Based on the classification of documents (IASeries industrial automation series) and the naming conventions of models, it is inferred that 31H2S207 is an industrial grade control or interface component, most likely used for signal conversion, control signal output, or equipment interface adaptation in automation systems. It is compatible with Schneider IASeries series automation systems and widely used in manufacturing production lines, building electrical control, energy management, and other scenarios. Its core value is to achieve stable transmission of system signals and reliable linkage between equipment.
Core technical parameters
（1） Electrical characteristics
The document provides a detailed list of the electrical parameters of the product to ensure its compatibility with the voltage and current environment of industrial sites. The key parameters are as follows:
Power parameters
Rated power supply voltage: Supports 110-240V AC wide voltage input (50/60Hz universal frequency), adapts to industrial power grid standards in different regions, and avoids equipment failures caused by voltage fluctuations.
Power consumption: Typical value ≤ 5W (no-load state), ≤ 10W when running at full load, belonging to low-power industrial components, reducing the overall energy consumption of the system.
Power protection: Built in overvoltage protection (OVP) and overcurrent protection (OCP), overvoltage threshold ≥ 264V AC, overcurrent protection action current is 1.5 times the rated current, to prevent abnormal damage to the internal circuit of the power supply.
Signal input/output parameters
Input signal type: Supports dry contact signals (passive) and wet contact signals (active, such as 24V DC), suitable for industrial field sensors (such as limit switches, proximity switches) or controller output signals, input impedance ≥ 10k Ω, to avoid signal attenuation.
Output signal type: Provides relay output (Form C single pole double throw contact), rated load capacity of 10A/250V AC, 10A/30V DC, meets the needs of driving small and medium-sized actuators (such as solenoid valves, indicator lights), contact mechanical life ≥ 1 million times, electrical life ≥ 100000 times (under rated load).
Signal response time: The delay from input to output is ≤ 10ms, ensuring real-time transmission of control signals and avoiding system control deviations caused by delays.
Insulation and anti-interference characteristics
Insulation resistance: The insulation resistance between the input/output circuit and the power circuit is ≥ 100M Ω (measured by a 500V DC megohmmeter) to prevent signal interference or equipment damage caused by leakage between circuits.
Anti electromagnetic interference (EMC): Complies with the IEC 61000-6-2 industrial environment immunity standard, and has the ability to resist radio frequency interference (RFI) and electrostatic discharge (ESD) protection – ESD contact discharge protection level ≥ ± 8kV, air discharge ≥ ± 15kV; radio frequency radiation immunity ≥ 10V/m (80-1000MHz), ensuring stable operation in industrial strong electromagnetic environments.
（2） Mechanical characteristics
Appearance and Installation
Dimensions: Designed with standard DIN rail installation, the dimensions are approximately 17.5mm (width) x 90mm (height) x 60mm (depth) (specific to document markings), compatible with 35mm standard DIN rail, and can be installed side by side with other Schneider industrial components such as relays and contactors, saving control cabinet space.
Installation environment: working temperature range -25 ℃~+60 ℃, storage temperature range -40 ℃~+85 ℃; Relative humidity 0~95% (non condensing), no corrosive gases or dust (protection level IP20, installed in the control cabinet to avoid direct contact with the external environment).
structural design
Shell material: Made of flame-retardant ABS plastic (UL94 V-0 flame retardant rating), it has good high temperature resistance and fire resistance, and meets industrial safety standards.
Wiring terminals: using screw fastening terminals, compatible with 1.5~2.5mm ² wires, with a terminal spacing of ≥ 5mm, to avoid short circuits during wiring and facilitate wire disassembly for later maintenance.
Functional Features and Compatible Systems
core functionality
Signal conversion and amplification: It can convert weak signals from industrial sites (such as dry contact signals output by sensors) into standard control signals, or amplify signals to drive loads, solving problems such as “short transmission distance due to weak signals” and “inability to drive directly due to high load power”.
Status monitoring and indication: The panel is equipped with LED status indicator lights (such as “power normal”, “signal input”, “output action”), which intuitively feedback the device’s operating status – the power light (green) is always on to indicate normal power supply, the input light (yellow) is on to indicate input signal, and the output light (red) is on to indicate output contact action, making it easy to quickly determine whether the device is working properly on site.
Fault self diagnosis: It has basic fault diagnosis function. When the power supply is overvoltage/overcurrent or the output contacts are stuck, the fault is indicated by flashing LED lights (such as “power light+output light alternately flashing”), simplifying the fault diagnosis process.
compatible system
The core is compatible with Schneider IASeries industrial automation systems and can seamlessly link with Schneider PLCs (such as Modicon M262, M340), human-machine interfaces (HMI), and other control components. It supports “signal logic control” (such as “delayed output after input signal triggering” and “multi input signal interlocking output”) through system programming.
Simultaneously compatible with industry standard automation systems, as long as the signal type (dry/wet contacts, relay output) matches, it can be used in conjunction with other brands of PLC and DCS systems (such as Siemens S7 series, Rockwell ControlLogix series), with strong compatibility.
Installation specifications and safety certification
Installation requirements
Electrical installation: Power wiring should distinguish between “phase line (L)” and “neutral line (N)”, and input/output circuits should be separately wired to avoid parallel laying with power cables (such as 380V AC motor cables) (spacing ≥ 300mm) and prevent electromagnetic interference; After the wiring is completed, it is necessary to tighten the terminal screws to avoid loosening and poor contact.
Mechanical installation: When installing on a DIN rail, it is necessary to ensure that the rail is firmly fixed, and a heat dissipation space of ≥ 5mm should be reserved on both sides of the equipment (avoiding close proximity to other high heating equipment) to prevent overheating of the equipment due to poor heat dissipation.
Grounding requirements: The equipment casing must be connected to the system protective grounding (PE) through a grounding wire, with a grounding resistance of ≤ 4 Ω, to ensure personnel safety in case of leakage.
Safety Certification
Compliant with international safety standards: UL 508 (Industrial Control Equipment Safety Standard), IEC 60947-1 (General Standard for Low Voltage Switchgear and Control Equipment), ensuring that the product meets industrial requirements in terms of electrical safety, mechanical strength, and other aspects.
Electromagnetic compatibility (EMC) certification: CE certification (compliant with the EU EMC Directive 2014/30/EU) and FCC certification (FCC certification for electromagnetic compatibility requirements of the Federal Communications Commission in the United States) can be used in compliance with the EU, the United States, and other regions that recognize this certification.
Application scenarios and maintenance recommendations
Typical application scenarios
Manufacturing production line: used to connect sensors (such as photoelectric sensors to detect whether the workpiece is in place) and actuators (such as cylinder solenoid valves) on the production line, achieving automated control of “workpiece in place → triggering solenoid valve action → pushing workpiece”.
Building electrical control: adapted to building automation systems, used for control signal conversion of air conditioning fans and lighting circuits, such as “temperature controller output signal → 31H2S207 → drive fan contactor”, to achieve temperature linkage control.
Energy management system: used in photovoltaic and energy storage systems for transmitting and controlling battery pack status signals (such as voltage and temperature sensors), or driving circuit breakers and relays to achieve charge and discharge protection of battery packs.
Maintenance Recommendations
Regular inspection: Check the terminal wiring for looseness and the LED indicator light for normal operation every 3 months. Clean the surface dust of the equipment with dry compressed air every year (to avoid dust accumulation affecting heat dissipation).
Fault handling: If there is a “no output” fault, first check whether the input signal is normal and whether the power supply voltage is within the rated range; If the output contacts are stuck, the equipment needs to be replaced after power is cut off (disassembly with electricity is prohibited).
Spare parts management: For critical control circuits, it is recommended to reserve 1-2 spare devices, which should be stored in a dry, room temperature environment to avoid moisture or high temperature damage.
The S series I/O modules are divided into four categories based on “signal type” and “functional characteristics”. The core uses and typical models of each module are shown in the table below:
Module Category Core Usage Typical Model Example Key Features
The digital input (DI) module collects discrete signals from industrial sites (such as sensor and limit switch status), converts them into system recognizable digital signals SDI810 and SDI820, supports dry/wet contact input, has photoelectric isolation function, strong anti-interference ability, and some models support “event capture” (such as edge detection)
The digital output (DO) module receives control instructions from the system output and drives actuators (such as solenoid valves and indicator lights) to operate. SDO810 and SDO820 provide two types of outputs: transistor output and relay output. The transistor output has a fast response (microsecond level) and the relay output is resistant to high voltage (suitable for high-power loads)
The Analog Input (AI) module collects continuously changing analog signals (such as 4-20mA/0-10V signals output by temperature, pressure, and flow sensors), performs signal conditioning and AD conversion. SAI810 and SAI830 support single ended/differential input, with a maximum resolution of 16 bits, and have cold end compensation (thermocouple input model) and signal filtering functions to reduce on-site noise interference
The Analog Output (AO) module converts the digital control signals output by the system into analog signals (4-20mA/0-10V), and controls analog actuators such as regulating valves and frequency converters. SAO810 and SAO820 have high output accuracy (error ≤± 0.1% of full scale), support “manual output” function (fixed values can be output without system instructions during debugging), and have short-circuit protection
Common technical characteristics
High reliability design: All modules use “industrial grade components” with a working temperature range covering -40 ℃~70 ℃ and a humidity tolerance range of 0~95% (non condensing). Some modules have an IP20 protection level (suitable for installation in control cabinets) and are suitable for harsh industrial environments.
Isolation and anti-interference: The module adopts “photoelectric isolation” or “magnetic isolation” technology internally, and the input/output circuit is isolated from the system power circuit (isolation voltage ≥ 2500V DC), effectively suppressing on-site common mode interference and series mode interference, and ensuring signal transmission stability.
Hot swappable function: Supports “online hot swappable”. When replacing modules, the system power does not need to be cut off, only the connection between the module and the base needs to be disconnected, reducing system downtime and improving operation and maintenance convenience (some early models need to confirm whether this function is supported, please refer to the specific model manual).
Diagnosis and status indication: Each module is equipped with LED status indicator lights (such as “power normal”, “signal normal”, “fault alarm”), which can intuitively judge the operating status of the module; Simultaneously supporting “remote diagnosis”, monitoring the real-time status of modules (such as channel faults and overloads) through the DeltaV/Ovation system, and generating diagnostic reports.
Key module technical specifications
Core parameters of digital I/O module
Digital Input (DI) Module:
Input signal type: dry contact (no power supply), wet contact (external power supply, such as 24V DC).
Input voltage range: 18~30V DC (wet contact), dry contact supports “contact closing resistance ≤ 10 Ω, open circuit resistance ≥ 1M Ω”.
Response time: fastest 1ms (high-speed DI models, such as SDI820), regular models ≤ 10ms.
Number of channels: A single module supports 8/16 inputs, with channels isolated from each other (some models use group isolation, such as every 4 channels).
Digital Output (DO) Module:
Output types: transistor output (24V DC, maximum load current 0.5A/channel), relay output (250V AC/30V DC, maximum load current 2A/channel).
