AutomationDirect Terminator Installation Manual

Terminator Installation

and I/O Manual

Manual Number: T1K-INST-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 codes.

At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation.

Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards. We do not guarantee the products described in this publication are suitable for your particular application, nor do we assume any responsibility for your product design, installation, or operation.

Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as on-line control equipment in hazardous environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of the product could lead directly to death, personal injury, or severe physical or environmental damage (“High Risk Activities”). AutomationDirect 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 AutomationDirect we constantly strive to improve our products and services, so we reserve the right to 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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~ 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.

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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. Esta publicación está basada en la información disponible al momento de impresión. En Automationdirect. com nos esforzamos constantemente para mejorar nuestros productos y servicios, así que nos reservamos el derecho de hacer cambios al producto y/o a las publicaciones en cualquier momento sin notificación y sin ninguna obligación. Esta publicación también puede discutir características que no estén disponibles en ciertas revisiones del producto.

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

~ AVERTISSEMENT

Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.com®, en faisant des 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 plus récente de ces codes.

Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du Code national de l’électricité et des codes de la National Electrical Manufacturer’s Association (NEMA). Des organismes de réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que les normes à respecter pour assurer une installation et un fonctionnement sûrs.

L’omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages à l’équipement ou causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication conviennent à votre application particulière et nous n’assumons aucune responsabilité à l’égard de la conception, de l’installation ou du fonctionnement de votre produit.

Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l’utilisation ou la revente en tant qu’équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par exemple, l’exploitation d’installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de la circulation aérienne, les équipements de survie ou les systèmes d’armes, pour lesquels la défaillance du produit peut provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux («activités à risque élevé»). La société AutomationDirect nie toute garantie expresse ou implicite d’aptitude à l’emploi en ce qui a trait aux activités à risque élevé.

Pour des renseignements additionnels touchant la garantie et la sécurité, veuillez consulter la section Modalités et conditions de notre documentation. Si vous avez des questions au sujet de l’installation ou du fonctionnement de cet équipement, ou encore si vous avez besoin de renseignements supplémentaires, n’hésitez pas à nous téléphoner au 770-844-4200.

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TerminaTor insTallaTion

and I/O Manual

Please include the Manual Number and the Manual Issue, both shown below,

when communicating with Technical Support regarding this publication.

Manual Number: T1K-INST-M

Issue: 3rd Edition, Rev. C

Issue Date: 08/20

Edition/Rev Date Publication History

First Edition 11/00 Original issue

Rev. A 02/01 Added new module and minor corrections Rev. B 07/01 Added new modules Rev. C 04/02 Added new modules and minor corrections Rev. D 12/02 Added new module and general updates Rev. E 04/03 Added new module and added Class 1, Division 2, Zone 2 Approval

2nd Edition 09/03 Added new module and minor corrections

Rev. A 09/04 Added new modules and minor corrections

3rd Edition 05/13 Converted manual from Interleaf to QuarkXpress and made minor corrections

Rev. A 10/16 Added T1F-16TMST thermistor input module Rev. B 01/18 Added Module Control Byte examples (4-21 to 4-24). General updates. Rev. C 08/20 T1H-PBC discontinued, added notes to Chapter 3 accordingly.

Chapter 1 - Getting Started

About This Manual .................................................................................................. 1-10

The Purpose of this Manual .................................................................................... 1-10

Supplemental Manuals ........................................................................................... 1-10

Technical Support................................................................................................... 1-10

Conventions Used .................................................................................................... 1-11

Key Topics for Each Chapter ................................................................................... 1-11

Terminator I/O Base Controllers ............................................................................. 1-12

Terminator I/O System Components ...................................................................... 1-13

Power Supplies ....................................................................................................... 1-13

I/O Modules ........................................................................................................... 1-13

Chapter 2 - Installation and Wiring

Safety Guidelines ..................................................................................................... 2-15

Plan for Safety ........................................................................................................ 2-15

Three Levels of Protection ...................................................................................... 2-16

Emergency Stops .................................................................................................... 2-16

Emergency Power Disconnect ................................................................................ 2-17

Orderly System Shutdown ...................................................................................... 2-17

Class 1, Division 2, Zone 2 Approval ...................................................................... 2-17

