AutomationDirect P1AM User Manual

Manual Number: P1AM-USER-M

~ WARNING ~

Thank you for purchasing automation equipment from Automationdirect.com®, doing business as,
AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or

uses this equipment should read this publication (and any other relevant publications) before installing or
operating the equipment.

To minimize the risk of potential safety problems, you should follow all applicable local and national
codes that regulate the installation and operation of your equipment. These codes vary from area to area
and usually change with time. It is your responsibility to determine which codes should be followed, and
to verify that the equipment, installation, and operation is in compliance with the latest revision of these
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At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical
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Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as
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specifically disclaims any expressed or implied warranty of fitness for High Risk Activities.

For additional warranty and safety information, see the Terms and Conditions section of our catalog.
If you have any questions concerning the installation or operation of this equipment, or if you need
additional information, please call us at 770-844-4200.

This publication is based on information that was available at the time it was printed. At
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make changes to the products and/or publications at any time without notice and without any obligation.
This publication may also discuss features that may not be available in certain revisions of the product.

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Copyright© 2020, Automationdirect.com® Incorporated

No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written
consent of Automationdirect.com® Incorporated. AutomationDirect retains the exclusive rights to all
information included in this document.

All Rights Reserved

~ ADVERTENCIA ~

Gracias por comprar equipo de automatización de Automationdirect.com®. Deseamos que su nuevo equipo
de automatización opere de manera segura. Cualquier persona que instale o use este equipo debe leer esta
publicación (y cualquier otra publicación pertinente) antes de instalar u operar el equipo.

Para reducir al mínimo el riesgo debido a problemas de seguridad, debe seguir todos los códigos de seguridad
locales o nacionales aplicables que regulan la instalación y operación de su equipo. Estos códigos varian de
área en área y usualmente cambian con el tiempo. Es su responsabilidad determinar cuales códigos deben ser
seguidos y verificar que el equipo, instalación y operación estén en cumplimiento con la revisión mas reciente
de estos códigos.

Como mínimo, debe seguir las secciones aplicables del Código Nacional de Incendio, Código Nacional Eléctrico,
y los códigos de (NEMA) la Asociación Nacional de Fabricantes Eléctricos de USA. Puede haber oficinas de
normas locales o del gobierno que pueden ayudar a determinar cuales códigos y normas son necesarios para una
instalación y operación segura.

Si no se siguen todos los códigos y normas aplicables, puede resultar en daños al equipo o lesiones serias a
personas. No garantizamos los productos descritos en esta publicación para ser adecuados para su aplicación
en particular, ni asumimos ninguna responsabilidad por el diseño de su producto, la instalación u operación.

Nuestros productos no son tolerantes a fallas y no han sido diseñados, fabricados o intencionados para uso
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tales como operación en instalaciones nucleares, sistemas de navegación aérea, o de comunicación, control de
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Para información adicional acerca de garantía e información de seguridad, vea la sección de Términos
y Condiciones de nuestro catálogo. Si tiene alguna pregunta sobre instalación u operación de este equipo, o
si necesita información adicional, por favor llámenos al número 770-844-4200 en Estados Unidos.
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PROPIEDAD LITERARIA

No se permite copiar, reproducir, o transmitir de ninguna forma ninguna parte de este manual sin previo consentimiento por escrito
de Automationdirect.com
este documento. Los usuarios de este equipo pueden copiar este documento solamente para instalar, configurar y mantener el equipo
correspondiente. También las instituciones de enseñanza pueden usar este manual para propósitos educativos.

®

Incorprated. Automationdirect.com retiene los derechos exclusivos a toda la información incluida en

©

2020, AUTOMATIONDIRECT.COM® INCORPORATED

Todos los derechos reservados

~ AVERTISSEMENT ~

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affaires comme, AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en
toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les
autres publications pertinentes) avant de l’installer ou de l’utiliser.

Afin de réduire au minimum le risque d’éventuels problèmes de sécurité, vous devez respecter tous les codes locaux
et nationaux applicables régissant l’installation et le fonctionnement de votre équipement. Ces codes diffèrent d’une
région à l’autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et
de vous assurer que l’équipement, l’installation et le fonctionnement sont conformes aux exigences de la version la
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les codes ainsi que les normes à respecter pour assurer une installation et un fonctionnement sûrs.

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770-844-4200.

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Tous droits réservés

ProductivityOpen User Manual

Please include the Manual Number and the Manual Issue, both shown below,
when communicating with Technical Support regarding this publication.

Manual Number: P1AM-USER-M

Issue: 1st Edition, Rev. A

Issue Date: 02/2020

Publication History

Issue Date Description of Changes

1st Edition 01/2020 Original

1st Ed. Rev. A 02/2020 Added Appendix A - Networks Security material.

Table of ConTenTs

Chapter 1 - Getting Started

Introduction .............................................................................................................. 1–2

Intended Use of This Product ..................................................................................1–2

Purpose of this Manual ..........................................................................................1–3

Important Online Resources .....................................................................................1–3

Conventions Used ...................................................................................................... 1–4

Key Topics for Each Chapter ..................................................................................... 1–4

Install Programming Software .................................................................................. 1–5

Mounting Hardware .................................................................................................. 1–8

Power the System ...................................................................................................... 1–9

Chapter 2 - Specifications

Overview ................................................................................................................... 2–2

Right Side Expansion - Productivity1000 Input/output Modules ............................... 2–2

Left Side Expansion - Arduino MKR-compatible Shields ........................................... 2–2

P1AM-100 Arduino Compatible CPU ........................................................................ 2–3

P1AM-100 Module Faceplate Layout ........................................................................ 2–4

P1AM-100 MicroB USB Programming Port ............................................................... 2–5

microSD Slot ............................................................................................................ 2–6

P1AM-100 CPU Headers ...........................................................................................2–7

Powering Your ProductivityOpen System ..................................................................2–8

AutomationDirect Shields .........................................................................................2–9

Ethernet Communications Shield .............................................................................2–9

Header Pin Breakout Module .................................................................................. 2–11

I/O Modules Overview ............................................................................................2–13

Table of Contents

Chapter 3 - Installation and Wiring

Safety Guidelines ....................................................................................................... 3–3

Plan for Safety .......................................................................................................... 3–3

Three Levels of Protection ........................................................................................3–4

Orderly System Shutdown ........................................................................................3–4

System Power Disconnect ........................................................................................3–4

Emergency Stop Circuits ..........................................................................................3–5

Introduction to the ProductivityOpen Mechanical Design ...................................... 3–6

Typical P1AM-100 ....................................................................................................3–6

Dimensions and Installation ...................................................................................... 3–7

Basic Dimensions .......................................................................................................3–9

Mounting Guidelines ............................................................................................... 3–12

Enclosures ..............................................................................................................3–12

Mounting Position ..................................................................................................3–12

Using Mounting Rails .............................................................................................3–12

Mounting Clearances .............................................................................................3–13

Temperature Considerations ................................................................................... 3–13

Power Considerations ............................................................................................. 3–13

Grounding .............................................................................................................3–14

Agency Approvals ...................................................................................................3–14

DIN Rail Mounting P1AM-100 System ....................................................................3–15

Surface Mounting P1AM-100 System ..................................................................... 3–15

Installing the I/O Modules ...................................................................................... 3–16

Wiring Guidelines ....................................................................................................3–17

Power Supply Wiring .............................................................................................. 3–17

Grounding .............................................................................................................3–17

Fuse Protection .......................................................................................................3–18

I/O Module Wiring Options ....................................................................................3–19

Hand Wiring System ............................................................................................... 3–19

ZIPLink Wiring System ...........................................................................................3–20

Terminal Block With Pigtail Cable ........................................................................... 3–20

Input and Output Modules ZIPLink Selections .......................................................3–21

Analog Modules ZIPLink Selections ........................................................................ 3–22

ii

Hardware User Manual, 1st Ed. Rev. A

Table of Contents

Removable Terminal Blocks (Optional) ................................................................... 3–23

P1-10RTB and P1-10RTB-1 .....................................................................................3–23

P2-RTB and P2-RTB-1 .............................................................................................3–23

Terminal Block Installation ...................................................................................... 3–24

Terminal Block Removal .......................................................................................... 3–25

Planning the I/O Wiring Routes .............................................................................. 3–25

System Wiring Strategies ........................................................................................3–26

CPU Isolation Boundaries .......................................................................................3–26

Sinking/Sourcing Concepts ....................................................................................3–27

I/O “Common Terminal” Concepts ........................................................................ 3–28

DC Input Wiring Methods ...................................................................................... 3–29

DC Output Wiring Methods ................................................................................... 3–29

Relay Outputs - Wiring Methods ............................................................................3–31

Relay Outputs – Transient Suppression for Inductive Loads in a Control System ..... 3–32

Appendix A - Security Considerations for Controls Networks

Security Considerations for Controls Networks .......................................................A–2

Hardware User Manual, 1st Ed. Rev. A

iii

Chapter

Chapter

Chapter

GettinG Started

1

1

1

In This Chapter...

Introduction .............................................................................................................. 1–2

Intended Use of This Product ..................................................................................1–2

Purpose of this Manual ..........................................................................................1–3

Important Online Resources .....................................................................................1–3

Conventions Used ...................................................................................................... 1–4

Key Topics for Each Chapter ..................................................................................... 1–4

Install Programming Software .................................................................................. 1–5

Mounting Hardware .................................................................................................. 1–8

Power the System ...................................................................................................... 1–9

Chapter 1: Getting Started

Introduction

Intended Use of This Product

The PIAM-100 is a small computer with on-board I/O based on the “Open-Source Arduino
platform”. This product can be used to solve various control and automation tasks using
customized programs.

The user community website of PIAM-100 (http://go2adc.com/p1am) is where you will find
various demo programs and libraries that will allow you to jump right into programming and
design.

Follow all applicable safety parameters when connecting to external I/O sensors and devices.
Any use other than described in this manual is not permitted, as this may expose the user to

possible harm and/or damage to the device or connected equipment.
The P1AM-100 must not be altered or modified. The safety instructions as well as the

maximum permissible ambient conditions and operating parameters are given in Chapter 2
“Technical Specifications”.

The instruction manual is meant to be read thoroughly while being mindful of safe and
proper operation. It contains important information on mounting, operating and handling
the P1AM-100.

CAUTION: The P1AM CPU Base Controller uses pins A3 and A4 so any shield that uses these same pins
will have a conflict. The MKR RGB shield is one that has this conflict.

1–2

Hardware User Manual, 1st Ed. Rev. A

Chapter 1: Getting Started

Purpose of this Manual

Thank you for purchasing the AutomationDirect ProductivityOpen Arduino compatible
Controller. This user manual provides information that will help you install, set up, program,
troubleshoot, and maintain your ProductivityOpen project.

The manual includes information that is critical to the safety of the personnel who will install
and use the controller and to the machinery, processes, and equipment controlled by the
P1AM-100.

The manual also includes important information about power and signal wiring, mounting the
CPU and modules, and configuring the system.