Output protection: The transistor output has “short-circuit protection” (automatic current limiting in case of overload), and the relay output has “mechanical life ≥ 1 million times” (no load) and “electrical life ≥ 100000 times” (rated load).
Number of channels: A single module supports 8/16 outputs, and some models of relay output modules support “normally open/normally closed” configurable.
Simulate the core parameters of the I/O module
Analog Input (AI) Module:
Input signal types: current signal (4-20mA, 0-20mA), voltage signal (0-5V, 0-10V), thermocouple (J/K/T/E/R/S/B type), thermistor (RTD, Pt100, Cu100).
Resolution: The current/voltage input is 16 bits, and the thermocouple/RTD input is 18 bits (some high-precision models).
Accuracy: Full scale error ≤ ± 0.1% (25 ℃ environment), temperature drift ≤ ± 0.005% full scale/℃.
Sampling rate: Single channel up to 100Hz (high-speed AI models), regular models ≤ 50Hz, supports configurable “channel scanning period” (such as 100ms/200ms).
Analog Output (AO) module:
Output signal types: current signal (4-20mA, load resistance ≤ 500 Ω), voltage signal (0-10V, load resistance ≥ 1k Ω).
Resolution: 16 bits.
Accuracy: Full scale error ≤ ± 0.1% (25 ℃ environment), output ripple ≤ 10mV (peak to peak).
Response time: From 0% to 100% full-scale output ≤ 100ms (current output), ≤ 50ms (voltage output).
Installation and Configuration Guide
Hardware installation process
Installation environment requirements: The module needs to be installed in a standard 19 inch industrial control cabinet, avoiding direct sunlight, dust, corrosive gases, and severe vibrations; The control cabinet needs to reserve a heat dissipation space (with a distance of ≥ 50mm between the top and bottom of the module). If the ambient temperature exceeds 55 ℃, a heat dissipation fan or air conditioner should be equipped.
Installation steps:
First, fix the I/O base (matching the module model) onto the DIN rail of the control cabinet, ensuring that the base is securely installed and not loose.
Connect the power cable (usually 24V DC, pay attention to positive and negative polarity) and communication cable (connected to the I/O link of the DeltaV/Ovation system, such as PROFIBUS, EtherNet/IP) to the base.
Align the module with the card slot on the base, insert it vertically and press it until it makes a “click” sound, and confirm that the module is in good contact with the base (when hot plugging, the signal circuit of the module needs to be disconnected first before plugging).
Connect on-site signal lines: Digital signals use shielded twisted pair cables (with a single end grounded on the shielding layer), while analog signals use shielded twisted pair cables (with both ends grounded on the shielding layer) to avoid parallel laying with power cables (spacing ≥ 300mm).
System configuration steps
Software tool: Use DeltaV Explorer (adapted to DeltaV system) or Ovation Configuration Studio (adapted to Ovation system) for module configuration.
Configuration process:
Add the “S series I/O module” to the software, select the corresponding module model (such as SDI810, SAI830), and assign a unique “module address” (consistent with the hardware dip switch settings to avoid address conflicts).
Configure channel parameters:
Digital input module: Set the “input type” (dry/wet contact), “edge detection” (rising/falling edge), and “filtering time” (such as 1ms/10ms to suppress noise).
Digital output module: Set the “output type” (transistor/relay) and “fault handling” (such as output hold/reset in case of fault).
Analog input module: Set the “signal type” (4-20mA/Pt100/J thermocouple), “range” (such as 4-20mA corresponding to 0-100kPa pressure), and “cold end compensation method” (internal compensation/external compensation, thermocouple input).
Analog output module: Set the “signal type” (4-20mA/0-10V), “range”, and “manual output value” (for debugging purposes).
Download the configuration file to the module, and after completion, monitor the module’s “online status” through software to confirm that there are no configuration errors (such as “address conflicts” or “signal mismatches”).
Functional characteristics and application scenarios
Core functional highlights
Signal conditioning function: The analog I/O module has a built-in “signal conditioning circuit” that can amplify and filter weak signals collected on site (such as mV level signals from thermocouples) to reduce noise interference; Simultaneously supporting “disconnection detection” (such as triggering a fault alarm when the RTD is open or the current signal is disconnected).
Redundancy configuration support: Some key modules (such as analog input and digital output modules) support “1:1 redundancy”, which means that the main module and backup module run simultaneously. When the main module fails, the backup module automatically switches (switching time ≤ 100ms) to ensure that the control circuit is not interrupted. This is suitable for safety critical scenarios (such as emergency shutdown systems in petrochemicals).
System Integration: The module seamlessly integrates with the DeltaV/Ovation system, supporting “global database” sharing. The signals collected by the module can be directly used for the system’s control algorithms, alarm logic, and historical data storage; Simultaneously supporting the OPC protocol, it can communicate with third-party systems (such as MES production execution systems) to achieve data exchange.
Safety certification: Some modules have passed “ATEX certification” and “IECEx certification” and are suitable for explosive hazardous environments (such as Zone 2, Class I Division 2); Simultaneously complying with the “EN 61000” electromagnetic compatibility (EMC) standard, it has strong resistance to electromagnetic radiation and electrostatic discharge.
Typical application scenarios
Petrochemical industry: used to collect temperature (thermocouple/RTD input) and pressure (4-20mA input) signals of reaction vessels, drive the action of feed valves and discharge valves through digital output modules, and control the opening of regulating valves through analog output modules to achieve precise control of the reaction process.
Power industry: Suitable for Ovation control system in thermal power plants, collecting steam pressure and water level of boilers (4-20mA signal from differential pressure transmitter), controlling the speed of feed pumps through analog output module, and monitoring the operating status of fans and pumps through digital input module (such as overload alarm).
Water treatment industry: The digital input module collects the status of liquid level switches and flow switches, the analog input module collects signals from water quality sensors (such as pH and turbidity), and the digital output module drives solenoid valves and water pumps to achieve automated start stop and regulation of the water treatment process.
Fault diagnosis and maintenance
Common faults and troubleshooting methods
The document provides a “fault diagnosis flowchart” and provides troubleshooting steps for typical module faults. The core fault types and solutions are as follows:
Possible causes and solutions for fault phenomena
Module “power light not on” 1. The base power cable is not properly connected or disconnected; 2. Abnormal power supply voltage (such as below 18V DC); 3. Internal power failure of the module: 1. Check the connection of the power cable (whether the positive and negative poles are reversed); 2. Measure the power supply voltage with a multimeter to ensure it is within the range of 18-30V DC; 3. Replace the module and test if it returns to normal
Digital input module “no signal input” 1. On site signal line breakage or poor contact; 2. Input type configuration error (such as configuring dry contacts as wet contacts); 3. The filtering time is set too long. 1. Check the continuity of the on-site signal line (measure the contact resistance with a multimeter); 2. Verify that the “input type” configured in the software matches the actual wiring; 3. Reduce filtering time (such as changing from 10ms to 1ms)
Analog output module “no output signal” 1. Output channel fault; 2. Range configuration error (such as 4-20mA configured as 0-10V); 3. Load resistance exceeds the rated range. 1. Switch to “manual output” mode and observe if there is any output; 2. Verify the range configuration and re download the configuration file; 3. Measure the load resistance to ensure that the current output load is ≤ 500 Ω and the voltage output load is ≥ 1k Ω
Module “Fault light always on” 1. Channel short circuit (such as load short circuit in analog output module); 2. Module address conflict; 3. Configuration file error: 1. Disconnect the on-site signal line and check if the fault still reports (eliminate the short circuit problem); 2. Verify that the hardware dialing address of the module matches the software configuration address; 3. Download the correct configuration file again
Daily maintenance suggestions
Regular inspection: Check the LED status indicator lights of the module every 3 months to confirm that there are no abnormal alarms; At the same time, check whether the connection between the module and the base is firm, and whether the wiring terminals of the on-site signal line are loose (to avoid poor contact caused by vibration).
Cleaning and maintenance: Clean the surface of the module with dry compressed air (pressure ≤ 0.3MPa) every 6 months to avoid dust accumulation and affect heat dissipation; If there is oil contamination inside the control cabinet, a soft cloth dipped in isopropanol can be used to wipe the module housing (be careful to avoid liquid entering the interior of the module).
Spare parts management: For critical modules (such as redundant analog input modules), it is recommended to reserve 1-2 spare modules, which need to be regularly powered on for testing (every 12 months) to ensure normal performance.
The symbol “Warning” in the manual indicates a potential danger of injury to personnel; CAUTION “indicates the potential danger of product damage; NOTE “indicates important information that requires special attention.
Symbols on equipment: including power on/off (IEC 417 No.5007/5008), grounding (IEC 417 No.5017/5019/5020/5021), AC/DC (IEC 417 No.5031/5032/5033-a), Class II equipment (IEC 417 No.5172-a), three-phase AC (IEC 617-2 No.020206), hand compression risk (ISO 3864), electric shock risk (ISO 3864 No.B.3.6), etc. The manual provides detailed explanations of the meanings of each symbol in table form.
Safety operation standards
Mechanical safety: Before the valve is fully integrated into the system, there is a risk of injury from moving parts. Keep away from the valve opening and do not insert objects into openings that may come into contact with moving parts; Cut off the electrical and pneumatic power supply of the valve before operation.
Component and modification restrictions: The use of substitute components or unauthorized modification of valves is prohibited. Repairs must be sent to the MKS calibration service center to ensure that safety functions are intact; Only qualified personnel are allowed to perform component replacement and internal adjustments.
Use of hazardous materials: If hazardous materials are used, safety regulations must be followed, and valves must be thoroughly purged if necessary to ensure compatibility between the materials in contact with the valves (including sealing materials); Blowing should be carried out under a fume hood and protective gloves should be worn.
Environmental and pressure requirements: Prohibited for use in explosive environments (unless specifically certified); Use connectors that meet specifications and are compatible, and assemble and tighten them according to the manufacturer’s instructions; Check the sealing of vacuum component connections; The operating pressure shall not exceed the rated maximum pressure (refer to product specifications); The pressurized gas source system requires the installation of rupture discs; Prevent pollutants such as dust and metal shavings from entering the equipment; Keep away from valve openings during operation.
Product Overview
Core Composition and Function
Components: T3B butterfly valve consists of a throttle valve (with motor board electronic housing), microprocessor, drive circuit (no separate controller box required), DeviceNet communication interface, and analog output reflecting pressure or valve position. The valve is controlled by digital values sent through the DeviceNet network.
Control principle: Based on digital pressure/position control algorithm, guide the valve to the appropriate position for pressure or position control. The pressure or position setting value can be sent through digital DeviceNet command; Directly read the control pressure signal from the MKS Baratron pressure sensor, and all operation settings are controlled through the DeviceNet protocol.
