RSD-CI2-Ex8 is an 8-channel analog input module launched by Pepperl+Fuchs, which focuses on signal acquisition and safety isolation in hazardous areas. It is suitable for 2-wire transmitter power supply and current signal transmission in industrial scenarios, with high safety, stability, and flexible functional configuration.
Core Features and Functions
Channel and signal support
8 independent channels, compatible with two input types: 2-wire transmitter (4-22mA) and current source (0-22mA).
To provide power supply for transmitters in hazardous areas, the available voltage at the transmitter end under 20mA current is not less than 15.5V, meeting the requirements of most industrial transmitters.
Adaptability to hazardous areas
Installation environment: Supports Zone 1, Zone 2 (gas hazardous area), and Zone 22 (dust hazardous area).
Explosion proof protection: Complies with multiple explosion-proof standards (EN 60079-0/11/26, etc.), protection type EEx ia/ib IIB/IIC, temperature level T4, and needs to be used in conjunction with a dedicated intrinsic safety power supply (RSD2-PSD2-Ex4.34 or RSA6-PSD-Ex4.34).
Hot swappable function: It can replace modules with electricity in Zone 1 hazardous areas without power outage, improving operation and maintenance efficiency.
Signal Processing and Protection
Signal isolation: Implement safe electrical isolation between input, bus, and power supply (EN 60079-11 standard), with a peak isolation voltage of 60V, to avoid interference and fault propagation.
Filtering and accuracy: Built in 10Hz anti aliasing filter, with customizable filtering parameters; 16 bit resolution, with a deviation of only 0.1% in the input signal range at 25 ℃, and a temperature drift coefficient of 0.0025%/K, ensuring measurement accuracy.
Fault monitoring: Each channel has the function of monitoring disconnection (LB, triggered by current ≤ 3.6mA) and short circuit (SC, triggered by voltage ≤ 4V). When a fault occurs, the corresponding channel’s LED flashes red and is fed back to the control system through the internal bus.
Technical parameters
1. Power supply and bus
Category parameter details
Power supply connection terminals 34 and 50 (V+); 35, 51 (V -)
Rated voltage 8.88-9.5V
Power loss of 5.2W; Power consumption 8.5W
Internal bus backplane bus, manufacturer customized interface, cycle time 1.6ms
2. Input characteristics
Parameter values
Input resistance 22 Ω
Step response of 60ms (0-90% measured value, under minimum filtering setting)
Working temperature -20-70 ℃ (253-343K); Storage temperature -20-100 ℃ (253-373K)
Relative humidity 95% (no condensation)
Anti disturbance impact 15g (11ms), vibration 2g (10-500Hz, IEC 60068-2-6)
Protection level IP20 (module itself), on-site installation requires at least IP54 rated enclosure
Mechanical installation DIN rail installation, weighing approximately 250g; wiring terminals support a maximum wire diameter of 2.5mm ²
Installation and usage precautions
Wiring and protection: Shielded power lines and channel signal lines are required to meet EMC (NAMUR NE 21 standard) requirements, with wire insulation strength ≥ 500V; input channels share the negative terminal (common terminal), and polarity should be noted when wiring.
Certification and Compliance: Compliance with EC Type Examination Certificate (DMT 98 ATEX E 017 X) and Declaration of Conformity is required. Relevant documents can be found on the official website of Beijiafu.
Alarm configuration: Supports alarm functions such as over range, under range, and disconnection. The alarm display of each channel can be independently configured to meet the fault response requirements of different scenarios.
The Approximately Nevada 3500/50M tachometer module is a dual channel module designed specifically for mechanical equipment condition monitoring. It can receive signals from proximity probes or magneto electric sensors, enabling real-time monitoring of shaft speed, rotor acceleration, and rotation direction. It triggers alarms through programmable alarm thresholds and is widely used in rotating machinery such as industrial turbines, generators, and compressors. It also supports providing conditioned Keyphasor signals to the 3500 rack backplane without the need for additional Keyphasor modules.
Core functions and positioning
1. Core monitoring capability
The module supports four types of monitoring configuration schemes, which can be flexibly selected according to the scenario, covering key parameters such as speed, acceleration, and direction:
Option 1: Speed monitoring, threshold alarm, and speed bandwidth alarm for devices that need to monitor the range of speed fluctuations (such as generators)
Scenario 2: Speed monitoring, threshold alarm, and zero speed notification require determining the start/stop status of the equipment (such as compressor start/stop confirmation)
Plan 3: Equipment for speed monitoring, threshold alarm, and rotor acceleration alarm to prevent sudden increase/decrease in speed (such as turbine overspeed acceleration prevention)
Option 4: Speed monitoring, threshold alarm, and reverse rotation notification for devices that prohibit reverse rotation (such as pump type mechanical anti reverse protection)
2. Featured Features
Keyphasor signal sharing: It can be configured to output conditioned Keyphasor signals to the 3500 rack backplane for use by other monitoring modules (such as vibration monitoring modules), reducing the number of modules in the rack.
Peak holding: Automatically stores the highest forward speed, highest reverse speed, and number of reversals during device operation. The peak can be manually reset for easy fault tracing.
Flexible alarm configuration: Supports two-level alarms (Alarm 1/Alarm 2), and the alarm threshold and delay time can be set by software to avoid false alarms (such as short-term speed fluctuations not triggering alarms).
Technical parameters
1. Input parameters
The module is compatible with two types of sensors, and attention should be paid to the usage restrictions of magneto electric sensors (see “Safety Warning”):
Parameters, specifications, and notes
The input signal source is close to the probe (recommended), and the magneto electric sensor does not support reverse monitoring or zero speed monitoring (the signal edge is unclear at low speeds, making it easy to misjudge)
The input signal range is+10.0V~-24.0V. If the signal exceeds the range, it is limited internally by the module to avoid damage
Input impedance standard: 20k Ω; TMR (Triple Modular Redundancy): 40k Ω; Built in isolation barrier: 7.15k Ω, suitable for different system requirements with different configurations
Minimum input frequency close to the probe: 0.0167Hz (1rpm, 1 pulse/rev); Magnetic electric sensor: 3.3Hz magnetic electric sensor does not support low-speed monitoring
The maximum input frequency of 20kHz corresponds to a maximum speed of 99999rpm (matching the number of pulses per revolution)
Number of pulses per revolution, rotor acceleration/zero speed channel: 1-255 pulses per revolution; Other channels: 0.0039~255 pulses per revolution, suitable for speed measuring gears with different numbers of teeth
2. Output parameters
Covering status indication, signal buffering, recording output, etc., to meet monitoring and data recording requirements:
Output type, specification, and function
Front panel LED OK (normal operation), TX/RX (rack communication), Bypass (bypass mode) intuitively judge the working status of the module
Buffer sensor output with 1 coaxial connector per channel (short circuit, ESD protection) for sensor signal multiplexing (such as simultaneous access to oscilloscope debugging)
The sensor power supply is 24VDC, with a maximum of 40mA per channel to provide power for the proximity probe
The recorder outputs a current signal proportional to the full range, with a resolution of 0.3662 µ A/bit, used for data recording and trend chart drawing. Short circuits do not affect module operation
Current output voltage range 0~+12VDC, load resistance 0~600 Ω, suitable for most industrial recorders
Output update rate of approximately 100ms to ensure real-time performance while avoiding data redundancy
Prohibited as an overspeed protection system: The module does not have redundant protection and sufficient response speed, and cannot be used alone or as a component for speed control systems or overspeed protection systems (such as turbine overspeed shutdown); Analog output is only used for data recording, plotting, or display, and alarms are only used for alarm notification and do not have safety interlock function.
Limitations of magnetic electric sensors: Magnetic electric sensors cannot be used for reverse rotation monitoring and zero speed monitoring. At low speeds, the sensor output signal has no clear edges, which can cause misjudgment of the rotation direction.
Installation in hazardous areas: I/O modules with isolation barriers must be installed according to the specified drawings (138547, 149243/149244) to ensure compliance with hazardous area certification requirements and avoid safety risks.