Mounting Guidelines ............................................................................................... 2-18

Dimensions ............................................................................................................ 2-18

Panel Mounting and Layout ................................................................................... 2-19

Enclosures .............................................................................................................. 2-20

Environmental Specifications .................................................................................. 2-21

Power ..................................................................................................................... 2-21

Agency Approvals ................................................................................................... 2-21

Table of Contents

Assembling the Components .................................................................................. 2-22

Assembling the I/O Modules and Bases .................................................................. 2-22

Mounting the Components on DIN Rail ................................................................. 2-22

Connecting the Components on the DIN Rail ........................................................ 2-23

Removing I/O Modules from the Base .................................................................... 2-23

Multiple Power Supplies / Local Expansion Configurations .................................. 2-24

Multiple Power Supply Configuration ..................................................................... 2-24

Example Using T1K-10CBL and T1K-10CBL-1 Expansion Cables ............................. 2-24

Example Using T1K-05CBL-RR-1 and T1K-05CBL-LL Expansion Cables ................... 2-25

Example Using T1K-10CBL and T1K-05CBL-RR-1 Expansion Cables ........................ 2-26

Example Using T1K-05CBL-RR-1 Expansion Cables ................................................. 2-27

Power Supply Wiring Guidelines ............................................................................. 2-28

Power Wiring ......................................................................................................... 2-28

Chapter 3 - I/O Wiring and Specifications

I/O Wiring Strategies ................................................................................................ 3-3

Terminator I/O System Isolation Boundaries ............................................................. 3-3

Powering I/O Circuits with the Auxiliary Supply ....................................................... 3-4

Powering I/O Circuits Using Separate Supplies ......................................................... 3-5

Sinking / Sourcing Concepts .................................................................................... 3-6

I/O “Common” Terminal Concepts .......................................................................... 3-7

Connecting DC I/O to Solid State Field Devices ....................................................... 3-8

Solid State Input Sensors .......................................................................................... 3-8

Solid State Output Loads .......................................................................................... 3-8

Relay Output Guidelines ......................................................................................... 3-10

Relay Outputs - Transient Suppression for Inductive Loads in a Control System...... 3-10

I/O Modules Position, Wiring and Specifications ................................................... 3-15

Multiple Power Supply Configuration ..................................................................... 3-15

Overview of I/O Expansion Configurations ............................................................. 3-16

Types of Modules Available for the Terminator System ........................................... 3-17

Discrete Module Status Indicators .......................................................................... 3-17

Color Coding of I/O Modules ................................................................................. 3-17

Wiring the I/O Module Bases .................................................................................. 3-18

Selecting Internal 24VDC Power Supply ................................................................. 3-19

Using Internal 24VDC Base Power .......................................................................... 3-19

Using Internally Bussed 24VDC (T1K-08ND3, T1K-16ND3 only) ............................ 3-19

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Table of Contents

External 24VDC Wiring Options ............................................................................. 3-20

Using T1K-01AC for External 24VDC Power ........................................................... 3-20

Using an External 24VDC Power Supply ................................................................. 3-20

I/O Wiring Checklist ............................................................................................... 3-21

Output Module Fusing ........................................................................................... 3-21

I/O Module Hot Swap Feature ................................................................................ 3-22

Hot Swap: I/O Module Replacement ...................................................................... 3-22

Outputs Enable / Disable Switch ............................................................................ 3-22

Check External 24VDC Wiring Before Hot Swapping .............................................. 3-22

Calculating the Power Budget ................................................................................ 3-23

Managing the Power Resource ............................................................................... 3-23

Power Supply Specifications ................................................................................... 3-23

Module Power Requirements .................................................................................. 3-24

Power Budget Calculation Example ........................................................................ 3-25

Power Budget Worksheet ....................................................................................... 3-26

I/O Specification Terms ........................................................................................... 3-27

Inputs or Outputs Per Module ................................................................................ 3-27

Commons Per Module ........................................................................................... 3-27

Input Voltage Range ............................................................................................... 3-27

Output Voltage Range ............................................................................................ 3-27

Peak Voltage ........................................................................................................... 3-27

AC Frequency ......................................................................................................... 3-27

ON Voltage Level ................................................................................................... 3-27