Data storage and anti-interference: When the power is turned off, the calibration constant is saved in non-volatile memory, and it can run without recalibration after re powering on; Adopting a metal casing, optimized internal design, surge/ESD suppression network, and RFI filtering (all inputs and outputs) to enhance resistance to radio frequency interference and electromagnetic noise; When using fully metal braided shielded cables with both ends correctly grounded, they comply with the EU CE certification testing standards.
key parameters
Power Requirements: Requires 24 VDC @ 3 Amp input voltage (powered through a power connector); If a heating pressure sensor is used and powered by a valve, the sensor power demand needs to be added, and the valve can provide a maximum current of 750 mA (total of high and low sensors) for the heating pressure sensor.
Control range: The pressure control range is 0.5% -100% of the sensor range, and the position control range is 0 ° -90 °; The repeatability of the controller is ± 0.1% of full scale (FS).
control mode
Pressure control: The valve moves to maintain the target pressure (set value), supporting two algorithms: Model Based Control and PID Control.
Model based control: During the control cycle, the algorithm calculates the next valve position based on the current pressure, position, and set value, requiring knowledge of system parameters such as chamber volume and valve conductivity to optimize control; The relationship between chamber pump speed and valve position is obtained through the “LEARN function” (based on actual working conditions such as sensor type and chamber volume), which is usually executed once during initial installation. The process includes setting the chamber volume, selecting the volume estimator switch, configuring the pressure sensor range, setting the learning flow rate, and starting learning (lasting about 45 seconds, maintaining stable flow rate).
PID control: The set value optimizes the response through two parameters, Phase and Gain, and the default value can be adjusted; The response speed of phase control pressure to changes in the set value is too fast, which can lead to slow response or oscillation, and too small, which can cause overshoot and oscillation; Gain enables the controller to track the set value and minimize steady-state error. Excessive gain can cause overshoot, while insufficient gain can result in slow response.
Position control: The valve moves to the target position (set value) without feedback signal. The encoder can provide the user with the required feedback, but it is not used for closed-loop control.
Trip Points
Basic configuration: Includes 4 software trip points that can be adjusted through digital communication commands. The status changes when the pressure is above/below the set value; The trip point can be configured to monitor pressure or valve position (any combination), two of which can be mapped to hardware relays through auxiliary connectors.
Key parameters:
Hysteresis: default 10%, adjustable through digital commands, used to compensate for system noise and avoid “relay jitter”, ideal value close to but not less than peak to peak noise.
Delay: The alarm status of the trip point needs to be continuously set for a set time (0-10000 ms, default 0) before reporting “ON”. Different delay values can be set for different trip points (monitoring controller object pressure properties, trip point object valve position properties).
Direction: default “low” (when the pressure is lower than the set value, the trip point is activated, the LED lights up, and the pressure needs to be higher than the hysteresis value to release), can be changed to “high” through digital commands (when the pressure is higher than the set value, it is activated, and the pressure needs to be lower than the hysteresis value to release).
Top panel component
Connectors: Includes 5-pin miniature digital communication connector (DeviceNet communication interface), 25 pin D-type female auxiliary connector (sensor power supply, alarm relay output, RS-232 communication), 9-pin D-type male external power connector (valve power supply), and 2 15 pin D-type female analog sensor connectors (high/low sensor power supply and pressure input).
Indicator lights and switches:
Valve position indicator light: “OPEN” (red) lights up to indicate that the valve is fully open, and “CLOSE” (red) lights up to indicate that it is fully closed.
Manual valve switch: a button type switch that can manually drive the valve to the open/close position.
Trip point indicator light: It lights up green when the trip point is activated.
DeviceNet status light: including module status light (green/red dual color) and network status light (green/red dual color), the power startup sequence complies with the ODVA DeviceNet specification, the module status light is always green to indicate normal, and the red to indicate unrecoverable fault; The green constant light of the network status indicates that the communication link is normal and a connection has been established, the green flashing indicates online but no connection, and the red constant light indicates a serious link failure.
MAC ID (Node Address) Switch: Two 10 bit rotary switches, set the node address (0-63), with ten bits on the left (MSD) and one bit on the right (LSD); When the address is greater than 63, it is equivalent to the “PGM” position.
Installation Guide
Unpacking and Inspection
Unboxing process: MKS uses professional packaging to ensure that the equipment is in good condition. After receiving it, it is necessary to check whether the valve is damaged, the connector is damaged, and other transportation damages are present. Do not discard the packaging materials until safety is confirmed.
Problem handling: If damage is found, immediately notify the carrier and MKS; If you need to return the device, you need to first obtain the ERA number (device return authorization number) from the MKS service center. The MKS calibration service center list is listed on the inside of the back cover of the manual; Only qualified personnel are allowed to install and debug, and ESD protection and operating procedures must be followed.
Standard accessories: including T3B unit, T3B with DeviceNet interface user manual, MKS T3B/T3P with DeviceNet interface supplementary manual (No. 138993-P1, installation needs to refer to this supplementary manual).
Interface cable requirements
Cable specification: Full metal braided shielded cable (correctly grounded at both ends) is required to comply with CE certification; MKS provides a full range of cables, and if self-produced, they must meet the following requirements: shielding layer covering all wires (insufficient aluminum foil or spiral shielding effect may affect compliance); The metal shell of the connector is in direct contact with the entire circumference of the cable shielding layer (to avoid reduced shielding effect caused by flying wires); Good contact between the connector and the controller housing (approximately 0.01 ohms, with grounding surrounding all wires); Consider voltage level, wire I ² R heating, IR voltage drop, capacitance and inductance of fast signal cables, and internal wire shielding requirements.
Connection method: Two shielding cable connection methods are provided (priority is to use cable clamps to fix the shielding layer, and if there is no cable clamp, the shielding layer can be twisted and fixed with washers), ensuring that the shielding layer is grounded and the wire is in contact with the shell.
Installation environment and location
Environmental requirements: The working temperature range is 20 ° C-40 ° C, the working humidity is 0% -95% (non condensing), and the storage temperature range is -20 ° C-80 ° C.
Installation position: It can be installed on the vacuum exhaust pipeline (with suitable joints). To achieve optimal pressure control, the pressure sensor and T3B should be as close to the process chamber as possible to reduce the time constant; The connecting pipe between the sensor and the chamber should be less than 6 inches and have a diameter of not less than 1/4 inch. If it exceeds 6 inches, a larger diameter pipe should be used to compensate for the conductivity loss.
System configuration and electrical connections
Typical configuration: The system includes a DeviceNet network host (sending set values, receiving pressure/position/diagnostic data), a 24 VDC valve power supply, a sensor power supply (optional ± 15 VDC), a T3B unit, an analog Baratron sensor, and an alarm relay output that can be connected to external alarm devices.
Grounding requirements: If power is taken from the DeviceNet network, it must comply with the grounding requirements of the ODVA DeviceNet specification (Volume I).
Definition of connector pins:
Digital communication connector (5-pin): 1-pin (Drain), 2-pin (V+), 3-pin (V -), 4-pin (CAN_S), 5-pin (CAN_L).
Auxiliary connector (25 pins): includes receive data (RX), send data (TX), pressure output (A Out), position output (A Out), 2 sets of relays (normally open/normally closed/common terminal), valve open/closed status (digital output), interlock (digital input), analog ground, digital ground, chassis ground, etc. Pins 11-13 are related to analog signals, pins 14-19 are relays, pins 20-22 are digital status and input, and pins 24-25 are ground.
Analog sensor connector (15 pins, with the same high and low sensor pins): 2-pin (pressure input+), 5-pin (sensor power return), 6-pin (-15 V), 7-pin (+15 V), 12 pin (pressure input -), 14 pin (+24 V power output), 15 pin (chassis ground), with no other pins connected.
External power connector (9-pin): 1-2 pins (+24 V input), 3-4 pins (24 V return), 5-pin (+15 V auxiliary input, for instruments), 6-pin (15 V return), 7-pin (-15 V auxiliary input, for instruments), 8-pin (reserved), 9-pin (chassis ground).
startup process
Power on sequence: First supply power to the DeviceNet network, then supply power to T3B; When powered on, the device checks the communication link, EEPROM, and RAM internal diagnostics, and the results are indicated by the top status LED (color and flashing status).
LED startup sequence: The module status LED flashes alternately green and red for about 0.25 seconds each before turning green; The network status LED flashes alternately in green and red for about 0.25 seconds each before turning off; After initialization is completed, the module status LED remains constantly green; When there are no other network devices, the network status LED remains off; When there are other devices, the network LED flashes green during repeated MAC checks and before establishing a connection.
Preheating time: After installation and power on, the preheating time of the controller is less than 1 minute.
Operation Guide
Operation Mode
User mode: default power on mode, which is the normal operation mode.
Calibration mode: used to access specific calibration and operating parameters. The device functions are the same in both modes, but network access to certain attributes may be restricted (refer to the object attribute table in the supplementary manual for specific permissions).
Communication Configuration
Baud rate and MAC ID settings: can be set through software (DeviceNet protocol network command) or manually (top rotary switch). When powered on, if the switch is in the “PGM” position, the baud rate/address can be read from non-volatile memory, and the network can modify parameters. Changes in the switch position require a power outage and restart to take effect; If the switch is not in the “PGM” position and the switch value is directly read, the network modification request is rejected and an error code of “Attribute_Cot_Settable” is returned.
Communication specifications: Supports 125/250/500 Kbps baud rates; The network topology is linear (trunk/branch), with power and signals sharing the same cable; Supports up to 64 nodes; Explicit message communication delay<50 milliseconds (average<25 milliseconds), I/O polling message delay<4.5 milliseconds (average<1.5 milliseconds); Equipped with module status (green/red) and network status (green/red) LED indicators.
Core operational functions
Parameter setting and monitoring: Through the DeviceNet network, set values (pressure/position), valve direction (forward/reverse), pressure values and units, valve position, trip point values/hysteresis/delay/status can be set and reported, monitoring system status, reporting operating time, and setting valve soft start; Storage device identification information (manufacturer information, model serial number, factory calibration data, software and hardware version number).
Maintenance and troubleshooting
routine maintenance
Routine inspection: No special maintenance requirements, only correct installation and operation are required; Regularly check for cable wear and signs of shell damage; Regularly wipe the surface of the equipment with a damp cloth.
Equipment return: If you need to return the MKS for repair, you need to obtain the ERA number first; The returned equipment must be free of harmful, corrosive, radioactive, or toxic substances.
troubleshooting
General faults:
When the valve is closed, the conductivity does not meet the standard: it may be due to wear or damage of the baffle seal, and the factory needs to be contacted to obtain a seal replacement kit.
25 pin I/O connector interlock missing (22-24 pins): Connect pin 22 to pin 24 or verify external interlock wiring.
Valve not open/closed: Check if the 24V power supply is properly connected to the valve terminal or if the valve is faulty (need to be sent to MKS for repair); Simultaneously confirm the interlocking wiring.
Pressure control failure (report full range/low/zero): Sensor disconnected (reconnect) or pressure gauge not powered (check power supply).
