-240VAC), encoder input frequency and other parameters are similar to HP, and optional options include “keep active”/logic power input, brake output, etc. The parameters vary among different sub models.

Ndrive CP, CL, and MP: The working temperature of CP and CL ranges from 0-50 ° C, with CP output voltage of 100-320VDC, CL output voltage of ± 40VDC, and MP output voltage of 10-80VDC. The input power supply, encoder input frequency, update rate, and other parameters vary, and the available options also vary depending on the model.

Components and Dimensions

Each model has its own specific component configuration, such as the HP series including FireWire interface, Resolver interface (optional), power supply, and other components; The HL, CP, CL, and MP series also have corresponding components. At the same time, the document also provides detailed size parameters (including millimeters and inches) for each model and different configurations.

Displacement Measuring Interferometry improves positioning accuracy.  Zygo’s ZMI 2000 is the industry’s top performing Displacement Measuring Interferometer (DMI) System offering the highest resolution, the highest velocity, and lowest data age uncertainty for real time position control.  Zygo, a world-class interfero metric metrology company, supports you at all levels of design, engineering and manufacturing.  Zygo works as an extension of your research, engineering and  manufacturing teams in providing metrology solutions.

Performance Benefits of the ZMI 2000

• Positioning accuracy – Velocity and time dependent errors are eliminated.  All axes of motion are synchronized to an uncertainty of ≤1.7 ns.

•Overlay accuracy – λ/2048 resolution(0.31 nm) with 2 pass interferometers for excellent overlay and alignment capability.

• System throughput – Slew rates of 2.1 m/s with 2 pass interferometers enabled by the 20

MHz heterodyne split frequency

ZMI 2000 Systems are found in the most demanding feedback control applications:

• Lithography tools: optical steppers and scanners,e-beam and laser mask writers.

•Mask, wafer and LCD inspection and measurement tools, CD-SEM’s.

• Process equipment, memory repair tools.

Integration Benefits of the ZMI 2000 for real-time position control

•Reduce heat, cost and ESD sensitivity, improved electrical isolation, and minimal package size

Fiber optic cables are used on both the reference and measurement legs.

•Reduce cost in backplane space requirements

The ZMI 2002 offers two axes of interferometry on a single 6U VME board.

•Reduced design costs with simplified integration time – The measurement boards are fully programmable through the interface bus (VME or ISA), or the P2 interface.

•Reduced cost of integration – Standard hardware interfaces for up to 7.7 MHz P2 data rates for up to 16 axes.  Easily expanded to accommodate more axes at the same rates.

The ZMI 2000 as a Metrology System Unparalleled performance and flexibility.  All of the performance benefits of the ZMI 2000 with the following integration options:

• ZMI Systems Chassis with PCI-VME for processor speed real-time data,

• ZMI Systems Chassis with serial or GPIB interface for more cost effective solutions,

• ZMI PC for integration into an ISA slot.

ZMI 2000 Systems are in use in Standards Labs worldwide for applications in measurement and calibration of high resolution and high frequency mechanical motions:

• Piezo transducer calibration,

• Linear Scale calibration,

• Rotary Scale calibration,

• AFM stage calibration.

The ZMI 2000 System Laser Head

The laser source may be the single most critical component of the Displacement Measuring Interferometer.  To control and assure laser head quality, Zygo manufactures our own laser tubes.

The proprietary tube design, combined with a state-of-the-art assembly and test facility, provides for a highly reliable laser head with:

• > 50,000 hour lifetime,

• Longest basic warranty at 18 months,

• Extended warranties of up to 5 years,

• Up to 8 axes of interferometry on a single head,

• Multiple head synchronization.

ZMI 2000 System Integration Features

• Optical power monitor for the laser head output,

and measurement board input.

• Built in laser head diagnostics.

• Position, time, and velocity, all available independently on the P2, or VMEbus.

• Programmable synchronization signal.

• Measurement boards can be used in any standard 6U VME or ISA backplane.

The ZMI 2000 System technology combined with our world-class opto-mechanical design and manufacturing center in Middlefield, CT makes Zygo Corporation a key partner in the successful design, manufacture, and integration of your real-time position control systems.