OFF Voltage Level ................................................................................................... 3-27

Input impedance .................................................................................................... 3-27

Input Current ......................................................................................................... 3-27

Minimum ON Current ............................................................................................ 3-27

Maximum OFF Current .......................................................................................... 3-27

Minimum Load....................................................................................................... 3-27

External DC Required ............................................................................................. 3-27

ON Voltage Drop ................................................................................................... 3-28

Maximum Leakage Current .................................................................................... 3-28

Maximum Inrush Current ....................................................................................... 3-28

Base Power Required .............................................................................................. 3-28

OFF to ON Response .............................................................................................. 3-28

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

iii

Table of Contents

ON to OFF Response .............................................................................................. 3-28

Terminal Type ......................................................................................................... 3-28

Status Indicators ..................................................................................................... 3-28

Weight ................................................................................................................... 3-28

Fuses ...................................................................................................................... 3-28

T1K-01AC, T1K-01DC Power Supply ....................................................................... 3-29

Dimensions ............................................................................................................ 3-30

T1H-EBC Ethernet Base Controller (Obsolete) ....................................................... 3-31

Dimensions ............................................................................................................ 3-32

T1K-EBC Ethernet Port Pin-out ............................................................................... 3-32

T1K-EBC Serial Port Pin-out .................................................................................... 3-32

T1H-EBC100 Ethernet Base Controller .................................................................... 3-33

Dimensions ............................................................................................................ 3-34

T1K-EBC100 Ethernet Port Pin-out ......................................................................... 3-34

T1K-EBC100 Serial Port Pin-out .............................................................................. 3-34

T1K-DEVNETS .......................................................................................................... 3-35

T1K-DEVNETS Serial Port Pin-out ............................................................................ 3-36

Dimensions ............................................................................................................ 3-36

T1K-DEVNETS DIP Switch Settings ......................................................................... 3-36

T1K-MODBUS Base Controller ................................................................................ 3-37

Dimensions ............................................................................................................ 3-38

T1K-MODBUS DIP Switch Settings .............................................................. 3-38

T1K-RSSS Remote I/O Base Controller ................................................................... 3-39

Dimensions ............................................................................................................ 3-40

T1K-RSSS DIP Switch Settings................................................................................. 3-40

T1K-RSSS Serial Port Pin-out ................................................................................... 3-40

T1H-PBC Profibus Base Controller .......................................................................... 3-41

Dimensions ............................................................................................................ 3-42

T1H-PBC Port Pin-out ............................................................................................. 3-42

T1K-08ND3 DC Input ............................................................................................... 3-43

Wiring & Dimensions ............................................................................................. 3-44

Jumper Selection .................................................................................................... 3-44

T1K-16ND3 DC Input ............................................................................................... 3-45

Wiring & Dimensions ............................................................................................. 3-46

Jumper Selection .................................................................................................... 3-46

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Table of Contents

T1K-08NA-1 AC Input .............................................................................................. 3-47

Wiring & Dimensions ............................................................................................. 3-48

T1K-16NA-1 AC Input .............................................................................................. 3-49

Wiring & Dimensions ............................................................................................. 3-50

T1K-08TD1 DC Output ............................................................................................ 3-51

Wiring & Dimensions ............................................................................................. 3-52

T1K-08TD2-1 DC Output ......................................................................................... 3-53

Wiring & Dimensions ............................................................................................. 3-54

T1H-08TDS Isolated DC Output .............................................................................. 3-55

Wiring & Dimensions ............................................................................................. 3-56

T1K-16TD1 DC Output ............................................................................................ 3-57

Wiring & Dimensions ............................................................................................. 3-58

T1K-16TD2-1 DC Output ......................................................................................... 3-59

Wiring & Dimensions ............................................................................................. 3-60

T1K-08TA AC Output ............................................................................................... 3-61

Wiring & Dimensions ............................................................................................. 3-62

T1K-16TA AC Output ............................................................................................... 3-63

Wiring & Dimensions ............................................................................................. 3-64

T1K-08TAS AC Output ............................................................................................. 3-65

Wiring & Dimensions ............................................................................................. 3-66

T1K-08TR Relay Output ........................................................................................... 3-67