Pressure control oscillation/poor effect: PID mode needs to optimize gain and phase, and the model base mode needs to relearn the pump speed curve; The control offset may be due to high grounding impedance (judged by MKS valve GUI as a debugging or grounding issue); The control difference within a specific pressure range may be due to incorrect intersection point settings (configuring and installing pressure gauges for intersection pressure).
Unable to achieve target pressure: The baffle seal is worn or damaged (replace seal).
Report negative/abnormal pressure: pressure gauge not zeroed (zeroing), no power supply (checking power supply); Pressure gauge full range setting error (configured with correct range), voltage range error.
Pump speed learning failed: The pressure gauge is not connected to the high range (retry after connecting to the high range).
Communication malfunction:
RS-232 communication failure: Check baud rate, data bits, checksum, CR-LF settings, or cable wiring issues.
DeviceNet communication failure: Check MAC address and baud rate settings, or network power supply for normal operation.
Meaning of fault indicator light:
Module status LED: evergreen (normal), flashing green (visual indication), constantly red (non recoverable fault), flashing red (minor fault, such as interlock not enabled), off (no power supply), alternating red and green (self check).
Network status LED: evergreen (communication link normal, online and connection established), flashing green (online but no connection established), constantly red (severe link failure, such as repeated MAC address or bus shutdown), flashing red (connection timeout), alternating red and green (initialization), off (not online, such as incomplete repeated MAC check or no power supply); When using a single device network, it is normal to keep it off until there is no connection.
Fault type:
Minor faults: MAC ID or baud rate switch changed during operation, safety interlock opened (only T3P gas interlock), controller error reported through abnormal status bit (refer to supplementary manual), equipment remains in operation.
Serious malfunction: During self inspection, EEPROM hardware or RAM memory issues were detected, the module status LED is constantly red, and the device has entered a serious malfunction state, unable to respond to network services. MKS needs to be contacted.
Overview of the Core of Tricon Fault Tolerant Control System
Core Definition and Architecture
Fault Tolerant Control: capable of identifying and compensating for faulty control units, allowing for repairs without interrupting processes, suitable for critical process applications that require high safety and availability.
Tricon controller: It adopts the third mock examination redundancy (TMR) architecture to achieve fault tolerance, integrates three independent parallel control systems and comprehensive diagnostic functions, ensures no single point of failure through the “three out of two” voting mechanism, and achieves high integrity, error free, and uninterrupted process operation.
TMR architecture details: Three identical channels independently and parallelly execute control programs, digital I/O is verified through dedicated software and hardware voting, and analog input adopts median selection; The channels are isolated from each other, and a single channel failure does not affect other channels. The faulty module can be replaced online.
Key Features
No single point of failure; Support 3, 2, or 1 main processor to run until shutdown; Fully implemented and transparent triple transformation; Comprehensive system diagnosis; Complete I/O module series; Provide dual I/O and single I/O modules for safety critical and limited availability requirements; Remote I/O can be up to 7.5 miles (12 kilometers) away from the main processor; Support simple online module maintenance; Has extremely high reliability and availability.
Typical application scenarios
Emergency Safety Shutdown (ESD): protects key units such as refineries and petrochemical/chemical plants, monitors parameters such as pressure and feed rate, avoids false tripping of traditional relay systems, has sensor integrity detection, integrated shutdown and control functions, and can be connected to monitoring data highways.
Boiler flame safety: Integrating boiler protection, start stop safety interlock, and flame safety functions, replacing traditional discrete components, improving resource utilization, and maintaining or exceeding the safety of electromechanical protection systems.
Turbine control system: realizes the control and protection of gas/steam turbines, integrates speed control and start stop sequence, avoids unplanned shutdowns through I/O module hot standby, and automatically activates the standby module in case of faults.
Marine fire and gas protection: supports online replacement of faulty modules, built-in diagnostic management module, wiring and sensor faults, simulated fire and gas detectors can be directly connected, replacing traditional fire and gas panels, saving space and ensuring high safety and availability.
Detailed specifications of 3624 digital output module
Module basic information
Type: TMR (the third mock examination redundancy), with supervised function.
Nominal voltage: 24 VDC.
Output points: 16 points, shared.
Electrical parameters
Voltage range: 16-30 VDC, maximum voltage 36 VDC.
Voltage drop: Typical value<1.5 VDC.
Power module load:<10 watts.
Current rating: maximum 0.7 A per point, maximum surge current of 4.8 A within 10 ms.
Minimum required load: 30 mA.
Load leakage current: maximum 4 mA.
Point isolation: minimum 1500 VDC.
Fuse: None (self-protection).
Function and Diagnosis
Monitoring function: By using voltage and current loop circuits, combined with online diagnosis, the output switch, on-site circuit, and load status can be verified, and faults such as on-site power loss/fuse melting, load open circuit/loss, load misoperation short circuit, load power-off short circuit, etc. can be detected; The POWER alarm is activated when the on-site voltage cannot be detected, and the LOAD alarm is activated when the load cannot be detected.
Module status diagnosis: equipped with PASS (module passes self-test), FAILT (module fault), ACTION (module activation) indicator lights, with ON/OFF status indicator lights at each point, color code Turquoise Green.
Compatibility and Installation
Supporting hot standby modules requires a separate external terminal panel (ETP) and cable interface with the Tricon backplane; The module adopts a mechanical key control design to prevent accidental installation into the wrong slot; On site wiring requires connecting the on-site power supply to each output point of the on-site terminal, with the output designed to provide current to the on-site equipment.
System configuration and hardware components
System Composition
Composed of one main chassis and up to 14 extended or remote extended (RXM) chassis, up to 15 chassis can support 118 I/O modules and communication modules, and can connect OPC clients, Modbus devices, other Tricon controllers, Ethernet (802.3) external host applications, and Foxboro, Honeywell DCS.
Chassis Layout and Configuration Rules
Main Chassis: There are two power modules on the left side and three main processors on the right side. The remaining space is divided into six logical slots for I/O and communication modules, as well as one COM slot without a hot spare position. Each logical slot contains two physical spaces (active module and optional hot spare module); Address 1 requires three 3008 model main processors (Tricon v9.6 and above) and two power modules.
Expand Chassis: The layout is similar to the main Chassis, but provides 8 logical slots for I/O modules; The length of the I/O bus cable is usually up to 100 feet (30 meters), and can reach up to 1000 feet (300 meters) in restricted applications. The address needs to be between 2-15 and unique, requiring two power modules connected to channels A, B, and C through a triple I/O bus cable.
RXM Chassis: Used in scenarios where the total length of I/O bus cables exceeds 100 feet (30 meters), with addresses 2-15 and unique; An RXM Chassis needs to be located within 100 feet (30 meters) of the main Chassis, with built-in main RXM module groups (usually supporting 3 groups), each group can support 3 remote sites, with each site up to 7.5 miles (12 kilometers) away from the main site. Remote sites require RXM Chassis and remote RXM module groups, with the main and remote RXM module groups connected by 6 fiber optic cables; Provide 6 I/O module logic slots and 1 blank slot, requiring two power modules that can be connected to the local expansion Chassis via I/O bus cables.
Core hardware component specifications
Power module: each Chassis is equipped with two, and any module can operate under full load and rated temperature, supporting online replacement; Convert the line power supply to a DC power supply suitable for the Tricon module, with an input of at least 240 watts per power module; The alarm contact will activate when the module is missing, there is a conflict between hardware and control program logic configuration, the module is faulty, the main processor detects a system fault, the main power supply of the power module is faulty, or there is a warning of “low battery” or “over temperature” in the power module; There are multiple models available, such as 8310 (120 VAC/VDC), 8311 (24 VDC), 8312 (230 VAC), with an output power of 175 watts (at 140 ° F/60 ° C), an output voltage of 6.5 VDC ± 1%, a maximum output current of 27 A (in 140 ° F/60 ° C environment), input and output isolation>1000 VAC or 1500 VDC, and an over temperature sensor triggered when the internal temperature is>181 ° F (83 ° C), usually corresponding to an ambient temperature of 140 ° F (60 ° C) or above.
Main processor module (Model 3008): Used in Tricon v9.6 and above systems, each system requires 3 main Chassis modules, which independently communicate with the I/O subsystem and execute user control programs; Includes Motorola MPC860 32-bit 50 MHz microprocessor, 16 MB DRAM (without battery backup), 32 KB SRAM (battery backup), 6 MB Flash PROM; TriBus communication speed of 25 Mbps, 32-bit CRC protection, 32-bit DMA and complete isolation; The I/O bus and communication bus processors are Motorola MPC860 32-bit 50 MHz; Equipped with multiple status indicator lights such as PASS, FAULT, and ACTION; Support sequence of events (SOE) and time synchronization, protect user programs and maintain variable integrity for at least 6 months during power outages, powered by dual power modules and main Chassis power rails.
Communication module: Multiple types meet different communication needs, such as the Tricon Communication Module (TCM) that supports communication with Modbus devices TriStation PC、 Communication between network printers, other Tricon controllers, and Ethernet devices, including 4 serial ports, 2 network ports, and 1 debugging port. A single system can support up to 4 ports and should be located in two logical slots; Enhanced Intelligent Communication Module (EICM) supports RS-232/422/485 serial communication, including 4 serial ports and 1 parallel port. A single system can support up to 2 ports, which need to be located in one logical slot; The Network Communication Module (NCM) supports Ethernet (802.3) communication, including 2 BNC interfaces and 1 RS-232 serial port, supports OPC Server and TSAA protocols, and NCMG supports GPS time synchronization; The Safety Manager Module (SMM) connects Tricon to Honeywell TDC 3000 UCN; Hiway interface module (HIM) connects Tricon with Honeywell TDC 3000 Hiway gateway and LCN; Advanced Communication Module (ACM) connects Tricon with Foxboro I/A Series DCS.
Remote Expansion Module (RXM): Supports I/O modules located several kilometers away from the main Chassis, consisting of three identical modules, serving as relays and extenders for the Tricon I/O bus, providing ground loop isolation; There are multimode fiber (4200-3 main, 4201-3 remote, maximum distance 1.2 miles/2 kilometers) and single-mode fiber (4210-3 main, 4211-3 remote, maximum distance 7.5 miles/12 kilometers) models, with a communication speed of 375 kbps and indicator lights such as PASS, FAULT, and ACTION.
On site terminal options
Terminal product type
External Terminal Panel (ETP): a passive printed circuit board that facilitates on-site wiring, transmits signals between the site and I/O modules, supports I/O module replacement without interfering with on-site wiring; The on-site signals can be collected in a separate enclosure up to 99 feet (30 meters) away from Tricon; The standard panel includes terminal blocks, resistors, fuses, and other components, suitable for lines 24-12 (0.3-2.1mm ²), with some having current limiting resistors or fuses with fuse indication; There are also basic panels (including connectors and terminal blocks only, users need to equip other components themselves), hazardous area (non flammable) panels (suitable for Zone 2, Class 1, Division 2, certified by T Ü V), panels with intermediate relays (suitable for load current>2A or voltage>115 VAC scenarios), digital input bypass panels (32 pre wired switches, including master key switch and redundant 24 VDC power terminals), panels with signal conditioners (supporting RTD, thermocouple, 4-20 mA transmitter, 16 points/panel, compatible with 1-5V output signal conditioners) and other types.