2. Compliance certification
The module complies with multiple international standards and is suitable for industrial scenarios in different regions around the world
Certification category, compliance standards/directives, scope of application
EMC (Electromagnetic Compatibility) EU EMC Directive 2014/30/EU; EN 61000-6-2 (Industrial Immunity), EN 61000-6-4 (Industrial Emissions) European and globally recognized EMC standards regions
Electrical Safety EU Low Voltage Directive 2014/35/EU; EN 61010-1 Electrical Safety Requirements for Industrial Environments
Environmental Protection EU RoHS Directive 2011/65/EU restricts the use of hazardous substances
Maritime certification DNV GL classification society rules (ships, offshore platforms); ABS Classification Society Rules (Steel Ships, Marine Structures) for Maritime Ships, Marine Platform Equipment
Hazardous Area Certification cNRTLus: Class I, Division 2 (Groups A-D, T4); ATEX/IECEx: II 3G (Ex nA nC ic IIC T4 Gc) explosive environment (such as petrochemical workshops)
Configuration and ordering information
1. Configuration requirements
The specified version of firmware and software must be used to ensure compatibility between the module and the 3500 system
3500/22M module firmware Revision 1.70 firmware for rack communication
3500/01 configuration software Version 4.20 is used for module parameter configuration (such as alarm threshold, sensor type)
3500/02 Data Collection Software Version 2.52 is used to collect module monitoring data
3500/03 Display Software Version 1.52 is used for local or remote display of monitoring data and alarms
Incompatible module 3500/20 (all versions) cannot be shared with 3500/20 module in the same rack
2. Ordering models and accessories
(1) Module model (3500/50-AA-BB)
AA (I/O module type): 01=I/O module with internal terminals; 02=I/O module with external terminal; 04=I/O module with built-in isolation barrier and internal terminals.
BB (hazardous area certification): 00=no certification; 01=cNRTLus certification (Class I, Division 2); 02=ATEX/IECEx/CSA certification (Class I, Zone 2).
(2) Key accessories
Accessory type, model, description
External terminal block (ET Block) 125808-05 tachometer ET block (European connector)
128015-05 Tachometer ET Block (Terminal Block Connector)
128702-01 Recorder ET Block (European connector)
128710-01 Recorder ET Block (Terminal Block Connector)
Signal cable 135101-AAAA-BB tachometer signal to ET block cable (AAAA=length: 0005=5 feet/1.5 meters, 0010=10 feet/3.0 meters, etc.); BB=assembly status: 01=not assembled, 02=assembled)
129529-AAAA-BB recorder output to ET block cable (same specifications as signal cable)
Spare part 288062-02 3500/50M module complete machine
133442-01 I/O module with internal terminal
136703-01 Discrete I/O Module with Built in Isolation Barrier and Internal Termination
134938 3500/50M User Guide
Installation and usage precautions
Sensor selection: Reverse monitoring and zero speed monitoring must use proximity probes, and the use of magneto electric sensors is prohibited; During installation, ensure that the clearance between the proximity probe and the speed measuring gear meets the requirements (usually 0.25-1.0mm) to avoid weak or distorted signals.
Wiring specifications: I/O modules with external terminals require separate ordering of external terminal blocks and cables; Different types of I/O modules cannot be mixed (for example, internal and external terminal modules cannot be shared on the same channel).
Installation in hazardous areas: Modules with isolation barriers must be wired according to specified drawings (such as 138547) to ensure effective isolation barriers and avoid safety risks in explosive environments.
Peak reset: After equipment maintenance, it is necessary to manually reset the peak value to maintain data and avoid the influence of old peak values on fault diagnosis.
Software configuration: For the first use, the 3500/01 configuration software needs to be used to set parameters such as the number of pulses per revolution, alarm threshold, delay time, etc., to ensure that they match the actual operating parameters of the equipment (such as the number of teeth on the speed measuring gear).
Core function: Simultaneously achieve two major functions of speed control and load distribution – speed control maintains stable speed of the prime mover (engine/turbine), load distribution ensures proportional load sharing when multiple units are connected in parallel, avoiding single unit overload or uneven load.
Control mode:
Synchronous mode (Isochronous): suitable for single unit operation or multi unit isolated bus parallel connection, maintaining constant speed, requiring automatic power transmission (APTL), import and export control and other load adjustment accessories.
Droop mode: suitable for parallel connection of units to an infinite power grid or with non compatible governor units. The speed decreases with increasing load, and the droop rate can be adjusted through a potentiometer (formula:% droop=(no-load speed – full load speed)/no-load speed x 100).
2. Model and Key Parameters
(1) Model classification (9907 series)
The differences between different models are reflected in the actuator current, action direction, voltage level, and deceleration ramp function. The core parameters are shown in the table below:
Model actuator current action direction voltage level deceleration ramp
9907-020 0-200mA positive high voltage none
9907-021 0-200mA Reverse High Voltage None
9907-238 0-200mA positive low voltage none
9907-239 0-200mA Reverse Low Voltage None
9903-327 0-200mA Reverse Low Voltage None
Forward/Reverse Action: During forward action, the increase in actuator voltage corresponds to an increase in fuel/steam; When reversing the action, the decrease in voltage corresponds to an increase in fuel/steam (default to full fuel when power is off, compatible with mechanical backup governor).
Voltage level: Low voltage type (18-40VDC), high voltage type (90-150VDC or 88-132VAC), to be matched according to the system power supply.
(2) Key technical parameters
Speed range: Select four frequency ranges (500-1500Hz, 1000-3000Hz, 2000-6000Hz, 4000-12000Hz) through switch S1. The factory default is 2000-6000Hz, which needs to be matched based on the rated speed of the prime mover and the number of teeth on the speed measuring gear (formula: sensor frequency=number of teeth on the gear x speed (rpm)/60).
Actuators and sensors: support 0-200mA actuator output; Speed measurement requires the use of a magneto electric sensor (magnetic head), with a minimum signal requirement of 1.0Vrms (starting speed) and a maximum of 25Vrms (rated speed). The gap between the sensor and the gear should be controlled between 0.25-1.0mm.
Installation specifications and wiring
1. Installation environment and location requirements
Environmental conditions: working temperature -40-85 ℃ (-40-185 ℉), relative humidity 10% -95% (no condensation); Avoid direct contact with water, vibration sources, and strong electromagnetic interference equipment (such as high-voltage cabinets and high current cables).
Installation restrictions: It is prohibited to install directly on the engine; Reserved heat dissipation space is required (with a ventilation gap of ≥ 3cm and a distance of ≥ 15cm from heating components), and a vertical installation inclination angle of ≤± 45 ° (when there is no forced ventilation).
2. Electrical wiring and shielding requirements
(1) Core interface wiring
The controller terminals are concentrated on the front panel, and the key interfaces and wiring requirements are as follows:
Low voltage power input type (15-, 16+); High voltage type (0, 16) low voltage: 18-40VDC; High voltage: 90-150VDC/88-132VAC requires installation of XT-FIL-1/2 anti-interference filter (mandatory in maritime scenarios); Terminal creepage distance ≥ 6.5mm (compliant with the EU Low Voltage Directive)
Speed sensors 28 (signal+), 29 (signal -), and 27 (shielded) use shielded twisted pair cables. Only one end of the shielding layer is connected to terminal 27, and the other end is suspended with an insulation sensor gap of 0.25-1.0mm. The radial runout of the gear is ≤ 0.5mm
The output of the actuator is 20 (+), 21 (-), and 22 (shielding), and the shielding layer is only connected to terminal 22. It is forbidden to connect the actuator or other grounded actuators. The coil resistance is about 35 Ω, and open/short circuits need to be checked
Load sensor (CT/PT) CT (4-9), PT (1-3) CT secondary output 3-7A (rated 5A), PT secondary 100-120VAC/200-240VAC CT open circuit will generate high voltage, short circuit or power off before wiring
Load distribution lines 10 (+), 11 (-), and 12 (shielded) are shielded twisted pair cables. When multiple units are connected in parallel, the shielding layer is continuously connected without the need for additional relays. The controller is equipped with a built-in load distribution relay
(2) Shielding and anti-interference
All signal cables (speed measurement, actuator, load distribution lines) must use shielded twisted pair cables, with the shielding layer only grounded at the controller end (terminals 22, 27, 12) and the other end suspended to avoid the formation of ground current.
Strong current cables (power supply, CT/PT) should be wired separately from signal cables to avoid parallel laying; Severe electromagnetic interference scenarios require the use of metal conduits or double shielded cables.