Important Online Resources

Access to ADC Community based help for your ProductivityOpen projects is available from
our website: http://go2adc.com/p1am.

You will need libraries and other files available from our GitHub page at

https://github.com/facts-engineering/P1AM

The P1AM libraries and Board Support Package and other support files are located on Github.
A variety of other useful information about the Productivity1000 I/O modules, as well as code

for example tasks and more is available at https://facts-engineering.github.io.

The P1AM-100 may be programmed by Arduino IDE which may be downloaded from

https://www.arduino.cc/en/Main/Software. A graphical programming tool customized for

P1AM-100 based on ArduBlock (ProductivityBlocks® )is accessible from the Tools menu in the

Arduino IDE.

In addition, the Productivity1000 series power supplies and I/O modules, which work with the
P1AM-100, include an installation insert.

Use a QR symbol reader or click on graphic icon to see an overview video.

Hardware User Manual, 1st Ed. Rev. A

1–3

Chapter 1: Getting Started

Conventions Used

NOTE: When you see the “note pad” icon in the left-hand margin, the paragraph to its immediate right will be
a special note. Notes represent information that may make your work quicker or more efficient. The word
NOTE in boldface will mark the beginning of the text.

When you see the “exclamation point” icon in the left-hand margin, the paragraph to its immediate right
will be a warning. This information could prevent injury, loss of property, or even death in extreme
cases. Any warning in this manual should be regarded as critical information that should be read in its
entirety. The word WARNING in boldface will mark the beginning of the text.

Key Topics for Each Chapter

The beginning of each chapter will list the key
topics that can be found in that chapter.

1–4

Hardware User Manual, 1st Ed. Rev. A

Install Programming Software

NOTE: An active Internet connection is required to download the Arduino IDE and access the libraries and
board driver.

The P1AM-100 CPU may be programmed with the Arduino IDE. ProductivityBlocks® is
an optional graphical environment used with the IDE that AutomationDirect has adapted to
make Productivity1000 I/O modules conveniently accessible as blocks.

1. Download the latest version of the Arduino IDE software
from https://www.arduino.cc/en/Main/Software.

2. Library Install:

a. In the Arduino IDE go to “Sketch -> Include Library -> Manage Libraries…”
b. Leave the Type and Topic filters as “All” and type “P1AM” in the “Filter your search…” box
c. Click on the P1AM by FACTS Engineering that appears
d. Click the Install button
e. Close the Library Manager window
f. Confirm the installation by checking for “File -> Examples -> P1AM-100”. Several categories

of examples should be present.

Productivity

Blocks

CC

Chapter 1: Getting Started

Hardware User Manual, 1st Ed. Rev. A

1–5

Chapter 1: Getting Started

3. Arduino Board Support Package Install:

a. Go to “File->Preferences” and paste the following link into the “Additional Boards Manager

URLs” field.

NOTE: Make sure you right click on the link and choose “Copy Link”.

i. https://raw.githubusercontent.com/facts-engineering/facts-engineering.github.io/master/

package_productivity-P1AM-boardmanagermodule_index.json

b. Go to “Tools -> Boards -> Board Manager”. Type P1AM into the search box at the top.

Mouse over the result and click install. The install may take several minutes to complete.

c. If you are on a version of Windows before Windows 10 this is mandatory. For Windows

10 users, this may be run if you want the board to appear as P1AM-100 in device
manager.

i. Download the “driver install” file from this link:

https://github.com/facts-engineering/P1AMCore/raw/master/drivers.zip.

ii. Extract the file
iii. Run the “P1AM-100_install.bat” file to complete the driver installation.

d. If you are having trouble installing the BSP due to network issues such as firewall

restrictions, you can use the “Arduino SAMD Boards” (specifically the MKRZERO) as
an alternative. These are present in the board manager automatically.

4. Testing installation

a. Attach the modules and/or shields you wish to use. REMEMBER modules/shields must not

be connected or disconnected while power is applied - either 24V or USB.

b. Plug the micro USB cable into the P1AM-100 and computer

i. If using P1000 I/O modules power the system with 24V
c. Go to “Tools -> Board:” and select “P1AM-100” from the dropdown that appears.
d. Go to “Tools -> Port” and select the “P1AM-100” device that you have plugged in.
e. Go to File -> Examples -> P1AM-100->Basic->PrintModules to open the Print Modules

example. Note that the PrintModules example is intended for a system with Productivity1000

modules connected and powered.
f. Click the right facing arrow button under “Edit” to upload the code to the board.
g. Go to “Tools -> Serial Monitor” and check to see that the name of module(s) you have in the

base is printing to the terminal.

1–6

Hardware User Manual, 1st Ed. Rev. A

Productivity

Blocks

Chapter 1: Getting Started

5. Next Steps

a. Start with the “Basic” category of the P1AM-100 Library examples to become familiar with

the API.

b. Once you are comfortable with the basic examples you can move on to more complex

routines included in the P1AM-100 examples.

6. Install ProductivityBlocks

a. Run the ProductivityBlocks Installer.
b. ProductivityBlocks will be installed in the Documents -> ProductivityBlocks folder. The

ProductivityBlocks programming environment is accessible from the Tools menu in the
Arduino IDE.

c. Example ProductivityBlocks programs are also included in this folder.

®

Hardware User Manual, 1st Ed. Rev. A

1–7

Chapter 1: Getting Started

Mounting Hardware

Install Shields on the left side of the P1AM CPU and P1 I/O Modules on the right side of the
P1AM CPU.

The ProductivityOpen Shields and Productivity1000 Input/Output modules are DIN rail
mountable and designed to snap together to simplify connection. A system may include
communications, inputs and outputs. See Chapter 3 of this manual and Chapters 4 and 5 of
the Productivity1000 manual for more detailed hardware installation information.

!WARNING! Do not add or remove modules with field power applied!

Step One:

With latch in “locked” position,
align connectors on the side of
each module and stack by pressing
together. An audible click indicates
lock is engaged.

Step Two:

Attach field wiring using the removable
terminal block or ZIPLink wiring system.

Step Three:

To unstack modules, pull locking latch up
into the unlocked position and then pull
modules apart.

CAUTION: Ensure all latches

are secured after modules

are connected.

1–8

Hardware User Manual, 1st Ed. Rev. A

Power the System

NOTE: Ensure all modules are connected to the system before power is applied. Do not assemble or
disassemble the system while power is applied.

Productivity1000 Power Supplies:

1. Connect one of the Productivity1000 power supplies to P1AM-100. Should you choose
Arduino MKR compatible shields instead of or in addition to the ProductivityOpen shields,
the Productivity1000 power supplies cannot be used. In this case an alternative power supply
is required (See below for information on connecting an external power supply).

P1000 24VDC input power supplies:

• P1-01AC: AC Input 85–132 / 170–264 VAC, 16W
(power for P1AM-100 and up to 8 modules)

• P1-02AC: AC Input 85–132 / 170–264 VAC, 26W
(power for P1AM-100 and up to 15 modules)

• P1-01DC: DC Input 12–24 VDC, 16W
(power for P1AM-100 and up to 8 modules)

Chapter 1: Getting Started

P1-01AC

100-240V 48VA

125VDC, 20W

®

50-60Hz

P1-01AC

AC (L)
DC (+V)

AC (N)
DC (-V)

LG

P1-02AC

™

100-240V 74VA

50-60Hz

125VDC, 33W

AC (L)
DC (+V)

AC (N)
DC (-V)

G

G

LG

P1-02AC

P1-01DC

12-24V 21W

P1-01DC

™

+V

-V

G

LG

CAUTION: Ensure that only one power supply source is connected to the Arduino system. When a
Productivity1000 power supply is connected immediately to the left of the CPU module, the bottom Power
Connector must be removed before connecting P1-01AC Power Supply. This precludes connection of two
separate power supplies. If an AutomationDirect shield is connected between a Productivity1000 power
supply and the CPU module care must be taken to ensure an external power supply is not connected to the
bottom terminals.

Hardware User Manual, 1st Ed. Rev. A

1–9

Chapter 1: Getting Started

2. OR using an alternative 24VDC external power source connect directly to P1AM-100 Optional
Power Connector terminals. This option allows for the use of Input/Output modules from the
Productivity1000 family as well as all Arduino MKR compatible shields.

• The LG and minus terminals on the external power supply connection are internally
shorted.

• Use separate 24VDC supplies, one for the P1AM-100 and another for inductive loads to
keep the P1AM-100 supply power clean and free of voltage spikes caused by switching
inductive loads.

RHINO Power Supply

P/N PSV24-50s

Example of Alternative

24VDC Power Supply

1–10

Terminal Block Specications

Part Number

Number of positions

Pitch

Wire Range

Conductors

Screw Driver Width

Screw Size

Screw Torque

*Recommended screw driver P/N: TW-SD-MSL-2

PCON-KIT

3 screw terminals

3.5 mm

28–16 AWG (0.324 to 3.31 mm²) Solid / Stranded conductor
1/4 in (6–7 mm) Strip Length

Use copper conductors, 75°C or equivalent

1/8 in (3.175 mm) Maximum

M2

1.7 lb·in (0.4 N·m)

Hardware User Manual, 1st Ed. Rev. A

Chapter 1: Getting Started

3. OR using USB input power, connect to the microB USB port on the face of the P1AM-100.
USB power is intended for programming and will not power Productivity1000 Input /output
modules.

Micro USB Type B Input Specications

Port Name

Description

Port Status LED

Cables

Micro USB

Standard Micro USB input for programming and monitoring

Green LED is illuminated when a power cable is plugged in.

USB Type A to Micro USB Type B:
6ft cable part # USB-CBL-AMICB6
15ft cable part # USB-CBL-AMICB15

Hardware User Manual, 1st Ed. Rev. A

1–11

Chapter

Chapter

Chapter

SpecificationS

2

2

2

In This Chapter...

Overview ................................................................................................................... 2–2

Right Side Expansion - Productivity1000 Input/output Modules ............................... 2–2

Left Side Expansion - Arduino MKR-compatible Shields ........................................... 2–2

P1AM-100 Arduino Compatible CPU ........................................................................ 2–3

P1AM-100 Module Faceplate Layout ........................................................................ 2–4

P1AM-100 MicroB USB Programming Port ............................................................... 2–5

microSD Slot ............................................................................................................ 2–6

P1AM-100 CPU Headers ...........................................................................................2–7

Powering Your ProductivityOpen System ..................................................................2–8

AutomationDirect Shields .........................................................................................2–9

Ethernet Communications Shield .............................................................................2–9

Header Pin Breakout Module .................................................................................. 2–11

I/O Modules Overview ............................................................................................2–13

Chapter 2: Specifications

Overview

The ProductivityOpen system is intended to provide a robust selection of components for a
compact and expandable design with a simple-to-use philosophy.