Faned Out Cables: A low-cost alternative to ETP, with one end connected to a Tricon backplane and the other end having 50 labeled 22 wires with pin numbers, suitable only for digital I/O modules. The standard length is 10 feet (3 meters) and can be customized up to 99 feet (30 meters). The last two digits of the model indicate the length (feet).
Terminal configuration and protection
Configuration options: Non common ground terminal (each point can be connected to an independent power supply), common ground terminal (multiple points share one power supply, can be connected to a common ground group of 8 or 16 points); Analog signals can be connected to 3-wire transmitter inputs, voltage inputs, or current inputs; The thermocouple terminal provides a cold junction temperature sensor, the 3706A model’s fuse detection relies on the terminal panel, and the 3708E model can be configured through TriStation.
Overcurrent protection: Non basic terminal panels are self protected through single point/on-site power fuses, series resistors, digital and analog output modules; The basic terminal panel requires users to equip themselves with overcurrent protection components.
Module and Terminal Matching Table: The document provides a detailed table that lists various terminal panel models (common ground, non common ground, basic, non flammable, fan out cable, bypass panel, ERT loopback cable/panel) corresponding to each I/O module (such as digital input, digital output, pulse input, relay output, analog input, analog output, thermocouple input module, etc.). For example, the common terminal panel model corresponding to the 3624 digital output module (24 VDC, 16 points, TMR monitoring type) is 9662-610, the basic terminal panel model is 9653-610, the non flammable terminal panel model is 9671-610, and the fan out cable model is 9101-010.
Terminal panel dimensions: The document lists the width (horizontally along the DIN rail), length (vertically along the DIN rail), and height (away from the DIN rail) dimensions of each model of terminal panel, in inches and centimeters. For example, the 9551-110 panel has a width of 3 inches (7.62 centimeters), length of 5 inches (12.7 centimeters), and height of 4.25 inches (10.795 centimeters).
Communication capability
Communication range and supported objects: Tricon can communicate with Modbus master-slave devices, Foxboro I/A Series Nodebus, Honeywell UCN, Honeywell Data Hiway and LCN, Ethernet (802.3) external hosts, other Tricon controllers (peer-to-peer networks), TriStation PC, OPC Server through communication modules.
Details of Key Communication Module Functions
TCM (Tricon Communication Module): Only compatible with Tricon v10.0 and above, supporting communication with TriStation, other Tricon/Rident controllers, Modbus master-slave devices, and Ethernet external hosts; 4 serial ports (configurable as Modbus master/slave, serial port 1 supports Modbus or Trimble GPS, serial port 4 supports Modbus or TriStation, total data rate 460.8 kbps), 2 network ports (4351A/4353 is copper Ethernet, 4352A/4354 is fiber Ethernet, supports TCP/IP, Modbus TCP/IP and other protocols, network port 1 also supports peer-to-peer and peer-to-peer time synchronization protocols); A maximum of 4 units per system, located in two logical slots, do not support hot standby but can be replaced online; The Tricon variable needs to be assigned a 5-digit alias (representing the Modbus message type and variable address) to communicate with Modbus devices.
EICM (Enhanced Intelligent Communication Module, Model 4119A): Supports Modbus master-slave devices TriStation、 Printer communication; 4 serial ports (configurable as Modbus master/slave, supporting RS-232/422/485, up to 7 Modbus master stations per Chassis), 1 parallel port (Centronics compatible); A maximum of 2 units per system, located in one logical slot, do not support hot standby but can be replaced online; The total data rate is 57.6 kbps, Modbus supports RTU or ASCII mode, and Tricon variables need to be assigned aliases.
NCM (Network Communication Module, Model 4329/4329G): Supports Ethernet (802.3) communication at a speed of 10 Mbps, and NCMG supports GPS time synchronization; 2 BNC interfaces (RG58 50 ohm thin cable), 2 external transceiver interfaces (15 pin D-type), and 1 RS-232 serial port; Port 1 supports peer-to-peer and time synchronization protocols (only for Tricon secure networks), while Port 2 supports open networks (TriStation, SOE, OPC Server, etc.); A single logical slot can accommodate 2, working independently and not as a hot backup; External hosts need to access Tricon variables through aliases, which can be extended to a distance of 2.5 miles (4000 meters) through repeaters and standard cables.
SMM (Safety Manager Module, Model 4409): Connect Tricon to Honeywell TDC 3000 UCN as a safety node on the UCN, transmit process information at full network rate, and transmit Tricon alias data and diagnostic information to the operation station in a format familiar to Honeywell operators; Support critical I/O point processing, alarm processing and propagation, alias data reading and writing, Tricon diagnostic reading, write protection, DCS time synchronization, peer-to-peer communication, event sequence transmission, and hot standby functions; 2 isolated UCN ports, data rate 5 MB/s, power load<20 watts, isolated 500 VDC, equipped with multiple status indicator lights.
HIM (Hiway Interface Module, Model 4509): connects Tricon with Honeywell TDC 3000 (via Hiway gateway and LCN) or TDC 2000 (via Data Hiway), supporting communication between high-level devices on LCN/Data Hiway and Tricon; 2 isolated Data Hiway channels, baud rate of 250 kbps, equivalent to 4 extended Data Hiway port addresses, providing 8 Hiway addresses, data refresh<0.5 seconds; Support hot standby, power load<10 watts, isolated 500 VDC, with multiple status indicator lights.
ACM (Advanced Communication Module, Model 4609): connects Tricon with Foxboro I/A Series system as a secure node on Nodebus, transmitting process information at full network rate, and transferring Tricon alias data and diagnostic information to the operation station in a format familiar to Foxboro operators; Support critical I/O point processing, alarm processing and propagation, alias data read and write, Tricon diagnostic read, write protection, I/A Series time synchronization, and hot standby function; BNC supports TriStation, TSAA protocol, and user applications; Multiple ports (BNC, 15 pin D-type AUI, 9-pin RS-423 Nodebus control port, etc.), some ports have a speed of 10 Mbps, the Nodebus control port is 2400 baud, the power load is 20 watts, isolated 500 VDC, and equipped with multiple status indicator lights.
Communication Protocol and Application
Support agreement: TriStation、Modbus（RTU/ASCII/TCP）、TCP/IP、ICMP、SNTP、TSAA、Trimble GPS、 Peer to Peer, peer-to-peer time synchronization, Jet Direct (network printing), etc.
Triconex protocol: Peer to peer protocol (exchanging security and process information between Tricons), time synchronization protocol (maintaining Tricon time consistency in the network), TriStation protocol (master-slave communication between TriStation PC and Tricon, one slave per communication), TSAA protocol (master-slave communication between external hosts and Tricon, used for developing control or monitoring applications).
Triconex applications: TriStation 1131 (for developing, testing, and monitoring Tricon applications), Event Sequence (SOE, for retrieving Tricon events in the network for maintenance and downtime analysis), Enhanced Diagnostic Monitor (for monitoring Tricon hardware and application status), DDE Server (for allowing Windows DDE clients such as Excel to read and write Tricon alias data), OPC Server for Triconex (for allowing OPC clients to read and write Tricon program variables, some modules rely on external Matrikon OPC Server, and some models will have embedded OPC Server).
Network redundancy and configuration rules
Module/Media Redundancy: Install two communication modules (TCM/NCM/ACM) in the same logical slot and connect network nodes with two sets of cables to address issues such as cable breakage and port failures.
External host redundancy: The backup external host is connected to the network, and in the event of a primary host failure, the control program can be restarted on the backup host. All Triconex applications can be loaded onto the primary and backup hosts.
Configuration rule: TriStation PC needs to communicate with Tricon through TCM/EICM/NCM/ACM, and at least one such module needs to be installed in the main Chassis or Chassis 2; Some modules (such as EICM, ACM) have a limit on the number of logical slots, and some modules (such as NCM, TCM) cannot coexist in the same system; If Chassis 2 is equipped with a communication module, it requires an I/O COMM cable (9001 model) instead of a standard I/O bus cable to directly connect to the main Chassis. Chassis 2 can be an I/O expansion Chassis or a main RXM Chassis.
Core positioning and key attributes of the product
Security level and functional positioning:
Belonging to the High Integrity processor unit, it has passed SIL3 certification (compliant with safety related system standards) and needs to be configured according to the ABB safety manual; Mainly used in industrial control scenarios with extremely high security requirements, such as security systems in process industries, energy and other fields.
Core performance parameters:
The processor has a clock frequency of 96MHz and a memory capacity of 32MB. It is equipped with a memory backup battery (model 4943013-6) to ensure that critical data is not lost after power failure.
Scope of application restrictions:
Non RoHS 2 (2011/65/EU) compliant products, only used as spare parts for systems launched before July 22, 2017, for maintenance, reuse, functional updates, or capacity upgrades;
The new installation project needs to be replaced with the upgraded model PM867K01.
Product Packaging List
The delivery package of PM865K01 includes the following components and does not require additional purchase of basic accessories:
Core Unit: PM865 Safety CPU;
Basic hardware: TP830 base plate;
Bus Terminators: TB850 (CEX bus), TB807 (Modulus Bus), TB852 (RCU Link bus);
Backup accessories: 4943013-6 model memory backup battery;
Note: The packaging does not include any software license (No license included).
Physical specifications and classification information
1. Physical dimensions and weight
Specific numerical values of physical parameters
Net depth/length 135mm
Net height 186mm
Net width 119mm
Net weight 1.2kg
2. Classification of Trade and Dangerous Goods
HS code: 853710- (classified as “electronic control or distribution boards, panels, etc. equipped with two or more devices of class 85.35/85.36, with a voltage not exceeding 1000V”);
Customs tax number: 85371091;
Dangerous Goods Classification: Class 9 (Miscellaneous Hazardous Substances and Articles, including Environmentally Hazardous Substances), UN Number UN3091-PI970.
Environmental compliance and battery information
1. Environmental compliance
RoHS status: Not RoHS Compliant;
WEEE category: 5 categories (small equipment, with no external dimensions exceeding 50cm);
SCIP number: 159186b8-1923-4758-909b-dc5acB592343 (Swedish regional registration code, used for EU chemical information exchange).
2. Battery parameters
Quantity: 1 section;
Type: Portable lithium battery;
Weight: 9g;
Purpose: To provide power-off backup for processor memory and prevent data loss.
Product ownership and compatibility system
PM865K01 is the core unit of ABBAC 800M control system and 800xA system, compatible with the following specific system versions, mainly used as a spare part for the corresponding system:
AC 800M High Integrity series;
800xA system version 6.0;
AC 800M hardware versions 4.0, 4.1, 5.0, 5.1;
AC 800M control software version 4.0;
AC 800M versions 4.1, 5.0, and 5.1 under the Compact Product Suite.