3. Installation inspection process
Mechanical inspection: The actuator and the connecting rod of the prime mover are not loose/stuck, and the actuator lever does not touch the mechanical limit when the fuel is at its minimum position (to prevent the inability to stop the machine).
Wiring inspection: Check the power polarity, CT/PT phase, terminals are not loose, and the shielding layer is connected correctly according to the wiring diagram.
Sensor inspection: The gap between the magnetic head and the gear is 0.25-1.0mm, and there are no metal debris; Measure the sensor resistance (100-300 Ω) before powering on to determine if there is an open/short circuit.
Operation and debugging process
1. Initial settings before startup
All potentiometers must be pre-set according to the following requirements to avoid overload or overspeed during startup:
Initial setting function of potentiometer
Rated speed minimum (counterclockwise to the bottom) to avoid excessive speed during startup
Reset the middle position to adjust the speed and restore the speed
Speed stability when adjusting load changes in the middle position of gain (GAIN)
Ramp TIME (clockwise to the end) extends the acceleration time to prevent overspeed during startup
Low IDLE SPEED Maximum (clockwise to the bottom) ensures stable idle after starting
Adjust the load distribution ratio in the middle position of the load gain (LOAD GAIN)
DROOP Minimum (counterclockwise to the bottom) Initial default synchronization mode
Start Fuel Limit Maximum (clockwise to the bottom) to prevent excessive fuel smoke during startup
2. Startup and dynamic debugging
(1) Startup steps
Close the “rated speed” contact (terminal 19), close the droop contact (terminal 14), and set to synchronous mode.
Connect the power to the controller and calibrate the speed using a signal generator: Connect terminals 28-29, set the rated frequency, and slowly adjust the “rated speed” potentiometer to stabilize the actuator voltage at the intermediate value (not maximum/minimum).
Start the prime mover and observe if the speed is stable. If there is a rapid fluctuation (hunting), decrease the “gain” counterclockwise; If there is a slow fluctuation, increase the “reset” clockwise.
(2) Key parameter calibration
Low idle adjustment: Disconnect the “rated speed” contact (terminal 19) and adjust the “low idle” potentiometer counterclockwise to the recommended idle speed (higher than the fuel mechanical limit speed).
Load gain calibration: When a single unit is running synchronously, load to full load and adjust the “load gain” potentiometer to make the voltage between terminals 11 (-) and 13 (+) 6.0V (3.0V at half load, proportionally adjusted).
Sag adjustment:
Isolated load: Disconnect the droop contact, adjust the rated speed under no-load, and adjust the “droop” potentiometer to the target droop rate under full load (e.g. 5% droop corresponds to 60Hz no-load → 57Hz full load).
Grid parallel connection: calculate the full load frequency (rated frequency × (1+droop rate)), set the frequency at no-load, close the circuit breaker and then adjust “droop” and “load gain” to full load.
3. Parallel operation debugging
When multiple units are connected in parallel, the following conditions must be met:
All units have the same no-load speed (synchronous mode).
The load gain voltage is consistent (full load 6.0V).
CT/PT phase consistency: Ensure the CT wiring phase is correct and avoid circulating current through the “phase correction process” (see pages 23-25 of the manual).
Load distribution line connection: All units have 10 (+) and 11 (-) terminals connected in parallel, and the shielding layer is continuously grounded.
Troubleshooting and Maintenance
1. Common fault handling
The manual provides a detailed troubleshooting table, and the core faults and solutions are as follows:
Possible causes and solutions for the fault phenomenon
The prime mover cannot start, the actuator does not operate, and the polarity of the power supply is reversed/there is no voltage; The fuel limit for starting is too low; Check the polarity and voltage of the power supply when the speed signal is not cleared and the fault circuit is not cleared; Turn up the ‘Start Fuel Limit’ clockwise; Short circuit terminals 18-16 (temporary shielding fault signal)
Overspeed/smoking ramp time too short during startup; The rated speed is set too high; Turn up the “ramp time” clockwise when the fuel restriction is not in effect; Reduce the ‘rated speed’ counterclockwise; Delay starting for 1 second after power on (ensure fuel restriction is activated)
Uneven load distribution and differences in no-load speed of units; Inconsistent load gain voltage; CT phase error calibration of all units’ no-load speed; Unified load gain voltage to 6.0V (full load); Re execute CT phase correction
Unstable speed (fluctuation), high gain/low reset; Improper compensation of the actuator; If the sensor gap is too large, decrease the gain counterclockwise/increase it clockwise to reset; Fine tune the ‘actuator compensation’; Adjust the sensor gap to 0.25-1.0mm
Speed signal fault sensor open/short circuit; Poor shielding; Gear wear measurement sensor resistance (100-300 Ω); Check the connection of the shielding layer; Replace the gear (radial runout ≤ 0.5mm)
2. Maintenance and safety precautions
Daily maintenance: Check the tightness of the wiring terminals and the gap between sensors every month; Clean the controller panel quarterly (use a dry soft cloth, do not use solvents or sharp tools).
Static electricity protection: Before touching the circuit board, static electricity must be released (touching grounded metal); Do not touch PCB components or pins with your hands. When replacing the PCB, use anti-static bags for packaging.
Repair restriction: Self opening repair is prohibited, please contact Woodward authorized service center; When returning for repair, it is necessary to label the model, serial number, and fault description, and use the original factory packaging.
Key safety warning
Overspeed risk: The prime mover must be equipped with an independent overspeed shutdown device (independent of the controller) to prevent equipment damage or personnel injury caused by uncontrolled speed.
High voltage hazard: CT open circuit can generate fatal high voltage. When wiring or maintenance, it is necessary to short-circuit the CT terminal or cut off the power first; The terminal voltage of the high-voltage controller should be ≥ 88VAC, and insulated gloves should be worn for operation.
Static damage: Electronic components are sensitive to static electricity, and anti-static packaging should be used during transportation and installation. Plastic and vinyl materials are prohibited from contacting PCBs.
Emergency shutdown: Emergency shutdown measures should be prepared during startup. If abnormal actuator action or speed limit is found, the power supply should be immediately cut off.
Product ID/Model: IMDSI13 (ABB official model identification), document associated link labeled “SPDSI13”, speculated to be due to differences in series ownership or regional model labeling, core parameters are based on “IMDSI13”.
Product type: I-O-Module, specifically Digital Slave Input Module, is positioned as a slave device for Symphony Plus control system, receiving external digital signals and transmitting them to the main control system.
Belonging to the product system: classified under ABB’s “Products”, “Control Systems”, “Symphony Plus”, “I/Os”, HR Series (Harmony Rack) I/O “, which is the HR series (Harmony Rack) I/O module family under the Symphony Plus control system, suitable for rack mounted installation and system integration of this series.
2. Multi language support
The document page supports viewing in 16 languages (including Chinese, English, German, Japanese, Korean, etc.), making it convenient for users from different regions to access technical information. The corresponding version can be selected through the page language switching function.
Key physical and compliance parameters
1. Size and weight
Dimensions: The product has a net depth/length of 73.66mm, a net height of 360.68mm, and a net width of 269.24mm. It is compatible with the installation dimensions of the HR series (Harmony Rack) rack and requires confirmation of specific installation compatibility based on rack specifications.
Weight: The document indicates “0 kg”, which is speculated to be a simplified net weight label without packaging or data is currently missing. The actual weight of industrial I/O modules is usually around a few hundred grams to 1 kilogram, and the final technical document from ABB should be used as the standard.
2. Environmental and Compliance Attributes
WEEE classification: Belongs to “5. Small Equipment (No External Dimension More Than 50 cm)”, which means “small equipment (with no external dimensions exceeding 50 cm)” and meets the classification requirements of the EU Waste Electrical and Electronic Equipment Directive (WEEE). Disposal must comply with corresponding environmental standards.
Battery related: Excluding batteries (Number of Batteries: 0), there is no need to consider additional operations related to battery replacement and environmental recycling.
3. Import and export and tariff information
HS code: 853890 (specific sub target note: “853890- Parts suitable for use completely or primarily with the apparatus of heading 85.35, 85.36 or 85.37- Other”), which means “parts specifically or primarily used for equipment of heading 85.35, 85.36 or 85.37, other”.
Customs tariff code: 85389081, used for tariff accounting and classification during import and export customs declaration. The specific tax rate needs to be confirmed in conjunction with the customs policies of the importing region.