Wiring & Dimensions ............................................................................................. 3-68

T1K-16TR Relay Output ........................................................................................... 3-69

Wiring & Dimensions ............................................................................................. 3-70

T1K-08TRS Relay Output ......................................................................................... 3-71

Wiring & Dimensions ............................................................................................. 3-72

T1F-08AD-1 8-Channel Current Analog Input ........................................................ 3-73

Wiring & Dimensions ............................................................................................. 3-74

T1F-08AD-2 8-Channel Voltage Analog Input ........................................................ 3-75

Wiring & Dimensions ............................................................................................. 3-76

T1F-16AD-1 16-Channel Current Analog Input ...................................................... 3-77

Wiring & Dimensions ............................................................................................. 3-78

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Table of Contents

T1F-16AD-2 16-Channel Voltage Analog Input ...................................................... 3-79

Wiring & Dimensions ............................................................................................. 3-80

T1F-08DA-1 8-Channel Current Analog Output ..................................................... 3-81

Wiring & Dimensions ............................................................................................. 3-82

T1F-08DA-2 8-Channel Analog Output ................................................................... 3-83

Wiring & Dimensions ............................................................................................. 3-84

T1F-16DA-1 16-Channel Current Analog Output ................................................... 3-85

Wiring & Dimensions ............................................................................................. 3-86

T1F-16DA-2 16-Channel Voltage Analog Output ................................................... 3-87

Wiring & Dimensions ............................................................................................. 3-88

T1F-16RTD RTD Input Module ................................................................................ 3-89

Wiring & Dimensions ............................................................................................. 3-90

Setting Module Jumpers ......................................................................................... 3-91

T1F-RTD Data Format ............................................................................................. 3-92

T1F-16TMST Thermistor Input Module .................................................................. 3-93

Wiring & Dimensions ............................................................................................. 3-94

Setting Module Jumpers ......................................................................................... 3-95

T1F-TMST Data Format .......................................................................................... 3-96

T1F-14THM 14-Channel Thermocouple Input ........................................................ 3-97

Wiring & Dimensions ............................................................................................. 3-98

Setting Module Jumpers .......................................................................................... 3-99

T1F-THM Data Format .......................................................................................... 3-99

Select the Conversion Units .................................................................................... 3-99

T1F-8AD4DA-1 8-Channel Current Analog Input /

4-Channel Current Analog Output .................................. 3-101

Input Wiring & Dimensions .................................................................................. 3-102

T1F-8AD4DA-1 ..................................................................................................... 3-103

Output Wiring & Dimensions ............................................................................... 3-104

T1F-8AD4DA-2 8-Channel Voltage Analog Input /

4-Channel Voltage Analog Output ................................. 3-105

Input Wiring & Dimensions .................................................................................. 3-106

T1F-8AD4DA-2 ....................................................................................................... 3-107

Output Wiring & Dimensions ............................................................................... 3-108

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Table of Contents

T1H-CTRIO Counter I/O Module ........................................................................... 3-109

Wiring & Dimensions ........................................................................................... 3-110

LED Indicators ...................................................................................................... 3-110

T1H-CTRIO Input Wiring Diagrams ...................................................................... 3-111

T1H-CTRIO Input Wiring Diagrams ...................................................................... 3-112

T1H-CTRIO Output Wiring Diagrams ................................................................... 3-113

T1H-CTRIO Output Wiring Diagrams ................................................................... 3-114

T1K-08B(-1) I/O Module Base ............................................................................... 3-115

T1K-16B(-1) I/O Module Base ............................................................................... 3-115

Dimensions .......................................................................................................... 3-116

T1K-10CBL, T1K-10CBL-1 Expansion Cable .......................................................... 3-117

Specifications ....................................................................................................... 3-117

Dimensions .......................................................................................................... 3-118

T1K-5CBL-LL(-1) Expansion Cable ......................................................................... 3-119

T1K-5CBL-RR(-1) Expansion Cable ........................................................................ 3-119

Dimensions .......................................................................................................... 3-120

Cable Connection Examples .................................................................................. 3-121

Chapter 4 - I/O Memory Map and Analog Module Resolution

Master / Slave Communications ............................................................................... 4-2

Terminator I/O Backplane Communications ............................................................ 4-2