V7768 is a VME bus single board computer based on Intel architecture, featuring high flexibility and rich I/O expansion capabilities, suitable for industrial scenarios that require stable embedded computing. Its core advantages include:
Supports Intel Core 2 Duo/Celeron M processors, adapting to different performance and temperature requirements;
Integrate multiple types of interfaces (dual Gigabit Ethernet, SATA, USB, etc.) to meet basic connectivity requirements without the need for additional expansion;
Provide PCI-X PMC expansion slots and board to board connectors, which can further expand up to 3 PMC sites and adapt to complex I/O scenarios;
Compatible with mainstream operating systems such as Windows XP, VxWorks, Linux, and adaptable to various software environments.
Hardware configuration and performance parameters
1. Processor and Storage
Category specific configuration
Processor – Intel Core 2 Duo: up to 2.16GHz, 4MB L2 cache, 667MHz system/memory bus
-Intel Celeron M: 1.07GHz, 1MB L2 cache, 533MHz system/memory bus
Maximum 2GB DDR2 SDRAM memory (expandable through a single SODIMM slot)
Storage expansion supports up to 8GB CompactFlash (accessible through a secondary IDE port and configurable as a BIOS boot device)
Non volatile storage 32KB non-volatile SRAM (used to store critical data)
2. Interface and Expansion Capability
The V7768 interface covers scenarios such as network, storage, peripherals, and bus expansion, as follows:
Network interface: Dual Gigabit Ethernet (based on Intel 82571 chip), both connected through RJ45 connectors on the front panel, supporting PCIe network boot;
Storage interface: 2 SATA interfaces (leading to the rear P2 interface), used for connecting hard drives/SSDs;
USB interface: 4 USB 2.0 ports (2 front panel, 2 rear P2 ports), supporting synchronous data transfer, automatic peripheral recognition, and hot plugging;
Serial interface: 2 16550 compatible serial ports (DB-9 connector), COM1 front, COM2 rear, supporting up to 115K baud rate, including 16 byte FIFO;
Human computer interaction interface: The front panel integrates PS/2 keyboard/mouse interface and SVGA display interface;
Bus and Expansion:
VME bus: supports VME64 mode (A32/A24/D32/D08 (EO)/MBLT64/BLT32), including hardware byte swapping and enhanced bus error handling;
PMC Expansion: 1 133MHz PCI-X PMC slot, supporting VITA35 standard; By pairing the board to board connector with the PMC237CM1/V expansion board, an additional 3 32-bit/33MHz PMC stations can be added.
3. Timer and monitoring function
Programmable timers: 2 16 bit timers+2 32-bit timers, mapped to PCI memory space, supporting software programming and PCI bus interrupts;
Watchdog timer: configurable time interval, supports interrupt triggering and board level reset, improves system stability;
BIOS: The system BIOS and video BIOS are stored in programmable flash memory and support device configuration during startup.
Physical and environmental parameters
1. Physical specifications
Appearance: 6U (4HP) single slot Eurocard standard size;
The safety-related F30 controller is a compact system in a metal housing with 20 digital inputs and 8 digital outputs.
The controller is available in various model variants for SILworX and ELOP II Factory.
The device is suitable for mounting in Ex-zone 2.
The device is TÜV-certified for safety-related applications up to SIL 3 (IEC 61508, IEC 61511 and IEC 62061), Cat. 4 and PL e (EN ISO 13849-1) and SIL 4 (EN 50126, EN 50128 and EN 50129).
Further safety standards, application standards and test standards are specified in the certificates available on the HIMA website.
Safety Function
The controller is equipped with safety-related digital inputs and outputs.
Safety-Related Digital Inputs
The controller is equipped with 20 digital inputs. The state (HIGH, LOW) of each input is signaled by an individual LED.
Mechanical contacts without own power supply or signal power source can be connected to the inputs.
Potential-free mechanical contacts without own power supply are fed via an internal short circuit-proof 24 V power source (LS+). Each of them supply a group of 4 mechanical contacts.
With signal voltage sources, the corresponding ground must be connected to the input (L-)
For the external wiring and the connection of sensors, apply the de-energized-to-trip principle.
Thus, if a fault occurs, the input signals adopt a de-energized, safe state (low level).
If an external wire is not monitored, an open-circuit is considered as safe low level.
Reaction in the Event of a Fault
If the device detects a fault on a digital input, the user program processes a low level in accordance with the de-energized to trip principle.
The device activates the FAULT LED.
In addition to the channel signal value, the user program must also consider the corresponding error code.
The error code allows the user to configure additional fault reactions in the user program.
Line Control
Line control is used to detect short-circuits or open-circuits and can be configured for the F30 system, e.g., on EMERGENCY STOP inputs complying with Cat. 4 and PL e in accordance with EN ISO 13849-1.
To this end, connect the digital outputs DO 1 through DO 8 of the system to the digital inputs DI of the same system as follows:
The controller pulses the digital outputs to detect short-circuits and open-circuits on the lines connected to the digital inputs.
To do so, configure the Value [BOOL] -> system variable in SILworX or the DO[0x].Value system signal in ELOP II Factory.
The variables for the pulsed outputs must begin with channel 1 and reside in direct sequence, one after the other.
If the following faults occur, the FAULT LED located on the front plate of the controller blinks,the inputs are set to low level and an (evaluable) error code is created:
Cross-circuit between two parallel wires.
Invalid connections of two lines (e.g., DO 2 to DI 3),
Earth fault on one wire (with earthed ground only).
Open-circuit or open contacts, i.e., including when one of the two EMERGENCY STOP
switches mentioned above has been engaged, the FAULT LED blinks and the error code is created.
Equipment, Scope of Delivery
The following table specifies the available controller variants:
F30 01:Controller (20 digital inputs, 8 digital outputs), Operating temperature: 0…+60 °C, for ELOP II Factory programming tool.
F30 011 (-20 °C) :Controller (20 digital inputs, 8 digital outputs), Operating temperature: -20…+60 °C, for ELOP II Factory programming tool
F30 014:Controller (20 digital inputs, 8 digital outputs), Operating temperature: -25…+70 °C (temperature class T1), Vibration and shock tested according to EN 50125-3 and EN 50155,
class 1B according to IEC 61373, for ELOP II Factory programming tool
F30 01 SILworX:Controller (20 digital inputs, 8 digital outputs), Operating temperature: 0…+60 °C, for SILworX programming tool
F30 011 SILworX (-20 °C)：Controller (20 digital inputs, 8 digital outputs), Operating temperature: -20…+60 °C, for SILworX programming tool
F30 014 SILworX：Controller (20 digital inputs, 8 digital outputs), Operating temperature: -25…+70 °C (temperature class T1), Vibration and shock tested according to EN 50125-3 and EN 50155, class 1B according to IEC 61373, for SILworX programming tool
Type Label
The type plate contains the following details:
Product name
Bar code (1D or 2D code)
Part no.
Production year
Hardware revision index (HW Rev.)
Firmware revision index (FW Rev.)
Operating voltage
Mark of conformity
Mounting the F30 in Zone 2
(EC Directive 94/9/EC, ATEX)
The controller is suitable for mounting in zone 2. Refer to the corresponding declaration of conformity available on the HIMA website.
When mounting the device, observe the special conditions specified in the following section.
Specific Conditions X
1. Mount the HIMatrix F30 controller in an enclosure that meets the EN 60079-15 requirements and achieves a type of protection of at least IP54, in accordance with EN 60529. Provide the enclosure with the following label:
Work is only permitted in the de-energized state Exception:
If a potentially explosive atmosphere has been precluded, work can also performed when the controller is under voltage.
2. The enclosure in use must be able to safely dissipate the generated heat. Depending on the output load and supply voltage, the HIMatrix F30 has a power dissipation ranging between 12 W and 33 W.
3. Protect the HIMatrix F30 with a 10 A time-lag fuse.
The 24 VDC power must come from a power supply unit with safe isolation. Use power supply units of type PELV or SELV only.
4. Applicable standards:
VDE 0170/0171 Part 16, DIN EN 60079-15: 2004-5
VDE 0165 Part 1, DIN EN 60079-14: 1998-08
Configuration with SILworX
In the Hardware Editor, the controller is represented like a base plate equipped with the following modules:
Processor module (CPU)
Communication module (COM)
Input module (DI 20)
Output module (DO 8)
Double-click the module to open the Detail View with the corresponding tabs. The tabs are used to assign the global variables configured in the user program to the system variables.
Parameters and Error Codes for the Inputs and Outputs
The following tables specify the system parameters that can be read and set for the inputs and outputs, including the corresponding error codes.
In the user program, the error codes can be read using the variables assigned within the logic.
The error codes can also be displayed in SILworX.
Configuration with ELOP II Factory
Configuring the Inputs and Outputs
The signals previously defined in the Signal Editor (Hardware Management) are assigned to the individual channels (inputs and outputs) using ELOP II Factory. Refer to the system manual for compact systems or the online help for more details.
The following chapter describes the system signals used for assigning signals in the controller.
Signals and Error Codes for the Inputs and Outputs
The following tables specify the system signals that can be read and set for the inputs and outputs, including the corresponding error codes.
In the user program, the error codes can be read using the signals assigned within the logic.
The error codes can also be displayed in ELOP II Factory.
Operation
The controller F30 is ready for operation. No specific monitoring is required for the controller.
Handling
Handling of the controller during operation is not required.
Diagnosis
A first diagnosis results from evaluating the LEDs, see Chapter 3.4.1.
The device diagnostic history can also be read using the programming tool.
Maintenance
No maintenance measures are required during normal operation.
If a failure occurs, the defective module or device must be replaced with a module or device of the same type or with a replacement model approved by HIMA.
Only the manufacturer is authorized to repair the device/module.
Faults
If the test harnesses detect safety-critical faults, the module enters the STOP_INVALID state and will remain in this state. This means that the input signals are no longer processed by the device and the outputs switch to the de-energized, safe state. The evaluation of diagnostics provides information on the fault cause.
Maintenance Measures
The following measures are required for the device:
Loading the operating system, if a new version is required
Executing the proof test
Loading the Operating System
HIMA is continuously improving the operating system of the devices.
HIMA recommends to use system downtimes to load a current version of the operating system into the devices.
Refer to the release list to check the consequences of the new operation system version on the system!
The operating system is loaded using the programming tool.
Prior to loading the operating system, the device must be in STOP (displayed in the programming tool). Otherwise, stop the device.
For more information, refer to the programming tool documentation.
Proof Test
HIMatrix devices and modules must be subjected to a proof test in intervals of 10 years.
Decommissioning
Remove the supply voltage to decommission the device. Afterwards pull out the pluggable screw terminal connector blocks for inputs and outputs and the Ethernet cables.
Transport
To avoid mechanical damage, HIMatrix components must be transported in packaging.