Installation precautions
First, the importance of industrial equipment installation
In modern industrial production, various equipment and machines are widely used in various fields, such as manufacturing, energy industry, chemical industry and so on. The installation of industrial equipment is directly related to production efficiency and product quality. Proper installation and commissioning of good equipment can ensure the stable operation of the production line, improve production efficiency and product quality, reduce maintenance costs, and ensure the safety of employees.
Second, the steps of industrial equipment installation
1. Preparation: Before the installation of industrial equipment, it is necessary to carry out adequate preparation work. This includes the tools and equipment required for installation, cleaning and preparation of the installation site, and making installation plans and schedules.
2. Determine the installation position: Determine the installation position of the equipment according to the requirements of the equipment and the layout of the production line. When determining the location, the weight and size of the equipment need to be considered, as well as the coordination of the equipment with the surrounding environment.
3. Install the device: Assemble and install the device according to the installation instructions. Ensure that the device is securely and accurately connected, while protecting the appearance and internal components of the device.
4. Connect power supplies and pipelines: For devices that require power supplies and power supplies, properly connect power supplies and pipelines. The connection of power supply and pipeline should comply with safety standards to avoid hazards such as electric shock and leakage.
5. Commissioning the device: After the installation is complete, you need to commission the device to ensure that the device can run properly. It includes checking the functions and performance of the equipment, adjusting the parameters and Settings of the equipment, and carrying out the necessary tests and inspections.
6. Training operators: After the installation of the equipment, it is necessary to train the operators to understand the operation methods and precautions of the equipment, and improve the operation skills and safety awareness of the employees.
1. Safety first: When installing industrial equipment, safety is the most important consideration. You must operate in strict accordance with safety regulations and wear necessary protective equipment to ensure the safety of the workplace.
2. Strictly follow the equipment instructions: Industrial equipment usually comes with detailed installation instructions, you must carefully read and understand the contents of the instructions, and install the operation in accordance with the requirements of the instructions.
3. Pay attention to the assembly sequence: When installing the device, follow the correct assembly sequence to ensure that all components of the device are assembled correctly to avoid equipment failures or safety accidents caused by incorrect assembly sequence.
Eaton XV-102 is an industrial grade touch display screen that combines HMI (Human Machine Interface) and integrated HMI/PLC functions, suitable for mechanical manufacturing, system integration and other scenarios. It can achieve equipment monitoring, parameter setting and process control, with multiple size models, rich communication interfaces and industrial grade protection performance, and meets multiple international safety and industry certification standards.
Product positioning and core functions
Functional positioning: It can be used as an independent HMI terminal or integrated HMI/PLC device, with the core used for monitoring, operating, and controlling machines and systems in industrial scenarios. It does not support safety functions related to personnel or equipment safety protection.
Applicable scenarios: Mainly aimed at the fields of mechanical manufacturing and system construction, it can also be used in maritime scenarios through classification certification (DNV GL), and must meet specific installation and protection requirements.
Product model and hardware configuration
1. Equipment model classification
XV-102 offers three screen sizes (3.5 inches, 5.7 inches, 7.0 inches) and multiple versions (A/B/D/E/H types), with core differences reflected in display performance, communication interfaces, and expansion functions. The specific parameters are shown in the table below:
Model Version Screen Specification (Size/Resolution/Color) Core Interface Configuration Special Function Model Example
Version A 3.5-inch TFT-LCD (QVGA/32 grayscale) Ethernet USB Device， Optional Profibus/RS232/RS485/CAN 1 SD card slot, no additional expansion XV-102-A2-35MQR
Version B 3.5-inch TFT-LCD (QVGA/32 grayscale or 64K color) Ethernet USB Device， Optional RS232/RS485/CAN/Profibus/SmartWire DT Master 1 SD card slot, supports SmartWire DT Master (some models) XV-102-BE-35TQR
Version D 5.7-inch (VGA/64K color), 7.0-inch (WVGA/64K color) Ethernet USB Device/Host， Optional RS232/RS485/CAN/Profibus 1 SD card slot, large screen compatible with complex interface XV-102-D8-70TWR
Version E 5.7-inch (VGA/64K color), 7.0-inch (WVGA/64K color) Ethernet USB Device/Host， Support RS485+CAN/Profibus+SmartWire DT Master 1 SD card slot, enhance SmartWire DT integration XV-102-E6-57TVR
Version H 3.5/5.7/7.0 inches (64K colors) Ethernet, USB Device/Host (only 5.7/7.0 inches), optional RS232/RS485 basic communication function, suitable for simplified scenarios XV-102-H3-57TVR
Packaging and Accessories
The packaging contents of devices of different sizes may vary slightly, and the core accessories are as follows:
3.5-inch device: 1 touch screen, 4 mounting brackets with top wires, 1 sealing strip, 1 power connector (models with SmartWire DT include an additional SmartWire DT power connector).
5.7-inch device: 1 touch screen, 6 mounting brackets, 1 sealing strip, 1 power connector (models with SmartWire DT include an additional dedicated power connector).
7.0-inch device: 1 touch screen, 8 mounting brackets, 1 sealing strip, 1 power connector (models with SmartWire DT include an additional dedicated power connector).
Optional accessories: 10 touch pens (model ACCESSORIES-TP-TEN-10, item number 139808), need to be ordered separately.
Safety regulations and equipment protection
1. Core security warning
The manual clearly divides the danger level and provides protection requirements. The key warnings are as follows:
Explosion risk: In the potentially explosive environment of Zone 22, disconnecting the live interface or mechanical impact may cause an explosion. It is only used in non hazardous areas or Zone 22; Grounding resistance<10 ΩΩ; Avoid mechanical impact; After power failure, unplug and plug the interface again
There are live parts inside the electric shock risk equipment, and opening the cover may cause electric shock. Do not open the cover by yourself; Only operated by professionals
Static electricity damage: Static discharge may damage electronic components by touching grounded metal before coming into contact with equipment, releasing static electricity; Avoid touching interface pins
Data loss: When reading or writing from an SD card, power failure or unplugging the card may cause data damage. Only when the device is powered off and the SD card is unplugged or unplugged; Reduce SD card write operations (limited write life)
When a sudden change in temperature and humidity caused by a condensation short circuit leads to internal condensation of the equipment, it is forbidden to power on the equipment; Start up after the temperature stabilizes
2. Personnel and operational requirements
Personnel qualifications: Installation and operation personnel need to have industrial automation equipment operation qualifications, be familiar with this manual and relevant safety standards (such as UL 508, IEC/EN 61131-2).
Operating standards: The complete manual must be used (it is prohibited to split a single page for use to avoid missing safety information); Strictly follow the manual requirements for installation, wiring, and maintenance, and unauthorized modification of equipment is prohibited.
Installation and interface configuration
1. Installation requirements
(1) Environmental and location conditions
General requirements: Installed in control cabinets, control panels, or workstations, avoiding direct sunlight (to prevent plastic aging); Vertical installation tilt angle ≤ ± 45 ° (without forced ventilation); Ventilation gap ≥ 3cm (from ventilation opening), ≥ 15cm (from heating components such as transformers).
Special certification requirements:
Maritime Certification (DNV GL): A 24V DC power anti-interference filter must be installed, communication cables must be shielded, and comply with DNVGL-CG-0339 standard.
UL certification: environmental temperature ≤ 50 ℃, pollution level 2; The tightening torque of the power terminal is 0.6-0.8 Nm (5-7 Lb. In).
Installation steps: Make holes on the installation surface → Paste sealing strips (the joint should be at the bottom of the equipment without gaps) → Insert the equipment from the front → Fix with corresponding numbers of brackets (4 in 3.5 inches, 6 in 5.7 inches, and 8 in 7.0 inches, ensuring IP65 protection), and tighten the bracket top thread with a torque of ≤ 0.1 Nm (to prevent damage to the equipment).