Right Side Expansion - Productivity1000 Input/output Modules

The P1AM-100 can be expanded with the addition of easily connected I/O modules and does
not require a mounting base. I/O modules are connected via an expansion port on the right
side of the P1AM-100 case. A variety of I/O modules are available from the Productivity1000
series for flexible and optimal system configuration. Refer to the Productivity1000 user manual
for detailed descriptions (https://cdn.automationdirect.com/static/manuals/p1userm/

p1userm.html).

Left Side Expansion - Arduino MKR-compatible Shields

The left side of the case allows expansion with most* Arduino MKR compatible shields.
A selection of shields to support P1AM-100 in housings to conveniently connect to the
P1AM-100 specifically are available from AutomationDirect. See detailed descriptions
following.

* NOTE: The P1AM CPU Base Controller uses pins A3 and A4 so any shield that uses these same pins will
have a conflict. The MKR RGB shield is one that has this conflict.

2–2

Hardware User Manual, 1st Ed. Rev. A

P1AM-100 Arduino Compatible CPU

U

L

C

US

The P1AM-100 is an Arduino-compatible CPU. It uses the Atmel SAMD21G18 micro­controller and can be programmed using Arduino IDE or ProductivityBlocks®. It interfaces
with all Productivity1000 Series I/O modules connected to the right side of the P1AM-100
and most Arduino MKR form factor shields connected to the left side. The specifications are
listed in the tables below.

Chapter 2: Specifications

P1AM-100

R

User Specications

User Memory

Memory Type

Base Controller and I/O
Power Requirement

Recommended Fuse
(External)

Peripherals

Hardware Limits of System

Programming

¹ If you do not use a Productivity1000 power supply, like the P1-01AC, then use a power supply that has

transformer isolation. Use different 24VDC supplies for the CPU and inductive loads to keep the CPU power
clean and free of voltage spikes caused by switching solenoids, motors and relay coils.

² See MKR Expansion Bus table and notes for shield power budget restrictions.

1

256kB Flash with 10kB used for bootloader

Flash: 256kB, SRAM: 32kB

24VDC ±2%
Plan 0.5 W for the SAMD chip and base controller
Plan 1.25 W per P1000 I/O module
Plan 9W for max. header power draw (which

provides max. 4.25 W power to left side connected
shields).

Edison S5061-R, Time Delay, 1A Fuse
For 9–15 modules: Edison S5062-R, Time Delay,

2A Fuse

MicroB USB, Arduino MKR-compatible, microSD
card slot, User controlled LED

15 Productivity1000 I/O Modules; Arduino MKR

2

shields

Programmed in C/C++ with the Arduino IDE or
ProductivityBlocks

®

Productivity

Blocks

General Specications

Operating Temperature

Storage Temperature

Humidity

Environmental Air

Vibration

Shock

Heat Dissipation

Enclosure Type

Module Location

Weight

Agency Approvals

0° to 60°C (32° to 140°F)

-20° to 70°C (-4° to 158°F)

5 to 95% (non-condensing)

No corrosive gases permitted

IEC60068-2-6 (Test Fc)

IEC60068-2-27 (Test Ea)

4000mW

Open Equipment

Productivity1000 I/O modules connect on the right
side of module. Productivity1000 power supply,
P1AM Shields and MKR Shields connect on the left
side on the module.

76g (2.8 oz)

UL 61010-1 and UL 61010-2-201 File E139594,
Canada & USA

CE (EN 61131-2 EMC, EN 61010-1 and EN 61010­2-201 Safety)

Hardware User Manual, 1st Ed. Rev. A

2–3

Chapter 2: Specifications

P1AM-100 Module Faceplate Layout

Toggle Switch

- Tied to SWITCH_BUILTIN
or Digital Pin 31

CPU Status Indicators

- PWR LED indicates
power applied

- BASE LED indicates when
base controller is powered
and initialized

- LED controlled by writing to
LED_BUILTIN or Digital Pin 32

Power Option for the

Power Option for the

Power Option for the
Arduino and shields

Arduino and shields

Arduino and shields

- Programming

- Programming

- Programming

- Online monitoring

- Online monitoring

- Online monitoring

microSD Port

- removable flash memory

2–4

External Power

- 24VDC on bottom
connector

P1AM-100

CPU Status Indicators

PWR

BASE

LED

Green LED is illuminated when power is ON

Green LED is illuminated when P1AM I/O
controller is powered and has been initialized

Yellow LED is illuminated when commanded
by user program. LED can be referred to as
LED_BUILTIN or Pin 32.

Toggle Switch Specications

Switch can be read using the “digitalRead” function. Switch can be referred to as
“SWITCH_BUILTIN” or Pin 31.

Hardware User Manual, 1st Ed. Rev. A

Chapter 2: Specifications

P1AM-100 MicroB USB Programming Port

The P1AM-100 controller has one built-in communication port; used exclusively for connecting
to a PC running the Arduino IDE programming software. Following are the specifications and
pin-out diagram.

Micro USB Type B Specications

Port Name

Description

Port Status LED

Cables

MicroB USB

Standard MicroB USB input for programming, monitoring,
and a power option

Green LED is illuminated when a power cable is plugged in.

USB Type A to Micro USB Type B:
6ft cable part # USB-CBL-AMICB6
15ft cable part # USB-CBL-AMICB15

P1AM-100

Hardware User Manual, 1st Ed. Rev. A

2–5

Chapter 2: Specifications

PinSD

1
2
3
4
5
6
7
8

DAT2

CD/DAT3

CMD

VDD
CLK

VSS
DAT0
DAT1

microSD Slot

Retentive memory for data logging, parameter storage, etc. (Card not included with unit).

microSD Specications

Port Name

Description

Maximum Card
Capacity

Transfer Rate
(ADATA microSDHC
Class 4 memory card)

Port Status LED

microSD

Standard microSD socket for data logging

32GB

Mbps Minimum Typical Maximum

Read 14.3 14.4 14.6

Write 4.8 4.9 5.1

Green LED is illuminated when card is inserted and detected

1

8

Pin SD

1

DAT2

2

CD/DAT3

3

CMD

4

VDD

5

CLK

6

VSS

7

DAT0

8

DAT1

2–6

Hardware User Manual, 1st Ed. Rev. A

Chapter 2: Specifications

P1AM-100 CPU Headers

Following are the specifications and pin-out diagram for the Arduino MKR-compatible
expansion bus available for Left Side Expansion Arduino MKR-compatible shields.

MKR Expansion Bus Pins

GPIO A0–A6, 0–14

Analog Input Pins A0–A6

P1AM-100

Analog Output
Pins

PWM Pins 0–8, 10, A3, A4

Interrupt Pins 0, 1, 4–8, A1, A2

5V 5V supply output

Vin 5V regulated supply

VCC 3.3 V supply output

GND Ground

RST Reset

AREF

Critical Notes:

Pins A3, A4, and 8–10 are used for the base
controller.

Do not exceed 46mA combined from pins 0, 1,
and 4–10.

Do not exceed 3.3 V on any I/O pin.
Do not exceed 7mA on any I/O pin.
Do not apply power to 5V or VCC

A0

Analog Input Reference

Hardware User Manual, 1st Ed. Rev. A

2–7

Chapter 2: Specifications

Powering Your ProductivityOpen System

It is important to understand that the Productivity1000 I/O modules on the right side will be
powered either by the Productivity1000 power supply connected to the left of the CPU OR
by an external 24VDC power supply connected to the terminals at the bottom of the CPU
module. The ProductivityOpen shields sold by AutomationDirect will also be powered by
either of these sources.

NOTE: Only one of these 24VDC sources shall be connected.

Third party shields on the left side shall be powered in the field according to the manufacturer
specs.

The USB programming cable will power the CPU and shields connected on the left side of
the CPU.

CAUTION! Shields and I/O modules must not be connected or disconnected when power is applied.

Power Supply Options

LSX Shields

USB Power Cable
(5VDC)

ADC P1-01AC or
P1-02AC

AUX 24Vin

Open ADC ADC I/O

ø ø ø

ø ø ø

ø ø ø ø

CPU

RSX

2–8

MKR Header Power Limitations

Power Source 5V 3.3 V

USB 330mA 500mA 1.65 W

VIN (Pin Header) 600mA 1A 3.3 W

P1000 Series Supply
OR External 24V

850mA 1.28 A 4.25 W

Max. Combined

Power

Hardware User Manual, 1st Ed. Rev. A

AutomationDirect Shields

Ethernet Communications Shield

The P1AM-ETH is a housed Arduino Compatible Ethernet Shield based on the Wiznet W5500
Ethernet Controller. It interfaces to the left side of the P1AM-100 CPU and most Arduino MKR
form factor shields.

Ethernet Features

• Supports Hardwired TCP Protocols:
TCP, UDP, ICMP, IPV4, ARP, IGMP, PPPOE

• Supports 8 independent sockets simultaneously

• Supports Power Down Mode

• Supports Wake on LAN over UDP

• Supports High Speed Serial Peripheral Interface (SPI MODE 0, 3)

• Internal 32K bytes of Memory for TX/RX Buffers

• 10BaseT / 100BaseTX Ethernet PHY embedded

• Supports Auto Negotiation (Full and Half Duplex,
10 and 100-based)

• Does Not Support IP Fragmentation

• 3.3 V operation with 5V I/O signal tolerance

• LED outputs (Full / Half duplex, Link, Speed, Active)

Chapter 2: Specifications

!WARNING!

Do not add or remove

modules with field power

applied!

General Specications

Operating Temperature

Storage Temperature

Humidity

Environmental Air

Vibration

Shock

Heat Dissipation

Enclosure Type

Power Budget

Recommended Library

Module Location

Weight

Agency Approvals

0° to 60°C (32° to 140°F)

-20° to 70°C (-4° to 158°F)

5 to 95% (non-condensing)

No corrosive gases permitted

IEC60068-2-6 (Test Fc)

IEC60068-2-27 (Test Ea)

750mW

Open Equipment

150mA/5V

Arduino Ethernet

Connects to the left side of the P1AM-100 CPU.

20g (0.8 oz.)

UL 61010-1 and
UL 61010-2-201 File E139594, Canada & USA

CE

Hardware User Manual, 1st Ed. Rev. A

2–9

Chapter 2: Specifications

AutomationDirect Shields, cont’d

Header Pins Used for
Ethernet Shield

Pins Used Function

5

ETH SS

8

MOSI
SCK
MISO

SPI pins are shared
with other devices on
SPI bus

9
10

P1AM-ETH

MKR Expansion Bus Pins

GPIO A0–A6, 0–14

Analog Input Pins A0–A6

Analog Output
Pins

PWM Pins 0–8, 10, A3, A4

Interrupt Pins 0, 1, 4–8, A1, A2

5V 5V supply output

Vin 5V regulated supply

VCC 3.3 V supply output

GND Ground

RST Reset

AREF

Critical Notes:

Pins A3, A4, and 8–10 are used for the base controller.
Do not exceed 46mA combined from pins 0, 1, and 4–10.
Do not exceed 3.3 V on any I/O pin.
Do not exceed 7mA on any I/O pin.
Do not apply power to 5V or VCC

A0

Analog Input Reference

2–10

Hardware User Manual, 1st Ed. Rev. A

AutomationDirect Shields, cont’d

Header Pin Breakout Module

The P1AM-GPIO is a housed Arduino MKR form factor shield that brings a subset of the MKR
header pins out to the front 18 position terminal block. These pins include basic overvoltage,
undervoltage, and overcurrent protection. It connects to the left side of the P1AM-100 CPU
and most Arduino MKR form factor shields.