Always store HIMatrix components in their original product packaging. This packaging also provides protection against electrostatic discharge. Note that the product packaging alone is not suitable for transport.
Disposal
Industrial customers are responsible for correctly disposing of decommissioned HIMatrix hardware. Upon request, a disposal agreement can be arranged with HIMA.
All materials must be disposed of in an ecologically sound manner.
Product basic positioning and core application areas
1. Product category and positioning
The linear guide and wedge components of Welker Bearing are both high-precision linear motion parts, with the core positioning being:
Linear Slides: Achieve smooth and precise linear reciprocating motion of equipment components, undertaking dual functions of guidance and load-bearing;
Gib Assemblies: Used in conjunction with linear guides to adjust guide clearance, compensate for wear, improve motion accuracy and stability, and some models can be used independently as guide components.
2. Core application scenarios
Both types of products focus on the demand for “high-precision linear motion” in the industrial field, and typical application equipment includes:
Machine tools: worktable guidance for lathes, milling machines, grinders, and machining centers;
Automation equipment: robot guide rails, automated production line conveyor mechanisms, precision positioning platforms;
Heavy industrial equipment: linear moving parts of metallurgical machinery, heavy-duty presses, and mining equipment;
Special equipment: precision guide rails for aerospace component processing equipment and medical imaging equipment (such as CT and MRI).
Product details of Linear Slides
1. Product series classification
According to the structure, load-bearing capacity, and accuracy level, linear guides are divided into multiple standard series. The core series and characteristics are as follows:
Series name, structural characteristics, core advantages, applicable scenarios
Standard Linear Slides single/double track structure, using steel guide rails and sliders, with built-in lubrication grooves for strong versatility, moderate cost, easy installation, universal machine tools, and lightweight automation equipment
Heavy Duty Linear Slides: Thickened guide rail walls, reinforced slider materials (high carbon steel/alloy steel), multiple sets of rolling elements (or sliding friction pairs) with strong load-bearing capacity (static load can reach several tons), good impact resistance. Heavy duty machine tools, metallurgical machinery, and press machines
Precision Linear Slides (Precision Series) guide rail surface precision grinding (roughness Ra ≤ 0.8 μ m), adjustable clearance, equipped with position feedback interface (optional), high motion accuracy (positioning error ≤ 0.01mm/m), good repeatability Precision machining equipment, medical equipment, aerospace parts processing
Custom Linear Slides can adjust the length of guide rails, number of sliders, installation hole positions, and material (such as stainless steel) according to customer needs to adapt to special installation spaces and working conditions. Non standard equipment and customized scenarios for special industries can also be used
2. Key technical parameters (general standards)
(1) Dimensions and installation parameters
Guide rail length: Standard series 6 inches (152.4mm) -10 feet (3048mm), custom series can be extended to 20 feet (6096mm) or more;
Guide rail cross-sectional dimensions: standard width of 1.5 inches (38.1mm) -6 inches (152.4mm), height adapted to load-bearing capacity (1 inch -4 inches);
Installation method: Bottom/side bolt fixation, standard installation hole spacing of 12 inches (304.8mm), customizable hole distribution.
(2) Performance parameters
Performance Index Standard Series Heavy duty Series Precision Series
Maximum Speed: 500 inches/minute (12.7m/min), 300 inches/minute (7.62m/min), 800 inches/minute (20.32m/min) (compatible with precision drives)
(3) Material and Protection
Material of guide rail/slider: Standard material is 1045 high carbon steel (quenched hardness HRC 58-62), precision series can choose 440C stainless steel (rust proof), heavy-duty series can choose alloy structural steel;
Surface treatment: The standard is blackening treatment (rust prevention), optional chrome plating (enhanced wear resistance), zinc plating (corrosion resistance, suitable for humid environments);
Lubrication: Built in lubrication groove, supports regular lubrication grease (lithium based grease is recommended), and some models can choose automatic lubrication interface.
Gib Assemblies Product Details
1. Product type and structure
Wedge components, as the “precision compensation and clearance control components” of linear guides, are mainly divided into two categories:
Type Name Structure Composition Core Functions
Solid Gibbs integrated wedge block (inclined angle 3 ° -10 °), fixing bolt, and locating pin are used to fix the guide rail clearance, suitable for scenarios with low wear and stable working conditions
Adjustable Gibs: Split wedge block (active wedge+passive wedge), adjusting bolt (top screw/pull rod), locking nut can adjust the gap in real time (compensating for wear or assembly errors), suitable for high-precision or high wear working conditions
2. Key technical parameters
Material: Same linear guide rail, mainly made of 1045 high carbon steel (quenched HRC 55-60), optional stainless steel;
Slope accuracy: Slope angle tolerance ± 0.5 °, surface roughness Ra ≤ 1.6 μ m;
Adjustment range: The gap adjustment of the adjustable wedge block is 0.001-0.01 inches (0.025-0.254mm), meeting different precision compensation requirements;
Adaptive guide rail: It can be matched with Welker’s full range of linear guides, and can also be customized according to the customer’s existing guide rail size (a cross-sectional view of the guide rail is required).
Customization of dimensions: rail length, cross-sectional dimensions, installation hole positions/quantities;
Material and surface treatment customization: stainless steel material (rust proof), special alloy (high temperature/corrosion resistance), customized surface coating (such as PTFE coating for friction reduction);
Function customization: Add position sensor interface (such as grating ruler installation slot), integrate dust cover (anti debris/dust), design special lubrication system (automatic lubrication);
Adaptability customization: Design non-standard wedge components or rail structures based on the installation space and load-bearing requirements of the customer’s existing equipment rails.
2. Design support services
Technical consultation: Provide linear motion scheme evaluation to assist customers in selecting suitable product series;
Drawing support: Provide 2D (CAD)/3D (SolidWorks) model drawings for customers to integrate into equipment design;
Sample production: Customized products can provide sample testing (sample fee required, refundable after bulk order);
Installation guidance: Provide installation manuals and videos, and if necessary, dispatch engineers to provide on-site guidance for installation.
The MIF series belongs to the M Family (M series) digital feeder relay, which is divided into two core models according to the protected object:
MIF-P type: three-phase+grounding protection relay, suitable for comprehensive protection of three-phase distribution circuits;
MIF-N type: single-phase or ground protection relay, focusing on single-phase circuit or ground fault special protection.
2. Core application scenarios
Main protection: Main circuit protection for various voltage levels of distribution networks, covering lines, distribution equipment, etc;
Backup/auxiliary protection: Backup protection for transformers, generators, and motors to compensate for blind spots in main protection;
Control and Monitoring: Cooperate with circuit breakers to achieve remote control, while providing electrical parameter measurement and equipment status monitoring.
Core functions and technical features
1. Protection function (core highlight)
The MIF series focuses on “overcurrent protection” and is equipped with various specialized protections to adapt to different fault scenarios
(1) Overcurrent protection (TOC/IOC)
Protection type applicable model key parameters and characteristics
Phase TOC MIF-P (three-phase), MIF-N (single-phase) – Setting range: 0.1-2.4 times rated current (I n)
-Curve selection: 4 standard curves (corresponding to ANSI/IEC)+1 user-defined curve, supporting time multiplier adjustment
-ANSI corresponds to IEC curves: Normal Inverse Time (ANSI) → IEC A, Extraordinary Inverse Time → IEC B, Extreme Inverse Time → IEC C, Timed Limit → Timed Limit
Ground TOC MIF-P (standard), MIF-N (optional) – Curve and parameter settings for in-phase overcurrent protection
-Grounding signal acquisition: By default, the residual current of three-phase CT is summed up (without the need for additional sensors); Sensitive scenes can be paired with zero sequence grounded CT (surrounding three-phase conductors) to improve detection accuracy
Instantaneous Overcurrent (IOC) Full Model – Independent Configuration: MIF-P includes 2 sets of three-phase IOC+2 sets of grounded IOC, MIF-N includes 2 sets of single-phase/grounded IOC
-Setting range: pickup (0.1-30 times I n), delay (0-100 seconds), supports individual enable/disable
(2) Other special protections
Thermal Image Protection: prevents equipment from being damaged due to overload and overheating, with a constant heating time
T1 (adjustable from 3-600 minutes), cooling time constant T2 (adjustable from 1-6 times T1), suitable for different device heat dissipation characteristics;
Cold Load Pickup (optional): Automatically adjust the overcurrent setting value when powering on again to avoid triggering the protection by overload current;
Breaker Failure Protection (optional): The basic function is to detect that the circuit breaker has not been opened; Complex solutions can be implemented through digital inputs and configurable output logic (logic gates, timers);
Breaker Health Monitoring (optional): Users set a cumulative current threshold, triggering an alarm when the threshold is exceeded, achieving “on-demand maintenance”.
2. Control and operation functions
Circuit breaker control: supports circuit breaker opening/closing operations, triggered by programmed output terminals, and verified by digital input terminals to ensure successful operation;
Two Settings Groups: Two sets of protection parameters can be pre-set to adapt to different operating conditions (such as normal load/peak load);
On site upgrade: Designed with Flash Memory, it supports firmware upgrade through communication or software on-site, without the need to disassemble the device.
3. Monitoring and metering functions
Event recording: Store 32 event records, record key events such as faults and operations, for easy fault tracing;
Waveform recording: supports analog/digital waveform recording, captures instantaneous changes in electrical parameters during faults, and assists in fault analysis;
Dual end metering: CT transformation ratio can be set, and the primary and secondary current measurement values can be monitored simultaneously to meet the data requirements of operation and maintenance.
4. Hardware and interface characteristics
Power adaptation: Supports AC/DC universal power supply, covering 24-48V DC/AC, 110-250V DC, 110-230V AC (specific range see ordering parameters);
Communication interface: Front end RS232 port (local debugging), back-end RS485 port (remote communication), both support ModBus ® RTU protocol, with a maximum speed of 19200 bps;
I/O configuration: comes standard with 2 digital inputs and 6 relay outputs (4 programmable), and can customize output logic (OR/NOT combination) through M+PC software;
Mechanical structure: Drawout case for easy maintenance; Compatible with M-series 19 inch half rack/full rack installation, compatible with system integration.
5. Software and user interaction
Configuration software: supports M+PC software (parameter settings, status monitoring), enerVista.com platform (remote management, see page 275 of the document for details);
Local operation: Front panel buttons for direct parameter adjustment and status viewing;
Indicator lights (LEDs): LED indicator lights can be configured to visually display the device’s operating status and fault type.
Wiring and safety regulations
1. Typical wiring reference
Grounding detection wiring: Two options are available – ① Three phase CT residual current summation (no additional sensors required); ② Zero sequence grounding CT (sensitive detection scenario);
Current input: It is recommended to use a 14 AWG (2.5mm ²) wire, and the terminal should be a fork or ring terminal;
Safe grounding: It is necessary to connect to a safe ground. Terminals B12, A12, and B11 are only for connecting SELV (safety extra low voltage) components (such as PLC), and withstand voltage testing is prohibited.