2. Interface configuration and wiring
XV-102 provides rich industrial interfaces, supporting multi protocol communication and expansion. The core interface parameters are as follows:
Interface type specifications and functional wiring requirements
Power interface 24V DC SELV (safe ultra-low voltage), voltage range 19.2-30V DC, maximum power consumption of 5W for 3.5-inch, maximum 9.5W for 5.7/7.0-inch, using Phoenix MSTB 2.5/3-ST-5.08 connector (built-in); XT-FIL-1/2 anti-interference filter needs to be installed (for maritime/EMC B-level scenarios)
Ethernet 100Base TX/10Base-T (RJ45), supporting LED status indication (ACT flashing=data transmission, LINK constantly on=network connection) using shielded twisted pair (STP); Cross wires are used between devices, and straight wires are used to connect to switches; Maximum length 100m
RS232 (system port) 9-pin D-Sub male, non isolated, supports up to 115200 bit/s (within 2.5m) with shielded cable; The cable length is negatively correlated with the baud rate (e.g. ≤ 9600 bit/s at 30m); The GND terminal must be connected
RS485 9-pin D-Sub male, non isolated, supports 32 slave stations, and requires 120 Ω terminal resistors at both ends of the bus using shielded twisted pair cables; Maximum length 500m (0.75mm ² wire diameter); The GND terminal must be connected
CAN 9-pin D-Sub male head, non isolated, compliant with CiA standard, supports 32 shielded twisted pair cables with characteristic impedance of 120 Ω for slave stations; Maximum length of 5000m (at 10 kbit/s); Terminal resistors are required at both ends of the bus
Profibus 9-pin D-Sub female head, non isolated, up to 1.5 Mbit/s (within 200m) using Profibus Class A shielded twisted pair (impedance 150 Ω); Terminal resistors are required at both ends of the bus; 5V pin prohibits external power supply
SmartWire DT Master 8-pin interface (SWD)+POW/AUX power interface, non isolated, supports up to 99 SWD modules with dedicated SWD cables (such as SWD4-100LF8-24); UAUX requires external 2A circuit breaker (UL standard) or 3A fuse (DIN standard)
USB USB 2.0（Device Type B/Host Type A）， Non isolated shielded USB cable; Maximum length of 5m; Host interface supports external devices such as USB drives
Operation and Maintenance
1. Basic operations
Power on and off: No physical switch, automatically boots when powered on, shuts down when powered off; For the first startup, please refer to the “Windows CE System Instructions” (MN05010007Z) to configure system parameters and install applications.
SD card operation: Only plug and unplug when the device is powered off; Used to store project files or data, avoiding frequent writes (limited lifespan); Power off is prohibited during reading and writing.
Touch calibration: It has been calibrated at the factory. If there is an abnormal response, it needs to be recalibrated using system tools (refer to the “Windows CE System Instructions”); Operate only with fingers or a dedicated stylus, and avoid touching with sharp objects (to prevent damage to the resistive screen).
2. Maintenance and troubleshooting
(1) Daily maintenance
Cleaning: Use a clean, soft, and damp cloth to wipe the resistance screen. For stubborn stains, dip a small amount of detergent in it; Do not use sharp tools, corrosive solvents, or liquids to infiltrate the equipment.
Battery maintenance: Built in CR2032 lithium battery (3V/190mAh), non replaceable, can maintain real-time clock for about 10 years after power failure.
Repair restriction: Self opening repair is prohibited. Contact Eaton authorized repair center or supplier.
(2) Common fault handling
Possible causes and solutions for the fault phenomenon
The device cannot start and the power supply is not properly connected or the voltage is abnormal. Check the 24V DC power supply wiring; Confirm that the voltage is within the range of 19.2-30V DC
Touch screen unresponsive/response deviation touch screen not calibrated; Install the bracket too tightly and recalibrate the touch screen; Loosen the top wire of the bracket (torque ≤ 0.1 Nm)
Display screen black, backlight not activated or malfunction check, backlight settings in visualization software; Fault needs to be returned to the factory for repair
Communication interruption (such as Ethernet/CAN) cable not connected properly; Terminal resistor missing; Interference check cable wiring; Confirm the connection of 120 Ω terminal resistors at both ends of the bus; Install anti-interference filter or magnetic ring
Technical parameters and compliance certification
1. Core technical parameters
Parameter category specification
Display performance of 3.5 inches (QVGA/32 grayscale/64K color), 5.7 inches (VGA/64K color), 7.0 inches (WVGA/64K color); The lifespan of LED backlight is about 40000 hours, and the brightness can be adjusted by software
System configuration: 32-bit RISC processor (400MHz); 64MB DRAM + 64MB NAND Flash； Some models include 125KB NVRAM
Protection level: IP65 on the front (requires correct installation of brackets), IP20 on the back
Environmental adaptability: working temperature 0-50 ℃, storage temperature -20-60 ℃; Relative humidity ranging from 10% to 95% (without condensation); Anti vibration (5-150Hz, 2g), anti impact (15g/11ms)
Power supply characteristics: 24V DC SELV, with reverse polarity protection and built-in fuses; Start impulse current 1.5A/2s
2. Compliance certification
Safety and EMC: Compliant with UL 508 (Industrial Control Equipment), UL 60950 (Information Technology Equipment), CE (EMC Directive 2014/30/EU); ATEX 2014/34/EU (Zone 22, 3D explosive environment).
Industry certification: DNV GL classification certification (TAA00000NC), suitable for maritime scenarios; Compliant with IEC/EN 61131-2 (Requirements for PLC Equipment) and EN 50178 (Electronic Equipment for Power Installation).
Storage, transportation, and disposal
Storage: ambient temperature -20-60 ℃, relative humidity 10% -95% (no condensation); Avoid direct sunlight, vibration, and chemical corrosion.
Transportation: Use original packaging to avoid impact and compression; The transportation environment must meet the storage conditions, and upon arrival, inspect for any transportation damage.
Disposal: The equipment contains lithium batteries (CR2032, containing 1.2-dimethoxyethane), which need to be professionally disposed of according to local environmental standards or returned to Eaton for disposal; The packaging materials (cardboard, PE bags) are recyclable.
ProSoft MVI56-MCM is a product designed specifically for Rockwell Automation ® ControlLogix ® The Modbus master-slave communication module designed by the processor enables convenient integration between the ControlLogix system and other devices that support the Modbus protocol, such as PLCs, process control devices, and SCADA systems. As an interface module between the Modbus network and the ControlLogix backplane, it has high compatibility, ease of configuration, and reliable communication performance.
Core Features and Advantages
The module meets the flexible communication and efficient operation and maintenance needs in industrial scenarios through targeted design. The core features and corresponding values are as follows:
Characteristics classification, specific characteristics, advantages
Backboard technology authorized by Rockwell Automation; Support 1756 backplane single slot installation (local/remote rack) 1. Implement high-speed data transmission between modules and ControlLogix processors
2. Compatible with ControlLogix system architecture, no additional hardware adaptation required
The protocol supports Modbus RTU (binary, with CRC-16 checksum) and Modbus ASCII (with LRC error checksum) protocols; Support floating-point data transmission (including Enron and Daniel) ® 1. Adapt to the communication requirements of different Modbus devices, with wide compatibility
2. Meet the transmission requirements of high-precision data (such as flow and temperature) in industrial scenarios
Configuration and Monitoring 1. Based on RSLogix ™ 5000 configuration, supports viewing module data and status through controller tags
2. Provide example ladder diagrams with complete annotations (including user-defined data types, steps, and labels), which can be used in most scenarios without modification
3. LED diagnostic indicator lights (module status, backplane transmission status, application status, serial activity)
4. Menu driven hardware and protocol diagnostic tools; Support viewing module database content through serial port connection to PC 1. Reduce configuration threshold and shorten deployment time
2. Operations personnel can quickly locate faults (such as communication interruptions, module abnormalities), reducing downtime
20 years of experience in developing industrial communication solutions with technical support and warranty; Global free unlimited technical support (pre-sales, deployment, troubleshooting); 3-year warranty: 1. Ensure long-term stable operation of equipment and reduce maintenance risks
2. Global service network ensures timely access to support and adapts to cross-border project needs
Functional specifications
The module supports both Modbus master and slave modes, allowing for flexible configuration of port roles according to different communication topology requirements.
（1） Modbus master mode
After configuring the port as a master, it can actively send instructions to slave devices in the Modbus network, with intelligent polling and detailed status feedback capabilities:
Instruction configuration: Each master port supports up to 100 configurable instructions, each of which can customize function codes, slave addresses, register read/write addresses, and word/bit counts.