Discrete Input Module Memory Map ....................................................................... 4-3

Discrete Output Module Memory Map .................................................................... 4-4

8-Channel Analog Input Module Memory Map ....................................................... 4-5

16-Channel Analog Input Module

(T1F-16AD-x, T1F-16RTD, T1F-16TMST and T1F-14THM) ........................................ 4-7

T1F-14THM, T1F-16TMST and T1F-16RTD Channel Burnout Bit .............................. 4-7

16-Channel Analog Input Module Memory Map ..................................................... 4-8

Analog Input Module Resolution ............................................................................ 4-10

Input Module Resolution ........................................................................................ 4-10

Channel Data Bits ................................................................................................... 4-10

Analog and Digital Value Conversions .................................................................... 4-11

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

vii

Table of Contents

T1F-08DA-x, Analog Output Module Memory Map ............................................... 4-12

T1F-8AD4DA-x, Analog Output Module Memory Map .......................................... 4-17

Analog Output Module Control Byte ..................................................................... 4-21

Analog Output Module Resolution ......................................................................... 4-25

Output Module Resolution ..................................................................................... 4-25

Channel Data Bits ................................................................................................... 4-25

Analog and Digital Value Conversions .................................................................... 4-26

Appendix A - European Union Directives (CE)

European Union (EU) Directives ............................................................................... A-2

Member Countries ................................................................................................... A-2

Applicable Directives ................................................................................................ A-2

Compliance .............................................................................................................. A-2

General Safety .......................................................................................................... A-4

Special Installation Manual ....................................................................................... A-4

Other Sources of Information ................................................................................... A-4

Basic EMC Installation Guidelines ............................................................................. A-5

Enclosures ................................................................................................................ A-5

Electrostatic Discharge (ESD) .................................................................................... A-5

AC Mains Filters ....................................................................................................... A-6

Suppression and Fusing ............................................................................................ A-6

Internal Enclosure Grounding ................................................................................... A-6

Equi–potential Grounding ........................................................................................ A-7

Communications and Shielded Cables ..................................................................... A-7

Analog and RS-232C Cables ..................................................................................... A-8

Multidrop Cables ...................................................................................................... A-8

Shielded Cables within Enclosures ............................................................................ A-9

Analog Modules and RF Interference ........................................................................ A-9

Network Isolation ..................................................................................................... A-9

DC Powered Versions ............................................................................................... A-9

Items Specific to the Terminator I/O System ........................................................... A-10

viii

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Chapter

GettinG Started

In This Chapter...

About This Manual .................................................................................................... 1-2

Conventions Used ...................................................................................................... 1-3

Terminator I/O Base Controllers ............................................................................... 1-4

Terminator I/O System Components ........................................................................ 1-5

Chapter 1: Getting Started

About This Manual

The Purpose of this Manual

This manual is written for the user of the Terminator I/O line of ﬁeld bus termination I/O products. This manual shows you how to install and wire the equipment. It provides speciﬁcations for the input and output modules.

Supplemental Manuals

In addition to this manual, you will want to have the speciﬁc manual for your Terminator I/O Base Controller. In some cases you may need an additional manual such as the master PLC User Manual or perhaps the manual for the PC-based control software you may be using.

Technical Support

We strive to make our manuals the best in the industry. We rely on your feedback to let us know if we are reaching our goal. If you cannot ﬁnd the solution to your particular application, or, if for any reason you need technical assistance, please call us at:

770–844–4200 Our technical support group will be pleased to work with you to answer your questions. They

are available Monday through Friday from 9:00 A.M. to 6:00 P.M. Eastern Time. We also encourage you to visit our web site where you can ﬁnd technical and non-technical information about our products and our company.

http://www.automationdirect.com

1-10

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Conventions Used

When you see the “notepad” icon in the left-hand margin, the paragraph to its immediate right will be a special note. The word NOTE: in boldface will mark the beginning of the text.

When you see the “exclamation mark” 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). 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.

Chapter 1: Getting Started

Getting Started

CHAPTER

In This Chapter...