General Specications

Operating Temperature

Storage Temperature

Humidity

Environmental Air

Vibration

Shock

Heat Dissipation

Enclosure Type

Module Location

Weight

Agency Approvals

Chapter 2: Specifications

0° to 60°C (32° to 140°F)

-20° to 70°C (-4° to 158°F)

5 to 95% (non-condensing)

No corrosive gases permitted

IEC60068-2-6 (Test Fc)

IEC60068-2-27 (Test Ea)

475mW

Open Equipment

Connects to the left side of the P1AM-100 CPU.

56g (2.0 oz.)

UL 61010-1 and
UL 61010-2-201 File E139594, Canada & USA

CE

!WARNING!

Do not add or remove

modules with field power

applied!

Terminal block connector sold separately.
Recommended connector options P2-RTB or
P2-RTB-1.

Hardware User Manual, 1st Ed. Rev. A

2–11

Chapter 2: Specifications

AutomationDirect Shields, cont’d

P1AM-GPIO

MKR Expansion Bus Pins

GPIO A0–A6, 0–14

Analog Input Pins A0–A6

Analog Output
Pins

PWM Pins 0–8, 10, A3, A4

Interrupt Pins 0, 1, 4–8, A1, A2

5V 5V supply output

Vin 5V regulated supply

VCC 3.3 V supply output

GND Ground

RST Reset

AREF

Critical Notes:

Pins A3, A4, and 8–10 are used for the base
controller.

Do not exceed 46mA combined from pins 0,
1, and 4–10.

Do not exceed 3.3 V on any I/O pin.
Do not exceed 7mA on any I/O pin.
Do not apply power to 5V or VCC

A0

Analog Input Reference

Terminal Block Pins

Pin Functions

VCC 3.3 V supply output

DAC0*

A1 GPIO, Analog input, Interrupt

A2 GPIO, Analog input, Interrupt

A5 GPIO, Analog input

A6 GPIO, Analog input

0 GPIO, PWM, Interrupt

1 GPIO, PWM, Interrupt

2 GPIO, PWM

3 GPIO, PWM

4 GPIO, PWM, Interrupt

6 GPIO, PWM, Interrupt

7 GPIO, PWM, Interrupt

11 GPIO, SDA

12 GPIO, SCL

13 GPIO, RX

14 GPIO, TX

GND Ground

*There is no ESD, overvoltage, or overcur­rent protection on the DAC0 pin.

GPIO, Analog input,
Analog output

2–12

Hardware User Manual, 1st Ed. Rev. A

I/O Modules Overview

A variety of discrete and analog I/O modules from our Productivity1000 line are available
for use with the P1AM-100.

Chapter 2: Specifications

Productivity1000 Modules

Part Number Number of Inputs Description

Input Modules

P1-08SIM

P1-08ND3

P1-16ND3

P1-08NE3

P1-16NE3

P1-08NA

Output Modules

Number of Outputs

P1-08TD1

P1-08TD2

P1-15TD1

P1-15TD2

P1-08TA

P1-08TRS

P1-16TR

Input/Output Modules

Inputs Outputs

P1-15CDD1

P1-15CDD2

P1-16CDR

8 7

8 7

8 8

8

8

16

8

16

8

8 Sinking DC Output

8

15 Sinking DC Output

15

8

8

16

Input Simulator
Module

Sinking/Sourcing
12–24 VDC Input

Sinking/Sourcing
12–24 VDC Input

Sinking/Sourcing
24V AC/DC

Sinking/Sourcing
24V AC/DC

AC Isolated
100–240 VAC

Sourcing DC Output

Sourcing DC Output

AC Output

Isolated Relay
Output

Relay Output

Input: Sinking/
Sourcing; Output:
Sinking

Input: Sinking/
Sourcing; Output:
Sourcing

Input: Sinking/
Sourcing; Output:
Relay

Productivity1000 Modules

Part Number Number of Inputs Description

Input Modules

P1-04AD

P1-04ADL-1

P1-04ADL-2

P1-08ADL-1

P1-08ADL-2

P1-04RTD

P1-04THM

P1-04NTC

Output Modules

Number of Outputs

P1-04DAL-1

P1-04DAL-2

P1-08DAL-1

P1-08DAL-2

Input/Output Modules

P1-4ADL2DAL-1

P1-4ADL2DAL-2

4

4

4

8

8

4 RTD Input

4

4

4

4

8

8

Inputs Outputs

4 2

4 2

Analog Input

(Current)

Analog Input

(Current)

Analog Input

(Voltage)

Analog Input

(Current)

Analog Input

(Voltage)

Analog

Thermocouple

Input

Analog Thermistor

Input

Analog Output

(Current)

Analog Output

(Voltage)

Analog Output

(Current)

Analog Output

(Voltage)

Analog Input/Analog

Output (Current)

Analog Input/Analog

Output (Voltage)

Details on connecting to the Productivity1000 modules can be found at

https://github.com/facts-engineering/P1AM/wiki.

The Productivity1000 User Manual contains electrical and installation details. It is available for
FREE download at: https://cdn.automationdirect.com/static/manuals/p1userm/p1userm.html

Hardware User Manual, 1st Ed. Rev. A

2–13

Chapter

Chapter

Chapter

InstallatIon and

IrIng

W

3

3

3

In This Chapter...

Safety Guidelines ....................................................................................................... 3–3

Plan for Safety .......................................................................................................... 3–3

Three Levels of Protection ........................................................................................3–4

Orderly System Shutdown ........................................................................................3–4

System Power Disconnect ........................................................................................3–4

Emergency Stop Circuits ..........................................................................................3–5

Introduction to the ProductivityOpen Mechanical Design ...................................... 3–6

Typical P1AM-100 ....................................................................................................3–6

Dimensions and Installation ...................................................................................... 3–7

Basic Dimensions .......................................................................................................3–9

Mounting Guidelines ............................................................................................... 3–12

Enclosures ..............................................................................................................3–12

Mounting Position ..................................................................................................3–12

Using Mounting Rails .............................................................................................3–12

Mounting Clearances .............................................................................................3–13

Temperature Considerations ................................................................................... 3–13

Power Considerations ............................................................................................. 3–13

Grounding .............................................................................................................3–14

Agency Approvals ...................................................................................................3–14

DIN Rail Mounting P1AM-100 System ....................................................................3–15

Surface Mounting P1AM-100 System ..................................................................... 3–15

Installing the I/O Modules ...................................................................................... 3–16

Wiring Guidelines ....................................................................................................3–17

Power Supply Wiring .............................................................................................. 3–17

Grounding .............................................................................................................3–17

Fuse Protection .......................................................................................................3–18

Table of Contents

I/O Module Wiring Options ....................................................................................3–19

Hand Wiring System ............................................................................................... 3–19

ZIPLink Wiring System ...........................................................................................3–20

Terminal Block With Pigtail Cable ........................................................................... 3–20

Input and Output Modules ZIPLink Selections .......................................................3–21

Analog Modules ZIPLink Selections ........................................................................ 3–22

Removable Terminal Blocks (Optional) ................................................................... 3–23

P1-10RTB and P1-10RTB-1 .....................................................................................3–23

P2-RTB and P2-RTB-1 .............................................................................................3–23

Terminal Block Installation ...................................................................................... 3–24

Terminal Block Removal .......................................................................................... 3–25

Planning the I/O Wiring Routes .............................................................................. 3–25

System Wiring Strategies ........................................................................................3–26

CPU Isolation Boundaries .......................................................................................3–26

Sinking/Sourcing Concepts ....................................................................................3–27

I/O “Common Terminal” Concepts ........................................................................ 3–28

DC Input Wiring Methods ...................................................................................... 3–29

DC Output Wiring Methods ................................................................................... 3–29

Relay Outputs - Wiring Methods ............................................................................3–31

Relay Outputs – Transient Suppression for Inductive Loads in a Control System ..... 3–32

3–2

Hardware User Manual, 1st Ed. Rev. A

Safety Guidelines

NOTE: Products with CE marks perform their required functions safely and adhere to relevant standards
as specified by CE directives provided they are used according to their intended purpose and that the
instructions in this manual are adhered to. The protection provided by the equipment may be impaired if
this equipment is used in a manner not specified in this manual. A listing of our international affiliates is
available on our Web site at http://www.automationdirect.com.

WARNING: Providing a safe operating environment for personnel and equipment is your responsibility
and should be your primary goal during system planning and installation. Automation systems can
fail and may result in situations that can cause serious injury to personnel or damage to equipment.
Do not rely on the automation system alone to provide a safe operating environment. You should
use external electromechanical devices, such as relays or limit switches, that are independent of the
P1AM-100 application to provide protection for any part of the system that may cause personal injury
or damage. Every automation application is different, so there may be special requirements for your
particular application. Make sure you follow all national, state, and local government requirements for
the proper installation and use of your equipment.

Plan for Safety

The best way to provide a safe operating environment is to make personnel and equipment
safety part of the planning process. You should examine every aspect of the system to determine
which areas are critical to operator or machine safety. If you are not familiar with controller
type system installation practices, or your company does not have established installation
guidelines, you should obtain additional information from the following sources.

• NEMA — The National Electrical Manufacturers Association, located in Washington,
D.C., publishes many different documents that discuss standards for industrial control
systems. You can order these publications directly from NEMA. Some of these include:
ICS 1, General Standards for Industrial Control and Systems
ICS 3, Industrial Systems
ICS 6, Enclosures for Industrial Control Systems

• NEC — The National Electrical Code provides regulations concerning the installation
and use of various types of electrical equipment. Copies of the NEC Handbook can
often be obtained from your local electrical equipment distributor or your local library.

• Local and State Agencies — many local governments and state governments have
additional requirements above and beyond those described in the NEC Handbook.
Check with your local Electrical Inspector or Fire Marshall office for information.

Chapter 3: Installation and Wiring

Hardware User Manual, 1st Ed. Rev. A

3–3

Chapter 3: Installation and Wiring

Arm

Three Levels of Protection

WARNING: The control program must not be the only form of
protection for any problems that may result in a risk of personal
injury or equipment damage.

The publications mentioned provide many ideas and
requirements for system safety. At a minimum, you should
follow these regulations. Also, you should use the following
techniques, which provide three levels of system control.

1. Orderly system shutdown sequence in
the P1AM-100 control program.

2. Mechanical disconnect for output module power.

3. Emergency stop switch for
disconnecting system power.

Orderly System Shutdown

The first level of fault detection is ideally the P1AM-100 control program, which can identify
machine problems. Certain shutdown sequences should be performed. These types of
problems are usually things such as jammed parts, etc., that do not pose a risk of personal
injury or equipment damage.