Polling strategy: supports flexible instruction list polling configuration, including continuous polling, polling when data changes, and can be manually or automatically enabled for polling; For slave stations with abnormal communication, the polling frequency will be automatically reduced to optimize network resource utilization.
Status feedback: Provide error codes for individual instructions and maintain a list of slave status for each active master port for troubleshooting purposes.
（2） Modbus Slave Mode
The port is configured to allow remote master access to all data within the module after the slave station (data can come from other Modbus slave stations in the network, master station ports, or the module itself):
Node address: Supports 1-247 software selectable addresses, suitable for multi device networking requirements.
Status monitoring: Each configured slave port provides error codes, counters, and port status data, providing real-time feedback on communication health.
（3） Supported Modbus Function Codes
Covering commonly used read and write operations in industrial scenarios to meet data collection and control requirements:
Function code function description applicable mode (master/slave)
1. Read the status of the coil from the master station (sending) and slave station (responding)
2. Read input status: master station (sending), slave station (responding)
3 Read and hold register master (send), slave (respond)
Communication standard: Supports RS-232/485/422, with full hardware handshake control (suitable for radio stations, modems, and multi machine networking scenarios)
Communication parameters: baud rate 110-115200 baud (depending on the protocol); Data bits 5/6/7/8; Stop position 1/2; Check bit none/odd/even; RTS switch delay 0-65535 milliseconds (software configurable).
The Watlow Series CLS200 is a compact loop control system that provides powerful control functions in a 1/8 DIN package. It features multi loop control, flexible input-output configuration, and multiple firmware options, making it suitable for a wide range of industrial control scenarios and complying with multiple international safety and electromagnetic compatibility standards.
Core product features and advantages
Multi loop PID control: Available in 4, 8, and 16 loop versions, it can simultaneously control heating and cooling circuits, saving panel space and reducing installation time for each loop, with fewer parts, and improving system reliability.
Intelligent control function: equipped with Auto tune function, parameter tuning can be quickly completed without the need for professional personnel, ensuring control accuracy; Supports storing and calling 8 job programs, making it easy to quickly switch production processes.
Flexible input support: Compatible with multiple sensor inputs, including thermocouples (Type B/E/J/K/R/S/T, etc.), RTDs (only supported for 4/8 loop models, divided into 2 ranges), linear DC voltage/current, and pulse signals, reducing learning costs and inventory pressure; Equipped with sensor fault detection, it can quickly troubleshoot issues such as reverse wiring, short circuits, and open circuits.
Intuitive operation and communication: equipped with a 32 character vacuum fluorescent display screen and an 8-key keyboard, menu guided operation, supporting single channel/multi-channel display switching; Built in EIA/TIA-232 and 485 serial communication interfaces, can be connected to computers or software to achieve configuration loading, data acquisition, and integration with other controllers. The baud rate can be selected from 2400, 9600, 19200, and supports ANSI X3.28-1976 (compatible with Allen Bradley PLC/2) and Modbus ® RTU protocol.
Alarm and output configuration: Each input channel has high/low process alarms and deviation alarms, and the alarm dead zone, delay, and startup suppression can be customized; Up to 34 digital outputs are provided (depending on the wiring method), which can be configured as switch time proportional control or distributed zero crossing control. The maximum sinking current for a single output is 60mA (5VDC), and the onboard power supply provides 350mA (5VDC) power supply; There are also global alarm outputs (triggered by any alarm) and watchdog outputs (indicating normal operation of the controller).
Firmware Options
According to application requirements, different firmware functions can be selected to meet basic to complex control scenarios:
Standard firmware closed-loop PID control, automatic tuning, alarm, job storage, sensor fault detection, basic temperature/process control, without the need for complex timing or special algorithms
The Ramp and Sok firmware includes standard functions, including temperature control programs and process variable retransmission. In batch production, heating is required according to specific temperature curves (such as material annealing and food processing)
The enhanced firmware includes standard features such as process variable retransmission, remote simulation set points, cascade control, ratio control, and differential control that require multi parameter linkage (such as temperature control in the main loop and heating power control in the secondary loop in cascade control) or remote setting of target values
Customized firmware development for unconventional industrial scenarios based on user specific needs, requiring dedicated control logic (contact Watlow representative)
Input/output and expansion module
（1） Digital I/O wiring options
Different wiring methods correspond to different I/O quantities and interface types, adapting to different installation requirements:
Wiring type suitable for controller (number of circuits), I/O quantity, interface and accessories
Screw terminals (TB18) 4, 8, 15 outputs (10 can be used for control circuits), 3 inputs with back screw connections, no additional accessories required, suitable for small batch I/O connections
Large scale termination (SCSI) series with 34 outputs, 8 digital inputs+1 pulse input, 50 pin SCSI interface, requires SCSI cable and TB50 terminal board, suitable for multi I/O centralized connection
（2） Analog expansion module
Due to the lack of onboard analog output in the controller, analog signal conversion needs to be achieved through the following modules:
DAC module (digital to analog converter): converts 1-2 distributed zero crossing (DZC) outputs of the controller into analog signals, which can be configured on-site as 4-20mVDC, 0-5VDC, or 0-10VDC.
SDAC module (serial digital to analog converter): converts 1 controller output into high-precision voltage/current signals, supports process variable retransmission, open-loop control, motor/belt speed control, etc., in compliance with CE and UL ®、 C-UL ® Standard.
Key technical parameters
（1） Input performance
Analog input: 4/8 circuit model is differential input, 16 circuit model is single ended input; The maximum common mode voltage is 5V (4/8 circuits), the common mode rejection ratio (CMR) is>60dB (DC to 1kHz), 120dB (selected line frequency), the noise suppression is 120dB (60Hz), and the input overvoltage protection is ± 20V (relative to digital ground).
Thermocouples: Type B (66-1760 ℃, ± 4.0 ℃), Type E (-200-787 ℃, ± 1.0 ℃), etc., with accuracy measured in a 25 ℃ environment (Type B is only valid in the 800-3200 ° F range).
RTD: Only 4/8 circuits are supported, RTD1 (-100-275 ℃, ± 1.1 ℃) and RTD2 (-120-840 ℃, ± 1.6 ℃) require factory pre installed scaling resistors.
（2） Power Supply and Certification
Power requirements: 15-24VDC (± 3VDC), maximum current 1A, no-load current 300mA.
Compliance certification: UL ®、 C-UL ® Certification (compliant with UL) ® 61010-1 standard), CE mark (compliant with EU EMC directive), RoHS design.
Order Information
The configuration needs to be selected according to the following dimensions, and the final model needs to be confirmed with a Watlow sales representative:
Digital I/O termination method: screw terminal (TB18)/large-scale termination (SCSI).
Accessories: Do you need TB50 terminal board, SCSI cable (3 feet, including optional right angle connector), serial communication cable (10 feet, DB-9 female/bare wire).
Serial communication jumpers: EIA/TIA-232, EIA/TIA-485 (not terminated), EIA/TIA-485 (terminated).
Special Input: If RTD or linear current/voltage input is required, factory pre installed scaling resistors are required (RTD is not supported for 16 circuit models).
The Allied Telesis IS230 Series is a multipurpose product line of managed Layer 2 switches ideal for industrial applications, including manufacturing, rail transportation (telecommunication and signaling), road transportation (traffic control), and Smart Cities.
With fanless operation and a wide operating temperature range of -40° to 75°C, the robust IS230 Series easily tolerates harsh and demanding environments, such as those found in industrial and outdoor deployments.
An integrated voltage regulator ensures the PoE output voltage always stays at the rated value, regardless of any fluctuations in the input voltage of powered devices. An extended input voltage range makes the IS230 Series ideal for deployment in traffic control cabinets.
Network resiliency
The IS230 Series supports highly stable and reliable ICT network switching, with recovery times down to 50ms. The IS230 can be customized with the most appropriate mechanism and protocol to prevent network connection failure.
Choices include Allied Telesis Ethernet
Protection Switched Ring (EPSRing™), and the standards-based ITU-T G.8032.
Securing the Network Edge
Ensuring data protection means controlling network access. Protocols such as IEEE 802.1X port-based authentication guarantee that only known users are connected to the network. Unknown users who physically connect can be segregated into a pre-determined part of the network. This offers network guests Internet access, while ensuring the integrity of private network data.