General Information

Terminator I/O Base Controllers................................................1-4

.................................................................1-2

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter 1: Getting Started

T1H–PBC T1K–MODBUS T1K–RSSS

Terminator I/O Base Controllers

Terminator I/O offers ﬁve base controller modules. All modules include an on board RJ-12, RS-232C serial port.

The ﬁve base controllers are:

•Ethernet Base Controller

- T1H-EBC (discontinued)

- T1H-EBC100

•DeviceNet Base Controller

- T1K-DEVNETS

•Proﬁbus

- T1H-PBC

•Modbus

- T1K-MODBUS

•DirectLOGIC Remote I/O Base Controller

- T1K-RSSS

™ DP Base Controller

™ RTU Base Controller

T1H–EBC100

(Discontinued)

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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STENVED–K1TCBE–H1T

Terminator I/O System Components

PROFIBUS

Terminator I/O is a modular system which combines the functions of terminal blocks and I/O modules for distributed I/O. Each Terminator I/O system has the following components: a Power Supply, a Base Controller, and one or more I/O Module(s). Terminator I/O systems can contain up to 16 I/O modules per slave (node). Each slave (node) system can be divided into one row of base I/O plus two rows of local expansion I/O using a base expansion cable.

Power Supplies

120/240 VAC and 12/24 VDC power supplies are available. The AC version has a built-in 24VDC supply. A power supply must be the leftmost component in a slave system followed by the base controller. Additional power supplies should be added between I/O modules to meet power budget requirements.

I/O Modules

A Terminator I/O module assembly consists of an I/O module and a separate base, as shown below. A complete range of discrete modules which support 12/24 VDC, 110/220 VAC and up to 7A relay outputs is offered. The analog I/O modules provide 12-bit and 14-bit resolution and several selections of I/O signal ranges (including bipolar). The temperature input modules provide 16 bit resolution with several temperature input range selections. All Terminator I/O modules can be Hot Swapped (replaced) without removing system power (except for the base controller and power supply). Refer to the I/O Module Hot Swap section in Chapter 3 for details.

Chapter 1: Getting Started

Power Supply

Base Controller

MODULE STATUS LINK ACTIVE LINK GOOD ERROR

Profibus Base Controller

I/O Module

I/O Base

I/O Modules

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter

InstallatIon and WIrIng

In This Chapter...

Safety Guidelines ....................................................................................................... 2-2

Mounting Guidelines ................................................................................................. 2-5

Assembling the Components .................................................................................... 2-9

Multiple Power Supplies / Local Expansion Conﬁgurations .................................. 2-11

Power Supply Wiring Guidelines ............................................................................. 2-15

Chapter 2: Installation and Wiring

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: 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 PLC 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 PLC 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.

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Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Three Levels of Protection

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.

• Emergency stop switch for disconnecting system power

• Mechanical disconnect for output module power

• Orderly system shutdown sequence in the PLC control program

Emergency Stops

It is recommended that emergency stop circuits be incorporated into the system for every machine controlled by a PLC. For maximum safety in a PLC system, these circuits must not be wired into the controller, but should be hardwired external to the PLC. The emergency stop switches should be easily accessed by the operator and are generally wired into a master control relay (MCR) or a safety control relay (SCR) that will remove power from the PLC 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 PLC continues to receive power and operate even though all its inputs and outputs are disabled.

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

Chapter 2: Installation and Wiring

Guard Line Switch

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Emergency Stop

2-16

Chapter 2: Installation and Wiring

Retract

Emergency Power Disconnect

A properly rated emergency power disconnect should be used to power the PLC controlled system as a means of removing the power from the entire control system. It may be necessary to install a capacitor across the disconnect to protect against a condition known as “outrush”. This condition occurs when the output Triacs are turned off by powering off the disconnect, thus causing the energy stored in the inductive loads to seek the shortest distance to ground, which is often through the Triacs.

After an emergency shutdown or any other type of power interruption, there may be requirements that must be met before the PLC control program can be restarted. For example, there may be speciﬁc register values that must be established (or maintained from the state prior to the shutdown) before operations can resume. In this case, you may want to use retentive memory locations, or include constants in the control program to ensure a known starting point.

Orderly System Shutdown

Ideally, the ﬁrst level of fault detection is the PLC control program, which can identify machine problems. Certain shutdown sequences should be performed. The types o f problems are usually things such as jammed parts, etc. that d o not pose a risk of personal injury or equipment damage.