System Power Disconnect

You should also use electromechanical devices, such as master control relays and/or limit
switches, to prevent accidental equipment startup at an unexpected time. These devices should
be installed in a manner that will prevent any machine operations from occurring.

For example, if the machine in the illustration has a jammed part, the P1AM-100 control
program can turn off the saw blade and retract the arbor. If the operator must open the guard
to remove the part, you should also include a bypass switch that disconnects all system power
any time the guard is opened.

Jam
Detect

Turn off
Saw

RST

RST

Retract

3–4

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

1

Emergency Stop Circuits

Emergency stop (E-Stop) circuits are a critical part of automation safety. For each machine
controlled by a P1AM-100, provide an emergency stop device that is wired outside the P1AM­100 and easily accessed by the machine operator.

E-Stop devices are commonly wired through a master control relay (MCR) or a safety control
relay (SCR) that will remove power from the P1AM-100 I/O system in an emergency.

MCRs and SCRs provide a convenient means for removing power from the I/O system
during an emergency situation. By de-energizing an MCR (or SCR) coil, power to the input
(optional) and output devices is removed. This event occurs when any emergency stop switch
opens. However, the P1AM-100 continues to receive power and operate even though all its
inputs and outputs are disabled.

The MCR circuit could be extended by placing a P1AM-100 fault relay (closed during normal
P1AM-100 operation) in series with any other emergency stop conditions. This would cause
the MCR circuit to drop the P1AM-100 I/O power in case of a P1AM-100 failure (memory
error, I/O communications error, etc.).

EMERGENCY

STOP

Guard
Limit
Switch

L1 N

L

Use E-Stop and Master Control Relay

se E-Stop and Maste

E-Stop Power On

E-Stopower On

MCR

MCR

MCR

CR1

Limit

Switch

Master
Control

Relay (MCR)

CR1

Saw Arbor

WARNING: For some applications, field device power may still be present on the terminal block even
though the P1AM-100 is turned off. To minimize the risk of electrical shock, remove all field device
power before you expose or remove P1AM-100 wiring.

Hardware User Manual, 1st Ed. Rev. A

3–5

Chapter 3: Installation and Wiring

Introduction to the ProductivityOpen Mechanical Design

The ProductivityOpen is a modular system built by adding Productivity1000 Input/output
modules and Arduino MKR-compatible shields to a P1AM-100 Arduino-compatible CPU.
The I/O modules are connected directly to the right side of the P1AM-100 and to each other
in a continuous stack up to 15 modules.

Power budget does need to be considered - 8 or fewer modules can use the P1-01AC,
exceeding 8 modules uses P1-02AC. No backplane or base is required. Each module
connection extends the backbone communication bus.

Connect Arduino-MKR shields to the left side of the P1AM-100 CPU. The combinations on
the left side are limited only by the general purpose IO pins that must be dedicated to each
shield.

Typical P1AM-100

P1-08SIM

P1-08TD1

P1-15CDD1

C1

1

2

3

4

5

6

7

8

C2

1

2

3

4

5

6

7

V+

12-24VDC IN

3.3-24V OUT

INPUTSOUTPUTS

3.3-24VDC

SINK OUTPUT

COM

V+

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

OFF ON

INPUT SIMULATOR

P1-01AC

Power Supply

or Alternate

3–6

P1AM-PROTO

(Customizable

Shield Kit)

P1AM-GPIO

P1-15CDD1

Combo Module

P1AM-ETH

P1AM-100

Hardware User Manual, 1st Ed. Rev. A

P1-08TD1 Output

Module

P1-08SIM

Input Module

Dimensions and Installation

Before installing the P1AM-100 you will need to know the dimensions of the components
considered. The tables and diagrams on the following pages provide basic dimensions to use
in defining your enclosure specifications. Remember to leave room for expansion module
insertion and/or replacement and for potential expansion. If you are using other components
in your system, refer to the appropriate manual to determine how those units can affect
mounting dimensions.

The basic dimensions for the modules are listed in the tables. The width varies depending on
the type of module. P1AM-100 is designed to be mounted on standard 35mm DIN rail, or it
may be surface mounted. Make sure you have followed the installation guidelines for proper
spacing.

NOTE: Dimensional drawings for the P1AM-100, power supplies, and all modules are available on the
AutomationDirect.com site.

Productivity Open Component Dimensions

Module

P1AM-100

P1AM-GPIO

P1AM-ETH

Description

Controller 23.1 [0.91] 77.0 [3.03] 92.8 [3.65] 91.3 [3.59]

Left Side Communication Shields (LSX)

General Purpose I/O

Ethernet Communication

Chapter 3: Installation and Wiring

A B C D

Height
w/Tabs

mm [in]

Depth

mm [in]

Width

mm [in]

23.1 [0.91] 77.0 [3.03] 92.8 [3.65] 86.7 [3.41]

23.1 [0.91] 77.0 [3.03] 92.8 [3.65] 89.7 [3.53]

Height

Faceplate

mm [in]

P1-01AC

P1-02AC

P1-01DC

P1-08SIM

P1-08ND3

P1-16ND3

P1-08NE3

P1-16NE3

P1-08NA

P1-08TD1

P1-08TD2

P1-15TD1

P1-15TD2

P1-08TA

Productivity1000 Component Dimensions

AC/DC Power Supply 35.0 [1.38]

AC Power Supply 52.2 [2.06]

DC Power Supply 35.0 [1.38]

Discrete Expansion Modules (Right Side)

Simulator Input

Sinking/Sourcing 12–24 VDC Input

Sinking/Sourcing 12–24 VDC Input

Sinking/Sourcing 12–24 VDC Input

Sinking/Sourcing 12–24 VDC Input

AC Isolated 100–240 VAC

Sinking Output

Sourcing Output

Sinking Output

Sourcing Output

AC Output

17.2 [0.68] 77.0 [3.03] 93.6 [3.69] 86.6 [3.41]

Hardware User Manual, 1st Ed. Rev. A

77.0 [3.03] 92.8 [3.65] 98.3 [3.87]

3–7

Chapter 3: Installation and Wiring

Dimensions and Installation (continued)

ProductivityOpen Component Dimensions

A B C D

Module Description

P1-08TRS

Isolated Relay Output 17.2 [0.68]

Width

mm [in]

Height

Faceplate

mm [in]

mm [in]

Height
w/Tabs

Depth

mm [in]

P1-16TR

P1-15CDD1

P1-15CDD2

P1-16CDR

P1-04RTD

P1-04THM

P1-04NTC

P1-04AD

P1-04ADL-1

P1-04ADL-2

P1-04DAL-1

P1-04DAL-2

P1-08ADL-1

P1-08ADL-2

P1-08DAL-1

P1-08DAL-2

P1-4ADL2DAL-1

P1-4ADL2DAL-2

P1-02HSC

P1-04PWM

Relay Output 26.3 [1.03]

Input: Sinking/Sourcing;

Output: Sinking

Input: Sinking/Sourcing;

Output: Sourcing

Discrete Relay Combo Module 26.3 [1.03]

Analog Expansion Modules

Di󰀨erential RTD

Analog Thermocouple Input

Analog Thermistor Input

Analog Input (Current)

Analog Input (Current)

Analog Input (Voltage)

Analog Output (Current)

Analog Output (Voltage)

Analog Input (Current)

Analog Input (Voltage)

Analog Output (Current)

Analog Output (Voltage)

Analog Input/Analog Output (Current)

Analog Input/Analog Output (Voltage)

Specialty Expansion Modules

High-Speed Input (Current)

Pulse Width Modulation Input (Voltage)

77.0 [3.03] 93.6 [3.69] 86.6 [3.41]

17.2 [0.68]

17.2 [0.68] 77.0 [3.03] 93.6 [3.69] 81.6 [3.21]

17.2 [0.68] 77.0 [3.03] 93.6 [3.69] 81.9 [3.22]

17.2 [0.68] 77.0 [3.03] 93.6 [3.69] 81.6 [3.21]

17.2 [0.68] 77.0 [3.03] 93.6 [3.69] 81.6 [3.21]

3–8

Hardware User Manual, 1st Ed. Rev. A

Basic Dimensions

P1AM-100

Chapter 3: Installation and Wiring

Units: mm [inches]

D

C

A

P1-01AC, P1-02AC and P1-01DC

C

B

B

A

Hardware User Manual, 1st Ed. Rev. A

D

3–9

Chapter 3: Installation and Wiring

Basic Dimensions (continued)

Productivity1000 I/O Modules

P1AM-ETH

C

C

A

B

D

B

3–10

A

Hardware User Manual, 1st Ed. Rev. A

D

Units: mm [inches]

P1AM-GPIO Module

Chapter 3: Installation and Wiring

C

A

B

D

Units: mm [inches]

Hardware User Manual, 1st Ed. Rev. A

3–11

Chapter 3: Installation and Wiring

Airflow

2ʺ

g

Mounting Guidelines

Enclosures

Your selection of a proper enclosure is important to ensure safe and proper operation of your
P1AM-100. Applications for the P1AM-100 vary and may require additional hardware
considerations. The minimum considerations for enclosures include:

• Conformance to electrical standards

• Protection from the elements in an industrial environment

• Common ground reference

• Maintenance of specified ambient temperature

• Access to the equipment

• Security or restricted access

• Sufficient space for proper installation and

maintenance of the equipment

Mounting Position

Mount the P1AM-100 and expansion modules horizontally, as shown in the illustration on the
following page, to provide proper ventilation. Do not mount vertically, upside down, or on a
flat horizontal surface.

NOTE: Add 2ʺ to mountin
depth when using ZIPLink
cable.

Using Mounting Rails

The ProductivityOpen modules can be secured within an enclosure or cabinet using mounting
rails. Use rails that conform to DIN EN standard 50022. We offer a complete line of DIN rail,
DINnectors and DIN rail mounted apparatus. The rails are approximately 35mm high, with a
depth of 7.5 mm. If you mount the module(s) on a DIN rail, consider using end brackets on
each side of the base. The end brackets keep the module(s) from sliding horizontally along the
rail, thus minimizing the possibility of accidentally pulling the wiring loose.

3–12

End Bracket (Part No. DN-EB35)

DIN Rail (Part No. DN-R35S1)

Hardware User Manual, 1st Ed. Rev. A

DIN Rail
Dimensions

7.5 mm

35 mm

Chapter 3: Installation and Wiring

Mounting Clearances

Provide a minimum clearance of 2 inches (50mm) on all sides of the assembled system. Allow
extra clearance for door mounted operator panels, push buttons, lights and other items. There
should be a minimum of 3 inches (76mm) vertical clearance between the module(s) and any
wire duct, and a minimum of 7.2 inches (183mm) vertical distance from chassis to chassis in a
multiple unit installation.

The clearances required for P1AM-100 are represented in the graphic below of a similar PLC
system when mounted in an enclosure.