Quality of Service
Comprehensive wire-speed QoS provides flow-based traffic management with Port/Tag Base and Type of Service prioritization. Bandwidth control limits ingress/
egress traffic and broadcast/multicast/flooded unicast packets.
Gigabit and Fast Ethernet support
The IS230 Series offers combo ports supporting both Gigabit and Fast Ethernet Small Form-Factor Pluggables (SFPs). Support for both SFP types allows organizations to stay within budget even as they migrate to faster technologies.
Configurable power budget
On PoE-sourcing IS230 switches, all LAN ports source POE+ up to 30W.
You can configure both the overall power budget and the power feeding limit on a per-port basis, to establish a close relationship between the power sourcing feature and the real capabilities of the external Power Supply Unit (PSU)1.
Dual power inputs
The IS230 Series provides redundant power inputs for higher system reliability; the power inputs are protected against reverse polarity and over-current.
ECO friendly
The IS230 Series are Energy Efficient Ethernet (EEE) devices. They facilitate power saving by switching off parts of the LAN that are not transmitting or recieving data. This sophisticated feature can significantly reduce operating costs, by reducing the
power requirements of the switch and any associated cooling equipment.
Key Features
Full Gigabit, wire speed ports
Uplink combo ports
100/1000Mbps SFP support
Flexible management interface (GUI, SNMP, CLI, TELNET and SSH)
Ethernet Protection Switched Ring (EPSRing™)
Ethernet Ring Protection Switching (ITU-T G.8032)
VLAN stacking (Q-in-Q)
Multicast support (IGMP and MLD snooping)
Loopback detection and storm control
Port mirroring
Port trunking/link aggregation (LACP)
Link Layer Discovery (LLDP)
IEEE 802.3at PoE+ sourcing (30W)
-40 to +75oC wide-range operating temperature
Dual power inputs with voltage boost converter
Alarm output
Fanless design
Performance
Up to 8K MAC addresses
Packet buffer memory: 512KB (4Mb)
8 priority QoS queues
4094 configurable VLANs
256 simultaneous VLANs
Supports 9KB jumbo frames
Up to 255 Layer 2 multicast entries
Environmental Specifications
Operating temperature range: -40°C to 75°C (-40°F to 167°F)
Storage temperature range: -40°C to 85°C (-40°F to 185°F)
The functional framework of the two TCM modules is consistent, with only differences in temperature range and resolution. The core capabilities include:
Control mode: Supports two operating modes: Open Loop and Closed Loop, suitable for different temperature control scenarios.
Channel configuration: It can achieve temperature control for up to 8 channels, each equipped with thermocouple input interface and relay output interface, and supports RTD (resistance temperature detector) input.
Voltage compatibility: Equipped with 12V common mode voltage capability, suitable for signal transmission needs in industrial scenarios.
Fault detection: supports automatic detection and reporting of two types of critical faults——
Thermocouple faults: including open circuit (Open) and reverse circuit (Reverse) faults;
Temperature anomaly: Detect and report temperature deviations that exceed the tolerance range.
Hardware Connection and Interface Description
The module is connected to external devices through two pairs of matching “plug-in connectors” with captive screw terminals for easy on-site wiring. The specific interface division is as follows:
Input connector module left thermocouple (8 channels, corresponding to 1+-1- to 8+-8- terminals), RTD (R+, R -, S+, S – terminals) – Channel input: 1+-1- to 8+-8- (each channel’s positive and negative terminals correspond to a thermocouple)
-RTD inputs: R+, R -, S+, S – (compatible with RTD sensors)
Output connector module right side relay (8 channels, corresponding to 1+-1- to 8+-8- terminals), external power supply (P+, P – terminals) – channel output: 1+-1-~8+-8- (each channel positive and negative terminal corresponds to a relay)
-External power supply: P+(positive pole), P – (negative pole, supplying power to the output relay)
-Grounding: G terminal (grounding connection)
In addition, there is an internal fuse located behind the front cover of the module for circuit overload protection. The specific parameters are “2 Amp, 125V ultra small fuse” (recommended model: Littlefuse Microfiuse 273 002 or equivalent).
Meaning of LED status indicator light
The front of the module is equipped with 6 types of LED indicator lights, which provide feedback on device operation and fault information through on/off/flashing status. The specific instructions are as follows:
Meaning and Status Explanation of LED Identification Colors
P (External Power) green – normal state: constantly on, indicating that the module has been connected to an external power source;
-Abnormal state: Off, possibly due to a blown internal fuse.
R (Run) green – normal status: constantly on, indicating that the module is running normally;
-Abnormal state: The red F (Fault) LED flashes alternately, indicating an internal fault in the module.
-Abnormal state: The green R (Run) LED flashes alternately, indicating an internal fault in the module.
S (Short) red – normal state: normally off;
-Abnormal state: illuminated, indicating a short circuit fault in one of the output circuits.
1-8 (Output Status) Green – Function: Corresponding to 8 output channels, the indicator light on/off ratio reflects the PWM (Pulse Width Modulation) cycle of that channel;
-Example: LED 8 corresponds to the channel to which the 8+and 8- terminals of the right connector belong, and the on/off rhythm is synchronized with the channel output adjustment.
Automatic data exchange with PLC
The module and the CPU of Series 90-30 PLC achieve control and status feedback through “automatic data transmission”, without the need for manual triggering. Each PLC sweep completes a data exchange, and the specific data flow is as follows:
1. PLC → TCM (Control Instruction Transmission)
PLC sends control instructions to TCM through% Q bit (digital output) and% AQ word (analog output), and the core instructions include:
Alarm Limit Values (temperature alarm upper and lower limits) transmission.
2. TCM → PLC (status information feedback)
TCM provides feedback on the operating status to PLC through the% I bit (digital input) and% AI word (analog input), with core information including:
Alarm status (such as over temperature alarm);
Output Short Circuit status;
Current Temperature (real-time temperature of each channel);
PWM period (the pulse period output by each channel);
TCM Error Code (locate specific fault type).
Core differences between TCM302 and TCM303
The two modules only differ in “temperature measurement range” and “resolution”. TCM303 is the “extended range version”, and the specific parameter comparison is as follows:
Comparison item IC693TCM302 IC693TCM303
J-type and L-type thermocouples have a temperature range of 0-450 ° C to 0-750 ° C
K-type thermocouple temperature range 0-600 ° C 0-1050 ° C
Resolution 12 bits/0.2 ° C (i.e. minimum temperature detection accuracy of 0.2 ℃) 12 bits/0.5 ° C (i.e. minimum temperature detection accuracy of 0.5 ℃)
Precautions for replacing fuses
When the P (External Power) LED goes out and the fuse is suspected to be blown, the following steps must be followed to replace it, and safety regulations must be followed:
Turn off the PLC power first, and then remove the TCM module;
Use a small standard screwdriver (pocket size) to loosen the side card of the front cover and gently pull the cover outward;
Use pointed nose pliers to pull out the old fuse from the front of the module and replace it with a fuse of the same specification (2A, 125V);
Warning: It is strictly prohibited to use fuses that do not meet the specifications, otherwise it may cause personal injury or equipment damage.
Product model: 979B (atmospheric pressure to vacuum sensor), part number 100014647
Safety and General Specifications
1. Safety warnings and preventive measures
Electrical safety: When replacing sensors or baking, the power supply must be disconnected first (there may be fatal voltage/current), and only qualified technicians can operate electronic components; Use+24 VDC@0.75 Amps power supply, ensure that the sensor is grounded through the vacuum flange and electrical connector rear housing.
Operation restriction: Do not turn on the filament power supply when the system pressure is higher than 5 × 10 ⁻ Torr (which may damage the hot cathode sensor); Prohibited from use in explosive/flammable gas environments (hot cathode heating elements, MicroPirani’s nickel film elements may ignite gases); Do not replace parts or modify equipment. Repairs must be sent to the MKS calibration service center.
Pollution protection: prevent dust, metal shavings and other pollutants from entering the equipment; During installation, stay away from electronic/ion sources and strong magnetic fields. If necessary, use a particulate filter (see “Accessories” section for details).