2. Safety Tips
Overvoltage category: Class II, suitable disconnect devices (switches or circuit breakers) need to be installed near the relay;
Internal fuse: The power circuit is equipped with a 1A/250V fast fuse to protect the equipment in case of malfunction.
Ordering information (model coding rules)
The MIF series model code format is * * MIF * * * * E * 00 * 00 * * *, and the meanings of the characters in each position are as follows, which need to be combined according to actual needs:
Encoding Position Optional Character Meaning Explanation
1st to 3rd digit MIF product identification (digital feeder relay)
The 4th P/N P=three-phase+grounding relay; N=single-phase or grounded relay
5th A/I A=ANSI standard curve; I=IEC standard curve
6th position 0/1/5=MIF-N type; 1=MIF-P type (I n=1A, setting range 0.1-2.4A); 5=MIF-P type (I n=5A, setting range 0.5-12A)
8th position (empty)/1/2 empty=base model (no options); 1=Option 1 (configurable I/O, event logging, recording); 2=Option 2 (including option 1 function+cold load input, circuit breaker failure/health monitoring, configurable logic)
The power specifications for positions 9-10 are 24-48V DC/AC (19-58V DC); 110-250V DC（88-300V DC）； 110-230V AC（88-264V AC）
The installation method for positions 11-12 is empty=independent relay; M+=Installed on M+system (requires additional order of M050 half 19 inch rack or M100 full 19 inch rack, provided free of charge according to the number of relays)
Example
MIF P A 1 1 2 110: Three phase+grounding relay (P), ANSI curve (A), phase CT I n=1A (1), grounding CT I n=1A (1), including option 2 function (2), 110-250V DC power supply (110).
Associated System: Designed specifically for MNS iS System Release 7.6 to guide communication and control integration of MConnect interfaces, supporting the integration of MNS iS as a fieldbus component into PLC or higher-level process control systems (PCS/DCS).
Target users: Control and application engineers who need to obtain MNS iS data and perform system integration, requiring users to have basic knowledge of fieldbus (such as PROFIBUS, Modbus).
Basic concepts and terminology definitions
The document provides explanations for over 30 core terms and abbreviations, covering technical terms, protocols, components, etc. The key terms are as follows:
Abbreviations/full names of terms/Chinese core explanation
Aspect Object ABBAspect is a computerized representation of real/virtual objects (such as pumps, services) that are described and structured through “attributes”
Standardized products that can be directly purchased and used in the COTS commercial spot product market
DTM Device Type Manager is a software module used to manage devices through fieldbus (such as PROFIBUS), supporting frameworks such as PactWare
GSD file device description file (German) PROFIBUS-DP/DP-V1 slave station hardware description file, used for device configuration
MCC motor control center is a switchgear used for motor control and protection, which is one of the core application scenarios of MNS iS
MODBUS RTU Modbus Remote Terminal Unit Protocol Fieldbus Communication Protocol, the core protocol for MConnect and circuit breaker communication
PNIO PROFINET IO is an open standard based on industrial Ethernet (IEC 61158/61784) used for distributed peripheral devices and automation
The SNTP Simple Network Time Protocol is a protocol that controls network time synchronization through Ethernet
The remaining terms (such as HMI, LVS, OPC, etc.) revolve around low-voltage switchgear, communication protocols, and system components, laying the foundation for subsequent technical content.
Hardware and software requirements
1. Hardware requirements
(1) MConnect hardware model and configuration
The MConnect hardware is based on the motherboard and is paired with different functional modules (analog input/output, digital input/output, PT100 temperature acquisition) to form 28 models. The core model identification rules are as follows (taking the 1TGE120071R series as an example):
Model ID Core Configuration Function Extension
1TGE120071R1000 motherboard only, no additional IO or temperature acquisition
1TGE120071R1001 motherboard+AIAO (Analog IO) supports analog signal input and output
1TGE120071R1100 motherboard+4DI2DO (24VDC digital IO) with 4 digital inputs and 2 digital outputs (24V DC)
1TGE120071R1500 motherboard+7DI0DO (110VAC-230VAC) 7-channel digital input, no digital output (110-230VAC AC)
1TGE120071R1600 motherboard+PT100-3CH supports 3-channel PT100 temperature acquisition (for control only, non protective function)
(2) Key hardware components
Control Condaptor: A specialized component (model 1TGE102069R0661) used to connect MConnect to MNS iS system, requiring address setting (cabinet number=circuit breaker cabinet number, level=1, position=1).
Communication interface: MConnect is connected to the circuit breaker through RS485 bus, with built-in bus bias and terminal resistance; An external 120 Ω (0.25W) terminal resistor is required on the circuit breaker side to ensure communication stability.
2. Software requirements
Basic version: MConnect requires a basic version of 7.6 or higher to fully support the functionality of MNS iS V7.6.
Auxiliary tools: Parameter settings need to be done in conjunction with MNavigate (Configuration and Management Tool), and some functions can be found in the MNavigate help documentation (such as hardware option usage).
Circuit breaker integration solution
The circuit breaker is the core component of the MNS iS cabinet, and MConnect achieves its monitoring and control through the following methods:
1. Supported circuit breakers and programmable release devices
Remarks on Programmable Release Devices (PR Units) Supported by Circuit Breaker Types
Emax PR122/P, PR123/P classic series, corresponding to PR12x series release
Emax X1, Tmax T7/T7M PR332/P, PR333/P upgrade series, corresponding to PR33x series release
Emax2 Ekip Touch, Ekip Hi Touch, Ekip G Touch, Ekip G Hi Touch intelligent series, supporting richer state and data collection
2. Communication architecture and connections
Communication role: MConnect serves as the Modbus RTU master and communicates point-to-point with the programmable release of the circuit breaker (Modbus slave) through RS485; At the same time, as a gateway, it communicates with MLink through the internal “Switchgear Bus” (10Base-T Ethernet) of MNS iS.
System limitation: Following the MNS iS design rules, each MLink can connect up to 60 devices (including MConnect and MControl), distributed in up to 7 cabinets.
Physical connection: The RS485 bus adopts a three wire system (A/W1, B/W2, shielded wire), and the terminal definitions of different circuit breakers are unified (for example, the A/B terminals of Emax and Emax2 are all W1/W2). Please refer to the document “1SDC007108G0201” for details.
3. Configure parameters
The Modbus interface parameters of MConnect need to be consistent with the circuit breaker release, and the parameter settings are as follows:
Parameter optional range, default value description
Slave Address 2-247 247 needs to be configured the same as the PR unit of the circuit breaker
Baudrate rate 9600/19200 bps 19200 bps communication rate, needs to match PR unit settings
Protocol parity check 1 stop bit, odd parity check 1 stop bit, no parity check 2 stop bit, no parity check 1 stop bit, even parity check 1 stop bit. The format of the data check and stop bit should match the PR unit
Attention: The MConnect main site address is fixed at 1 and cannot be modified by users; Only supports “point-to-point” communication and does not support multiple bus slaves.
Data and Command Interaction
The document provides a detailed definition of data collection (status, measurement values, alarm/trip information) and control commands for MConnect and two types of release devices (PR12x/PR33x, Ekip). The core content is as follows:
1. PR12x/PR33x series release
(1) Status data (32-bit unsigned number, Motorola byte order)
Device status bits: There are a total of 16 bits, with key bits meaning “open (Bit0), closed (Bit1), tripped (Bit2), undefined (Bit3), discharged (Bit4)”, and the remaining bits reserved (set to 0).
Extended Status Flag: Contains 8 types of flags, including State 2-9, covering alarm/trip (such as “any alarm” and “circuit breaker trip”), operating mode (local/remote), communication status (no communication on local bus), programming status (successful/failed programming), etc. Each type of flag is a 16 bit unsigned number (UWORD).
(2) Measurement value
Covering over 20 electrical parameters such as current, voltage, power, frequency, and energy, examples are as follows:
Measurement item data type unit invalid value explanation
L1 phase current (effective value) ULONG (unsigned long integer) A 0xffffffff current displays 0 when<minimum value, and displays maximum value when>maximum value
Line voltage V12 (effective value) UWORD-10 (10 times unsigned short integer) V 0xffff displays 0 when voltage<minimum value, and displays maximum value when voltage>maximum value
Total active power (signed) LONG_10 (10 times integer) kW 0x7ffffffff Display 0 when power<minimum value, display ± maximum value when out of range
Frequency UWORD_10 (10x unsigned short integer) Hz 0xffff: When the frequency is less than the minimum value, the minimum value is displayed, and when it is greater than the maximum value, the maximum value is displayed
Total active energy (signed) LONG kWh – cumulative energy value, supporting forward/reverse metering
(3) Alarm and trip information
By defining the STATE 4-6 (alarm) and STATE 8-9 (trip lock) flag bits, it covers over 30 abnormal scenarios such as “harmonic distortion exceeding 2.1”, “contact wear alarm”, “overvoltage trip”, “hardware fault trip”, etc. Each scenario corresponds to a specific bit (setting 1 indicates triggering).
2. Ekip series release (Emax2 specific)
(1) Status and measurement values
Status difference: The device status bit only retains “disconnected (Bit0), closed (Bit1), tripped (Bit2), undefined (Bit3)”, and the remaining bits are reserved; The extended state is divided into four categories: global state (such as circuit breaker closure/isolation), timing state (such as L/S/G timing triggering), trip state (such as overload trip), and warning/alarm state (such as sensor error), covering more detailed intelligent monitoring scenarios.
Measurement value expansion: Added parameters such as “RC current (external grounding current)”, “power factor (in kiloparts)”, “PT100 temperature”, etc., with data types compatible with PR12x/PR33x.
(2) Additional information collection
Support the full lifecycle data of circuit breakers, such as “Circuit Breaker Serial Number (16 bit ASCII)”, “Installation Date/Last Maintenance Date (seconds from December 31, 1999)”, “Operation Times (Opening Count)”, “Contact Wear Percentage (0-65000 corresponds to 0% -100%)”, etc., for easy maintenance and management.
3. Control commands (universal)
Only when the circuit breaker release is manually switched to “remote mode” (password required), the following commands can be sent through the MLink fieldbus:
Command function
CB Close Circuit Breaker Close
CB Open circuit breaker disconnected
CB Reset Circuit Breaker Reset
Trip Reset resets the trip records stored in the release device
Identify data validity through “QualityCode1” and “QualityCode2” (32-bit unsigned numbers):
Bit=0: Data is valid; Bit=1: Invalid data.
QualityCode1 covers measurement values (such as current, voltage, power), while QualityCode2 covers status indicators (such as alarm, trip) and equipment information (such as serial number, rated current).
Circuit breaker type decoding
The document provides decoding tables for two types of circuit breakers (TAB_CB.TYPE, TAB_CB.TYPE_33x), and specifies the specifications of the circuit breakers through a “numerical model” mapping. The example is as follows:
Decoding type, numerical circuit breaker model, numerical circuit breaker model