2”

50mm

min

7.2”

3”

min

3”

76mm

min

183mm

min

76mm

2”

50mm

min

Temperature Considerations

The P1AM-100 enclosure should be installed in an environment which is within the specified
equipment operating temperature. If the environment temperature deviates above or below the
specification, measures such as cooling or heating the enclosure should be taken to maintain
the specification.

Power Considerations

When the P1AM-100 is powered by a Productivity power supply (P1-01AC, P1-02AC or
P1-01DC), EMF/RFI line filters are not required to meet the requirements of the CE EMC
Directive.

Hardware User Manual, 1st Ed. Rev. A

3–13

Chapter 3: Installation and Wiring

In addition to the panel layout guidelines, other specifications can affect the installation of a
CPU system. Always consider the following:

• Environmental Specifications

• Power Requirements

• Agency Approvals

• Enclosure Selection and Component Dimensions

Grounding

A sound common ground reference (earth ground) is essential for proper operation of the
P1AM-100. One side of all control circuits and power circuits along with the ground lead
must be properly connected to earth ground (earthing) either by connecting to the incoming
power system ground or by installing a ground rod in close proximity to the enclosure. There
must be a single-point ground (i.e. copper bus bar) for all devices in the enclosure that require
an earth ground.

Panel

Ground Braid

Copper Lugs

Panel or

Single Point

Ground

WARNING: Do not disconnect equipment unless power has been switched off.

Agency Approvals

Some applications require agency approvals for particular components. The ProductivityOpen
agency approvals are listed below:

3–14

Star Washers

Star Washers

• UL (Underwriters’ Laboratories, Inc.)

• CUL (Canadian Underwriters’ Laboratories, Inc.)

• CE (European Economic Union)

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

DIN Rail Mounting P1AM-100 System

If you examine the module(s), you’ll notice retaining clips. To secure the module(s) to a
DIN rail, place the module(s) onto the rail and gently push up on the retaining clips. The
spring loaded clips lock the module onto the rail. To remove the module(s), pull down on the
retaining clips, slightly lift up the base, and pull it away from the rail.

This installation procedure applies to the P1AM-100, the P1AM-ETH and P1AM-GPIO
shields, and the Productivity1000 power supplies.

Step 1: Rotate unit upwards as you engage rear DIN
rail slot (image at right). Once engaged, rotate unit
downwards, firmly pressing into DIN rail. A noticeable
click affirms the unit is secure to DIN rail.

Step 2: Ensure all retaining clips are pushed up into
DIN rail.

Install end brackets on either side of unit to ensure unit
will not slide along the DIN rail.

Push up retaining

clips

Surface Mounting P1AM-100 System

The P1AM-100 system may be surface mounted as well. Extend the lower tabs for ease of
access. Use mounting holes in upper and lower tabs to secure the unit to panel surface.

Use Upper
Tab Slot

Use Extended
Lower Tab Slot

Hardware User Manual, 1st Ed. Rev. A

3–15

Chapter 3: Installation and Wiring

Installing the I/O Modules

With latch in “locked” position, align

Step One:

connectors on the side of each module
and stack by pressing together. An
audible click indicates lock is engaged.

Step Two:

To unstack modules, pull locking latch up
into the unlocked position and then pull
modules apart.

WARNING: Do not connect, disconnect modules or
operate switches while circuit is live. P1AM-100 does
not support Hot Swapping!

3–16

Hardware User Manual, 1st Ed. Rev. A

Wiring Guidelines

Power Hookup

P1-01AC

AC (L)

AC (N)

G

LG

100-240V 48VA

50-60Hz

125VDC, 20W

DC (+V)

DC (-V)

®

Power Hookup

P1-01AC

AC (L)

AC (N)

G

LG

100-240V 48VA

50-60Hz

125VDC, 20W

DC (+V)

DC (-V)

®

AC (L)

AC (N)

GND

LOGIC
GND

100–240 VAC

Power Supply Wiring

Connect the AC power source input wiring to the power supply as shown. The power supply
terminals can accept up to 14AWG solid or stranded wire. Do not over tighten the terminal
screws; the recommended torque is 7 to 9 inch-pounds (0.882 to 1.02 N·m).

P1-01AC and P1-02AC

Chapter 3: Installation and Wiring

125VDC 100–240 VAC

Grounding

+V

-V

GND

LOGIC
GND

AC (L)

AC (N)

GND

LOGIC
GND

P1-01DC

12–24 VDC

125VDC

+V

-V

GND

LOGIC
GND

WARNING: Once the power wiring is connected, secure the terminal block cover in the closed position.
When the cover is open there is a risk of electrical shock if you accidentally touch the connection
terminals or power wiring.

A good common ground reference (earth ground) is essential for proper operation of the
P1AM-100. One side of all control circuits and power circuits along with the ground lead
must be properly connected to earth ground by either installing a ground rod in close proximity
to the enclosure or by connecting to the incoming power system ground. There must be
a single-point ground (i.e. copper bus bar) for all devices in the enclosure that require an
earth ground.

Hardware User Manual, 1st Ed. Rev. A

3–17

Chapter 3: Installation and Wiring

Fuse Protection

Some of the Input and Output I/O module circuits do not have internal fuses. In order to
protect your modules, we suggest you add external fuses to your I/O wiring. A fast-blow fuse
with a lower current rating than the I/O bank’s common current rating can be wired to each
common; or a fuse with a rating of slightly less than the maximum current per output point
can be added to each output. Refer to the I/O module specifications in Chapter 2 to find the
maximum current per output point or per output common. Adding the external fuse does not
guarantee the prevention of CPU damage, but it will provide added protection.

Fuse Block

Power Supply

Fused Common

3–18

Fuse

Blocks

ZIPLink Fuse

Module

Fuse

Blocks

Hardware User Manual, 1st Ed. Rev. A

I/O Module Wiring Options

There are two available methods for wiring most I/O modules: hand wiring to the optional
removable I/O module terminal blocks or using the ZIPLink wiring system.

NOTE: Thermocouple, Thermistor, RTD, and HSC modules are not compatible with the ZIPLink system
and are shipped with fixed terminal blocks included.

Hand Wiring System

Field wiring may be attached using the removable terminal block connector. Use Wire Strip
Length reference on the terminal block as a guide when preparing wire for termination.
For easier assembly, wire may be connected to terminal block prior to installing block into
expansion module.

Chapter 3: Installation and Wiring

Hardware User Manual, 1st Ed. Rev. A

3–19

Chapter 3: Installation and Wiring

I/O Module Wiring Options (continued)

ZIPLink Wiring System

The ZIPLink wiring system is the recommended method, which allows quick and easy
connection using cables that are prewired to the I/O module terminals at one end and plug into
a ZIPLink connector module terminal block at the other end. Use the tables on the following
pages to specify your ZIPLink wiring system.

ZIPLink Wiring

System

ZIPLink Pre-Wired Cables

Terminal Block With Pigtail Cable

For most I/O modules you can also purchase ZIPLink pigtail cables.

3–20

ZIPLink Module

ZIPLink Pigtail Cable

Hardware User Manual, 1st Ed. Rev. A

Input and Output Modules ZIPLink Selections

Productivity1000 Input Module ZIPLink Selector

Input
Module

P1-08ND3

P1-16ND3

P1-08NE3

P1-16NE3

P1-08NA

Output
Module

P1-08TD1

P1-08TD2

P1-15TD1

P1-15TD2

P1-08TA

P1-08TRS

P1-16TR

I/O Module

# of Terms Component Module Part No. Cable Part No.

10

18 ZL-P1-CBL18*

10 ZL-P1-CBL10*

18 ZL-P1-CBL18*

10 ZL-P1-CBL10*

Feedthrough

Productivity1000 Output Module ZIPLink Selector

I/O Module

# of Terms Component Module Part No. Cable Part No.

10

18 ZL-P1-CBL18*

18 ZL-P1-CBL18*

10 ZL-P1-CBL10*

10 ZL-P1-CBL10*

18 ZL-P1-CBL18*

Feedthrough

ZIPLink

ZL-RTB20 or
ZL-RTB20-1

ZIPLink

ZL-RTB20 or
ZL-RTB20-1

Chapter 3: Installation and Wiring

ZL-P1-CBL10*

ZL-P1-CBL10*

Productivity1000 Combo Modules ZIPLink Selector

I/O Module

Output
Module

P1-15CDD1

P1-15CDD2

P1-16CDR

* Select the cable length by replacing the * with: Blank = 0.5 m, -1 = 1.0 m,

or -2 = 2.0 m.

# of Terms Component Module Part No. Cable Part No.

18 Feedthrough

ZIPLink

ZL-RTB20 or
ZL-RTB20-1

ZL-P1-CBL18*

Hardware User Manual, 1st Ed. Rev. A

3–21

Chapter 3: Installation and Wiring

Analog Modules ZIPLink Selections

Productivity1000 Analog Module ZIPLink Selector

Module

Analog Module # of Terms Component Module Cable

P1-04AD

P1-04ADL-1

P1-04ADL-2

P1-08ADL-1

P1-08ADL-2

P1-04RTD

P1-04THM

P1-04NTC

P1-04DAL-1

P1-04DAL-2

P1-08DAL-1

P1-08DAL-2

10 Feedthrough

Matched Only See Note 1

T/C Wire Only See Note 1

Copper
Conductors

10 Feedthrough

See Note 1

ZIPLink

ZL-RTB20 or
ZL-RTB20-1

ZL-RTB20 or
ZL-RTB20-1

ZL-P1-CBL10*

ZL-P1-CBL10*

Productivity1000 Analog Combo Module ZIPLink Selector

Module

Analog Module # of Terms Component Module Cable

P1-4DAL2ADL-1

P1-4DAL2ADL-2

10 Feedthrough

ZIPLink

ZL-RTB20 or
ZL-RTB20-1

ZL-P1-CBL10*

3–22

Productivity1000 Specialty Modules ZIPLink Selector

See Note 1

See Note 1

ZL-RTB20 or
ZL-RTB20-1

ZIPLink

ZL-P1-CBL10*

Module

Input Module # of Terms Component Module Cable

P1-08SIM

P1-02HSC

P1-04PWM

* Select the cable length by replacing the * with: Blank = 0.5 m, -1 = 1.0 m, or -2 = 2.0 m.

1. These modules are not supported by the ZIPLink wiring system.

10

Feedthrough

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

Removable Terminal Blocks (Optional)

The hand wiring method consists of purchasing the associated removable I/O module terminal
block (table below) and hand wiring from the I/O terminal block to a DIN rail mounted
terminal block.

P1-10RTB and P1-10RTB-1

Removable Terminal Block Specifications

Part Number P1-10RTB P1-10RTB-1

Number of
Positions

Wire Range

Conductors

Screw Driver

Screw Size
Screw Torque

* Recommended screw driver: P/N TW-SD-MSL-1.

10 Screw Terminals 10 Spring Clamp Terminals

30–16 AWG (0.051–1.31 mm²)
Solid / Stranded Conductor
3/64 in. (1.2 mm) Insulation Max.