2. General technical specifications
Specific project parameters
Measurement range 5 × 10 ⁻¹⁰ Torr to atmospheric pressure (ATM)
Set point range 5 × 10 ⁻¹⁰ Torr to 100 Torr
Analog output DAC1: 0.5-6.95 VDC (0.5 V/order of magnitude); DAC2: 0.75-10.02 VDC (0.75 V/order of magnitude)
Location selection: It is necessary to be able to accurately measure the pressure in the vacuum chamber, away from the pump and gas source to ensure representative readings; Avoid installing directly above the evaporation source (steam may contaminate the sensor), and shield and stay away from strong magnetic fields when approaching electronic/ion sources.
Installation direction: Supports installation in any direction, it is recommended that the vacuum port face downwards (to prevent particles/liquids from entering), which does not affect measurement accuracy.
2. Vacuum connection
The sensor offers multiple flange types: 2.75 “CF (rotatable), 1.33” CF (rotatable) KF16、KF25、KF40， Corresponding flanges need to be matched according to the system, and the manual provides dimension drawings of each flange for reference.
3. Electrical connection
Cable requirements: Use a 15 pin high-density D-sub female cable with strain relief; To meet the anti-interference requirements of EN61326-1, braided shielded cables are required, with metal hooks connected at both ends of the shielding layer and the power supply grounded.
Pin function: The 15 pin D-sub connector has clear pin division, and the core pins include: 1 pin (RS485-/RS232 TXD), 2 pins (RS485+/RS232 RXD), 3 pins (power+24V), 4 pins (power -), 5 pins (analog output+), 6 pins (analog output -), 9 pins (degassing state), 10 pins (filament selection), 13 pins (degassing on), as well as the common terminals (7, 11, 14 pins) and normal terminals (8, 12, 15 pins) of 3 relays. For details, please refer to the “979B Sensor Electrical Connection Table”.
Attention: The negative terminal (6-pin) of the analog output should not be connected to the negative terminal (4-pin) of the power supply or other grounding points (which may cause current diversion and measurement errors, and the longer the cable, the greater the error); When connecting inductive loads (such as solenoids and transformers), an arc extinguishing network (resistor R and capacitor C) needs to be installed. The calculation formula is
C=I 2/(1 × 10 7) (Farads), R=E/I a (ohms, where a=1+(50/E)), and R is at least 0.5 Ω and C is at least 1.0 × 10 ⁻⁹ F.
Operation control
1. Control and status pin operation
Degassing on (Pin13): Enable degassing when grounded, with priority higher than DG command or degassing button; After 30 minutes of degassing, it is necessary to disconnect and reconnect to restart degassing, and degassing should not exceed 30 minutes every 4 hours.
Degassing state (Pin9): When degassing is closed, it is open circuit/suspended, and when it is open, it is grounded; An external pull-up resistor with ≤ 24 VDC can be connected, and the current should be less than 15mA.
Filament selection (Pin10): By switching the active filament on/off the power supply, the state can be switched instead of selecting a fixed filament.
2. Factory default settings
The sensor parameters are preset to default values, including: active filament 1, address 253, baud rate 9600, degassing power off, automatic emission current (20 μ A>1 × 10 ⁻⁴ Torr, 1mA<1 × 10 ⁻⁴ Torr), control set point enabled, filament power off, gas correction 1, gas calibration type nitrogen, 3 set points disabled, hysteresis value 1.10E0 Torr, set point value 1.00E0 Torr, set point direction “below (BELOW)”, protection set point 1.0E-2 Torr, unit Torr, analog output DAC1, RS485 test off, RS delay on.
3. RS-485/RS-232 communication protocol
Basic parameters: Supports baud rates of 4800-112200 (default 9600), data format of 8-bit data bits, no checksum, and 1-bit stop bit; RS-485 is a half duplex two-wire system, which is the same protocol as RS-232.
Address rule: Standard address 001-253 (default 253); Universal address 254 (used for communication with unknown address devices, will respond), 255 (broadcast address, executes commands but does not respond, such as batch modification of baud rate).
Command syntax: The query format is @<device address><query command>?; FF (such as querying baud rate: @ 253BR?)?; FF）， The command format is @<device address><command instruction>! <Parameters>; FF (such as changing the baud rate to 19200: @ 253BR! 19200; FF）； The response starts with ACK (success) or NAK (failure), and the NAK code corresponds to different errors (such as 160=unrecognized message, 169=invalid parameter, 172=value out of range, etc.).
4. Core Command Set
The commands are divided into five categories: setting, status, pressure measurement and degassing, set point, and calibration. The core commands are as follows:
Command Type Command Identification Function Description Example
Set command AF (active filament) to query/select 2 filaments (value 1/2) of the hot cathode sensor. Query: @ 001AF?; FF; Setting: @ 001AF! 2; FF
DAC (Analog Output) Query/Set Analog Output Type (1=DAC1, 2=DAC2) Query: @ 001DAC?; FF; Setting: @ 001DAC! 2;FF
FD (factory default) restores all user calibration values to factory default command: @ 001FD!; FF
Status command DT (device type) query device type response: @ 001ACKMP-HC 979B; FF
FS (filament status) query for the on/off status of the active filament: @ 001FS?; FF
FV (firmware version) query firmware version response: @ 001ACK1.00; FF
SN (serial number) query device serial number response: @ 001ACK0000012345; FF
T (sensor status) query hot cathode status (F=filament fault, G=hot cathode on, etc.) Response: @ 001ACKO; FF (O=normal)
Pressure measurement and degassing FP (filament power supply) switch filament power supply (only effective when the control setpoint is disabled, disabled when the pressure is greater than 5 × 10 ⁻ Torr) command: @ 001FP! ON; FF
DG (degassing power supply) switch degassing (pressure must be<1 × 10 ⁻⁵ Torr, automatically shuts off after 30 minutes) query: @ 001DG?; FF; Setting: @ 001DG! ON; FF
Calibration command ATM (atmospheric pressure calibration) to calibrate MicroPirani to full range (requires ventilation to atmospheric pressure, stable for 20 minutes) Command: @ 001ATM! 7.60E+2; FF
VAC (vacuum calibration) calibration MicroPirani zero point (needs to be drawn to<1 × 10 ⁻⁴ Torr, stabilized for 20 minutes, automatically calibrated when hot cathode pressure<1 × 10 ⁻⁴ Torr) command: @ 001VAC!; FF
GC (gas correction) query/set gas correction coefficient for hot cathode (0.10-50.1, default 1, such as argon 1.29) setting: @ 001GC! 1.29; FF
Analog output and gas correction
1. Simulation output calculation and table
DAC1: Pressure calculation formula P=10 (2V − 11) (Torr), the manual provides a detailed voltage correspondence table for 1.0E-10 Torr (0.50V) to 1.0E+03 Torr (7.00V).
DAC2: Pressure calculation formula P=10 0.75 V − 7.75 (Torr), also provide a complete pressure voltage correspondence table.
2. Gas correction factor
MicroPirani is based on gas thermal conductivity measurement, and the hot cathode is based on gas ionization measurement, both of which need to be corrected according to the gas type:
Gas chemical formula gas correction factor (GC)
Air -1.00
Argon gas Ar 1.29
Carbon dioxide CO ₂ 1.24
Deuterium gas D ₂ 0.35
Helium He 0.18
Hydrogen H ₂ 0.46
Krypton gas Kr 1.94
Neon gas Ne 0.30
Nitrogen N ₂ 1.00
Nitric oxide NO 1.16
Oxygen O ₂ 1.01
Sulfur hexafluoride SF ₆ 2.50
Water H ₂ O 1.12
Xenon Xe 2.87
Maintenance and troubleshooting
1. Daily maintenance
Cleaning: The casing can be cleaned with water or alcohol to prevent liquids from entering the electronic casing; The sensor tube must not be cleaned (as it may damage the components), and the sensor needs to be replaced in case of severe contamination.
Degassing operation: When the hot cathode sensor is contaminated by process gas (especially when the sensitivity drifts when the pressure is ≤ 10 ⁻⁸ Torr), regular degassing is required; When degassing, the pressure should be less than 1 × 10 ⁻⁵ Torr. During this period, the pressure can be measured but the reading may be higher than the system pressure. When the pressure is greater than 1 × 10 ⁻⁴ Torr, degassing is paused and restarted after reaching the threshold. It will automatically terminate after 30 minutes, and degassing should not exceed 30 minutes every 4 hours.
2. Common faults and solutions
Possible causes/solutions for the fault phenomenon