1/4 in. (6–7 mm) Strip Length

“USE COPPER CONDUCTORS, 75°C” or Equivalent.

0.1 inch (2.5 mm) Maximum*

M2 N/A

2.5 lb·in (0.28 N·m) N/A

28–16 AWG (0.081–1.31 mm²)
Solid / Stranded Conductor
3/64 in. (1.2 mm) Insulation Max.

19/64 in. (7–8 mm) Strip Length

P2-RTB and P2-RTB-1

Removable Terminal Block Specifications

Part Number P2-RTB P2-RTB-1

Number of
Positions

Wire Range

Conductors

Screw Driver

Screw Size
Screw Torque

* Recommended screw driver: P/N TW-SD-MSL-1.

18 Screw Terminals 18 Spring Clamp Terminals

30–16 AWG (0.051–1.31 mm²)
Solid / Stranded Conductor
3/64 in. (1.2 mm) Insulation Max.

1/4 in. (6–7 mm) Strip Length

“USE COPPER CONDUCTORS, 75°C” or Equivalent.

0.1 inch (2.5 mm) Maximum*

M2 N/A

2.5 lb·in (0.28 N·m) N/A

28–16 AWG (0.081–1.31 mm²)
Solid / Stranded Conductor
3/64 in. (1.2 mm) Insulation Max.

19/64 in. (7–8 mm) Strip Length

Hardware User Manual, 1st Ed. Rev. A

3–23

Chapter 3: Installation and Wiring

Removable Terminal Blocks, continued

P1-10RTB (screw terminals)

Removable Terminal Block

P2-RTB (screw terminals)

Removable Terminal Block

Terminal Block Installation

P1-10RTB-1 (spring-clip terminals)

Removable Terminal Block

P2-RTB-1 (spring-clip terminals)

Removable Terminal Block

3–24

Use the Wire Strip Length gauge printed on the end of the terminal strip as a guide to properly
strip wire insulation prior to inserting into terminal block. For ease of assembly, block maybe
wired prior to installation, if desired.

Insert terminal block as follows:

Step 1: Raise finger-safe terminal guard.
Step 2: Align terminal block with module terminal pins, ensuring correct orientation of

block.

Step 3: Firmly and evenly press terminal block onto terminal pins until seated. Lower finger-

safe guard into place.

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

Terminal Block Removal

WARNING: Ensure local and remote power supplies have been disconnected prior to removing terminal
block.

Remove terminal block as follows:

Step 1: Raise terminal cover.
Step 2: Pull terminal block release lever forward.

This will lift terminal block away from
pins.

Step 2: Grasp block firmly and pull away from

module.

Terminal Release Lever

Planning the I/O Wiring Routes

The following guidelines provide general information on how to wire the I/O connections to
Productivity1000 modules. For specific information on wiring a particular I/O module refer
to the module specifications in Chapter 2.

1. If using removable terminal blocks, follow the wire size guidelines
in the I/O modules specifications in Chapter 2.

2. Always use a continuous length of wire. Do not splice wires to create a needed length.

3. Use the shortest possible wire length.

4. Use wire trays for routing where possible.

5. Avoid running low voltage control wires near high voltage wiring.

6. Avoid confusion by laying input wiring separate from output wiring where possible.

7. To minimize voltage drops when wires must run a long distance,
consider using multiple wires for the return line.

8. Avoid running DC wiring in close proximity to AC wiring where possible.

9. Avoid creating sharp bends in the wires; follow accepted Electrical Code standards.

Terminal Cover

Hardware User Manual, 1st Ed. Rev. A

3–25

Chapter 3: Installation and Wiring

System Wiring Strategies

The P1AM-100 is very flexible and will work in many different wiring configurations. By
studying this section before actual installation, you may find the best wiring strategy for your
application. This will help to lower system cost and wiring errors, and avoid safety problems.

CPU Isolation Boundaries

CPU circuitry is divided into three main regions separated by isolation boundaries, shown
in the drawing below. Electrical isolation provides safety, so that a fault in one area does not
damage another. The transformer in the power supply provides magnetic isolation between
the primary and secondary sides. Optical isolators provide isolation in Input and Output
circuits. This isolates logic circuitry from the field side, where factory machinery connects.
The discrete inputs are isolated from the discrete outputs because each is isolated from the
logic side. Isolation boundaries protect the devices which are connected to the communication
ports, such as PCs and HMIs, from power input faults or field wiring faults. When wiring a
controller, it is extremely important to avoid making external connections that connect logic
side circuits to any other.

Power

Input

Power Supply

communication devices

24VDC

Input/

Output

Circuit

Isolation Boundary

HMI or other

Com
Ports

ControllerShieldShield

Logic Circuit

PC

Com

Ports

Maximum 15 I/O Modules

Output ModuleInput Module

Logic

Circuit

Input

Circuit

Logic

Circuit

Output

Circuit

3–26

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

Sinking/Sourcing Concepts

Before wiring field devices to the CPU I/O, it’s necessary to have a basic understanding of
“sinking” and “sourcing” concepts. Use of these terms occurs frequently in input or output
circuit discussions. These terms only apply to DC circuits, not AC circuits. The purpose of
this section is to explain the terms. The short definitions are as follows:

• Sinking = Path to supply ground (–) or switching ground.

• Sourcing = Path to supply source (+) or switching +V.

Input and output points that are either sinking or sourcing can conduct current in only one
direction. This means it is possible to wire the external supply and field device to the I/O
point with current trying to flow in the wrong direction, in which case the circuit will not
operate.

Input
(sinking)

+

–

Common

CPU

Input
Sensing

of the arrow when the switch is closed. By applying the circuit principle above to the four
possible combinations of input/output sinking/sourcing types, we have the four circuits as
shown below.

The diagram on the left shows a “sinking” CPU input.
To properly connect the external supply, connect it so
that the input provides a path to ground (–). Start
at the CPU input terminal, follow through the input
sensing circuit, exit at the common terminal, and
connect the supply (–) to the common terminal.

The switch between the supply (+) and the input
completes the circuit. Current flows in the direction

Sinking Input Sinking Output

Input

+

–

Sourcing Input Sourcing Output

+

–

Common

Common

Input

CPU

Input
Sensing

CPU

Input
Sensing

Output
Switch

Output
Switch

CPU

CPU

Hardware User Manual, 1st Ed. Rev. A

Output

Common

Common

Output

Load

Load

+

–

+

–

3–27

Chapter 3: Installation and Wiring

I/O “Common Terminal” Concepts

In order for a CPU I/O circuit to operate, current must enter at one terminal and exit at
another. This means at least two terminals are associated with every I/O point. In the figure
below, the input or output terminal is the main path for the current. One additional terminal
must provide the return path to the power supply.

If there was unlimited module space then every I/O point could have two dedicated terminals
as the figure above shows. Providing this level of flexibility is not practical or necessary for
most applications. Most I/O point groups share the return path (common) among two or
more I/O points. The figure below shows a group (or bank) of four input points which share a
common return path. In this way, the four inputs require only five terminals instead of eight.

Field
Device

+

–

Main Path
(I/O point)

Return Path

Input 1

CPU

Input Sensing

CPU

I/O

Circuit

3–28

Input 2

Input 3

Input 4

+

–

Electrical Common
To All Input Points

Common

NOTE: In the circuit above, the current in the common path is equal to the sum of the energized channels.
This is especially important in output circuits, where larger gauge wire is sometimes needed for the
commons.

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

CPU DC Input

Field Device

CPU DC Input

DC Input Wiring Methods

I/O modules with DC inputs can be wired as either sinking or

Input

Common

Sinking Input Sensor (NPN Type) to CPU Sourcing Input

In the following example, a field device has an open-collector NPN transistor output. When
energized, it sinks current to ground from the DC input point. The CPU input current is
sourced from the common terminal connected to power supply (+).

sourcing inputs. The dual diodes (shown in this diagram) allow
current to flow in either direction. Inputs grouped by a common
point must be either all sinking or all sourcing. DC inputs typically
operate in the range of +12–24 VDC.

DC NPN Sensor

(Sinking)

Sourcing Input Sensor (PNP Type) to CPU Sinking Input

In the following example, a field device has an open-emitter PNP transistor output. When
energized, it sources current to the CPU input point, which sinks the current to ground. Since
the field device loop is sourcing current, no additional power supply is required for the module.

DC PNP Sensor

(Sourcing)

DC Output Wiring Methods

I/O modules with DC output circuits are wired as all current sinking only or current sourcing
only depending on which output module part number is used. DC outputs typically operate
in the range of +5–24 VDC.

CPU Sinking Output to Sourcing Load Device

Many applications require connecting a CPU output point to a DC input on a field device load.
This type of connection is made to carry a low-level DC signals.

In the following example, the CPU output point sinks current to ground (common) when
energized. The output is connected to a field device load with a sourcing input.

CPU Output

(Sinking)

Field Device

+DC Power

+

–

+

20-28 VDC

Input

(sourcing)

Input

(sinking)

Output

(sinking)

Supply

Ground Common

Output (sourcing)

Ground Common

Power

Output

(sinking)

Common

–

Input

(sourcing)

Ground

CPU Input
(Sourcing)

CPU Input

(Sinking)

Field DeviceCPU DC Output

DC Load

(Sourcing)

Hardware User Manual, 1st Ed. Rev. A

3–29

Chapter 3: Installation and Wiring

CPU DC Output

V

pull-up

CPU DC Sinking Output to Sinking Load Device

In the example below, a sinking output point is connected to the sinking input of a field device
load. In this case, both the CPU output and field device input are sinking type. Since the
circuit must have one sourcing and one sinking device, we add sourcing capability to the CPU
output by using a pull-up resistor. In the circuit below, we connect R pull-up from the output
to the DC output circuit power input.

Common

pull-up

I

input

R

pull-up

Power

R

pull-up

(sourcing)

Output

properly.

=

=

Supply

V

input

R

supply

DC NPN Load

Field Device

R

Input

+

–

pull-up

(sinking)

Ground

. In order to do so, we need to know the

input

(Sinking)

) when the input is energized. If this value

. Then calculate the power P

pull-up

input (turn–on)

input

– 0.7

I

input

R

–

input

input

pull-up

and

(in

CPU Output

(Sinking with

Pull-up Resistor)

NOTE: DO NOT attempt to drive a heavy load (>25mA) with this pull-up method.

NOTE: Using the pull-up resistor to implement a sourcing output has the effect of inverting the output

point logic. In other words, the field device input is energized when the CPU output is OFF, from a ladder
logic point-of-view. Your ladder program must comprehend this and generate an inverted output. Or, you
may choose to cancel the effect of the inversion elsewhere, such as in the field device.

+DC pwr

(sinking)

It is important to choose the correct value of R
nominal input current to the field device (I
is not known, it can be calculated as shown (a typical value is 15mA). Then use I
the voltage of the external supply to compute R
watts), in order to size R

3–30

P

pull-up

V

=

R

supply

2

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

Relay with Form A contacts

Relay Outputs - Wiring Methods

Relay outputs are available for the ProductivityOpen. Relays are best for the following
applications:

• Loads that require higher currents than the solid-state outputs can deliver

• Cost-sensitive applications

• Some output channels need isolation from other outputs (such as when some loads

require different voltages than other loads)

Some applications in which NOT to use relays:

• Loads that require currents under 10mA

• Loads which must be switched at high speed or heavy duty cycle.

Relay outputs are available in two contact arrangements. Form
A type, or SPST (single pole, single throw) type. They are
normally open and are the simplest to use. The Form C, or
SPDT (single pole, double throw) type has a center contact
which moves and a stationary contact on either side. This
provides a normally closed contact and a normally open contact.

Relay with Form C contacts

The relays in some relay output modules share common
terminals, which connect to the wiper contact in each relay of
the bank. Other relay modules have relays which are completely
isolated from each other. In all cases, the module drives the
relay coil when the corresponding output point is on.

Hardware User Manual, 1st Ed. Rev. A

3–31

Chapter 3: Installation and Wiring

Relay Outputs – Transient Suppression for Inductive Loads in a Control System

The following pages are intended to give a quick overview of the negative effects of transient
voltages on a control system and provide some simple advice on how to effectively minimize
them. The need for transient suppression is often not apparent to the newcomers in the
automation world. Many mysterious errors that can afflict an installation can be traced back
to a lack of transient suppression.

What is a Transient Voltage and Why is it Bad?

Inductive loads (devices with a coil) generate transient voltages as they transition from being
energized to being de-energized. If not suppressed, the transient can be many times greater
than the voltage applied to the coil. These transient voltages can damage CPU outputs or other
electronic devices connected to the circuit, and cause unreliable operation of other electronics
in the general area. Transients must be managed with suppressors for long component life and
reliable operation of the control system.

This example shows a simple circuit with a small 24V/125mA/3W relay. As you can see, when
the switch is opened, thereby de-energizing the coil, the transient voltage generated across the
switch contacts peaks at 140V.

Example: Circuit with no Suppression

Volts

160

140

120

100

80

60

40

20

0

-20

24 VDC

Oscilloscope

+

-

Relay Coil
(24V/125mA/3W,
AutomationDirect part no.
750R-2C-24D)

3–32

In the same circuit, replacing the relay with a larger 24V/290mA/7W relay will generate a
transient voltage exceeding 800V (not shown). Transient voltages like this can cause many
problems, including:

• Relay contacts driving the coil may experience arcing, which can pit the contacts and
reduce the relay’s lifespan.

• Solid state (transistor) outputs driving the coil can be damaged if the transient voltage
exceeds the transistor’s ratings. In extreme cases, complete failure of the output can
occur the very first time a coil is de-energized.

• Input circuits, which might be connected to monitor the coil or the output driver, can
also be damaged by the transient voltage.

A very destructive side-effect of the arcing across relay contacts is the electromagnetic
interference (EMI) it can cause. This occurs because the arcing causes a current surge, which
releases RF energy. The entire length of wire between the relay contacts, the coil, and the
power source carries the current surge and becomes an antenna that radiates the RF energy. It
will readily couple into parallel wiring and may disrupt the CPU and other electronics in the
area. This EMI can make an otherwise stable control system behave unpredictably at times.

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

Oscilloscope

Oscilloscope

CPU’s Integrated Transient Suppressors

Although the CPU outputs typically have integrated suppressors to protect against transients,
they are not capable of handling them all. It is usually necessary to have some additional
transient suppression for an inductive load.

Here is another example using the same 24V/125mA/3W relay used earlier. This example
measures the PNP transistor output of a typical CPU, which incorporates an integrated Zener
diode for transient suppression. Instead of the 140V peak in the first example, the transient
voltage here is limited to about 40V by the Zener diode. While the CPU will probably tolerate
repeated transients in this range for some time, the 40V is still beyond the module’s peak
output voltage rating of 30V.

Example: Small Inductive Load with Only Integrated Suppression

Volts

45

40

35

30

25

20

15

10

5

0

-5

VDC

* For this example, a 24V/125mA/3W

relay is used (AutomationDirect

part no. 750R-2C-24D)

24

Relay
Coil*

The next example uses the same circuit as above, but with a larger 24V/290mA/7W relay,
thereby creating a larger inductive load. As you can see, the transient voltage generated is much
worse, peaking at over 50V. Driving an inductive load of this size without additional transient
suppression is very likely to permanently damage the CPU output.

Example: Larger Inductive Load with Only Integrated Suppression

Volts

60

50

40

30

20

10

0

-10

��

9' &

Relay
Coil*

* For this example, a 24/290mA/7W

relay is used (AutomationDirect

part no. SC-E03G-24VDC)

Additional transient suppression should be used in both of these examples. If you are unable
to measure the transients generated by the connected loads of your control system, using
additional transient suppression on all inductive loads would be the safest practice.

Hardware User Manual, 1st Ed. Rev. A

3–33

Chapter 3: Installation and Wiring

Sinking

Types of Additional Transient Protection

DC Coils:

The most effective protection against transients from a DC coil is a flyback diode. A flyback
diode can reduce the transient to roughly 1V over the supply voltage, as shown in this example.

24 VDC

DC Flyback Circuit

Oscilloscope

+
_

Sourcing

Volts

30

25

20

15

10

5

0

-5

Many AutomationDirect socketed relays and motor starters have add-on flyback diodes
that plug or screw into the base, such as the AD-ASMD-250 protection diode module and
784-4C-SKT-1 socket module shown below. If an add-on flyback diode is not available for
your inductive load, an easy way to add one is to use AutomationDirect’s DN-D10DR-A
diode terminal block, a 600VDC power diode mounted in a slim DIN rail housing.

3–34

AD-ASMD-250

Protection Diode Module

784-4C-SKT-1

Relay Socket

DN-D10DR-A

Diode Terminal Block

Hardware User Manual, 1st Ed. Rev. A

Chapter 3: Installation and Wiring

DC MOV or TVS Diode Circuit

Sinking

Sourcing

A

Two more common options for DC coils are Metal Oxide Varistors (MOV) or TVS diodes.
These devices should be connected across the driver (CPU output) for best protection as shown
below. The optimum voltage rating for the suppressor is the lowest rated voltage available that
will NOT conduct at the supply voltage, while allowing a safe margin.

AutomationDirect’s ZL-TSD8-24 transorb module is a good choice for 24VDC circuits. It
has a bank of 8 uni-directional 30V TVS diodes. Since they are uni-directional, be sure to
observe the polarity during installation. MOVs or bi-directional TVS diodes would install at
the same location, but have no polarity concerns.

+

24 VDC

_

ZL-TSD8-24

Transorb Module

AC Coils:

Two options for AC coils are MOVs or bi-directional TVS diodes. These devices are most
effective at protecting the driver from a transient voltage when connected across the driver
(CPU output) but are also commonly connected across the coil. The optimum voltage rating
for the suppressor is the lowest rated voltage available that will NOT conduct at the supply
voltage, while allowing a safe margin.

AutomationDirect’s ZL-TSD8-120 transorb module is a good choice for 120VAC circuits. It
is a bank of eight bi-directional 180V TVS diodes.

C MOV or Bi-Directional Diode Circuit

VAC

ZL-TSD8-120

Transorb Module

NOTE: Manufacturers of devices with coils frequently offer MOV or TVS diode suppressors as an add­on option which mount conveniently across the coil. Before using them, carefully check the suppressor
ratings. Just because the suppressor is made specifically for that part does not mean it will reduce the
transient voltages to an acceptable level.

For example, a MOV or TVS diode rated for use on 24-48 VDC coils would need to have a
high enough voltage rating to NOT conduct at 48V. That suppressor might typically start
conducting at roughly 60VDC. If it were mounted across a 24V coil, transients of roughly
84V (if sinking output) or -60V (if sourcing output) could reach the CPU output. Many
semiconductor CPU outputs cannot tolerate such levels.

Hardware User Manual, 1st Ed. Rev. A

3–35

Security
conSiderationS for
control SyStemS

Appendix

Appendix

Appendix

networkS

In This Appendix...

Security Considerations for Controls Networks .......................................................1–2

A

A

A

Appendix A: Security Considerations for Control Systems Networks

Security Considerations for Control Systems Networks

Manufacturers are realizing that to stay competitive, their Automation and Control Systems
need to be more integrated within their plant. The systems often need to be integrated with
upstream Enterprise Data Systems, and even further integrated to allow information to be
accessible across multiple plants, or even through the Internet. This convergence of the IT
world with the Automation World creates challenges in maintaining secure systems and
protecting your investments in processes, personnel, data and intellectual property.

While Automation Networks and Systems have built-in password protection schemes, this
is only one very small step in securing your systems. Automation Control System Networks
need to incorporate data protection and security measures that are at least as robust as a typical
business computer system. We recommend that users of PLCs, HMI products and SCADA
systems perform your own network security analysis to determine the proper level of security
required for you application. However, the Department of Homeland Security’s National
Cybersecurity and Communications Integration Center (NCCIC) and Industrial Control
Systems Cyber Emergency Response Team (ICS-CERT) has provided direction related to
network security and safety under an approach described as “Defense in Depth”, which is
published at https://ics-cert.uscert.gov/sites/default/files/recommended_practices/NCCIC_

ICSCERT_Defense_in_Depth_2016_S508C.pdf.

This comprehensive security strategy involves physical protection methods, as well as process
and policy methods. This approach creates multiple layers and levels of security for industrial
automation systems. Such safeguards include the location of control system networks behind
firewalls, their isolation from business networks, the use of intrusion detection systems, and
the use of secure methods for remote access such as Virtual Private Networks (VPNs). Further,
users should minimize network exposure for all control system devices and such control
systems and these systems should not directly face the internet. Following these procedures
should significantly reduce your risks both from external sources as well as internal sources,
and provide a more secure system.

It is the user’s responsibility to protect such systems, just as you would protect your computer
and business systems. AutomationDirect recommends using one or more of these resources in
putting together a secure system:

• US-CERT’s Control Systems Security Program at the following web address:

www.us-cert.gov/control_systems/

• Special Publication 800-82 of the National Institute of Standards and Technology – Guide to
Industrial Control Systems (ICS) Security

https://csrc.nist.gov/publications/detail/sp/800-82/rev-2/final

• ISA99, Industrial Automation and Control Systems Security

http://www.isa.org/MSTemplate.cfm?MicrositeID=988&CommitteeID=6821

(please note this is a summary and these standards have to be purchased from ISA)

The above set of resources provides a comprehensive approach to securing a control system
network and reducing risk and exposure from security breaches. Given the nature of any
system that accesses the internet, it is incumbent upon each user to assess the needs and
requirements of their application, and take steps to mitigate the particular security risks
inherent in their control system.

A–2

Hardware User Manual, 1st Ed. Rev. A