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.

Jam Detect

Turn off Saw

RST

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Class 1, Division 2, Zone 2 Approval

This equipment is suitable for use in Class 1, Zone 2, Division 2, groups A, B, C and D or non-hazardous locations only.

WARNING: Explosion Hazard! Substitution of components may impair suitability for Class 1, Division 2. Do not disconnect equipment unless power has been switched off or area is known to be nonhazardous.

WARNING: Explosion Hazard! Do not disconnect equipment unless power has been switched off or the area is known to be non-hazardous.

WARNING: All models used with connector accessories must use R/C (ECBT2) mating plug for all applicable models. All mating plugs shall have suitable ratings for device.

WARNING: This equipment is designed for use in Pollution Degree 2 environments (installed within an enclosure rated at least IP54).

WARNING: Transient suppression must be provided to prevent the rated voltage from being exceeded by 140%.

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Mounting Guidelines

Base Controller / Power Supply

Before installing the Terminator I/O system you will need to know the dimensions of the components. The diagrams on the following pages provide the component dimensions to use in deﬁning your enclosure speciﬁcations. Remember to leave room for potential expansion.

NOTE: If you are using other components in your system, refer to the appropriate manual to determine how those units can affect mounting dimensions.

Dimensions

The following diagrams show the base controller, power supply and I/O module dimensions. Terminator I/O components mount on 35mm wide DIN rail.

Chapter 2: Installation and Wiring

9.2 (0.36)

10.3 (0.41) 10.3 (0.41)

48 (1.89)

Terminator I/O components mount on 35mm wide DIN rail.

I/O Modules

(8 pt.)

48 (1.89)

80 (3.15)

83.3 (3.28)

80 (3.15)80 (3.15)

(16 pt.)

89 (3.5)

80 (3.15)

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter 2: Installation and Wiring

Panel Mounting and Layout

It is important to design your panel properly to help ensure that the Terminator I/O products operate within their environmental and electrical limits. The system installation should comply with all appropriate electrical codes and standards. It is important that the system also conforms to the operating standards for the application to ensure proper performance.

Airflow

1. Only mount the unit horizontally as shown to provide proper ventilation.

2. If you place more than one unit in a cabinet, there should be a minimum of 7.2 in. (183mm) between them.

3. Provide a minimum clearance of 2in. (50mm) between the units and all sides of the cabinet. There should also be at least 1.2 in. (30mm) of clearance between the base and any wiring ducts.

Temperature Probe

Power Source

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Ground braid

Panel

Star Washers

copper lugs

Star Washers

Panel or single

point ground

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Earth Ground

Panel Ground

Terminal

Chapter 2: Installation and Wiring

4. There must be a minimum of 2in. (50mm) clearance between the panel door and the nearest Terminator I/O component.

5. The ground terminal on the Terminator I/O power supply must be connected to a single point ground. Use copper stranded wire to achieve a low impedance. Copper eye lugs should be crimped and soldered to the ends of the stranded wire to ensure good surface contact. Remove anodized ﬁnishes and use copper lugs and star washers at termination points. A general rule is to achieve a 0.1 ohm of DC resistance between the Terminator I/O slave and the single point ground.

6. There must be a single point ground (i.e. copper bus bar) for all devices in the panel requiring an earth ground return. The single point of ground must be connected to the panel ground termination. The panel ground termination must be connected to earth ground. For this connection you should use 12AWG stranded copper wire as a minimum. Minimum wire sizes, color coding, and general safety practices should comply with appropriate electrical codes and standards for your region. A good common ground reference (earth ground) is essential for proper operation of the Terminator I/O. There are several methods of providing an adequate common ground reference, including: a) Installing a ground rod as close to the panel as possible. b) Connection to incoming power system ground.

7. Properly evaluate any installation where the ambient temperature may approach the lower or upper limits of the speciﬁcations. Place a temperature probe in the panel, close the door and operate the system until the ambient temperature has stabilized. If the ambient temperature is not within the operating speciﬁcation for the Terminator I/O system, measure points in the panel in consideration for installing a cooling/heating source to provide the ambient temperature to meet the Terminator I/O operating speciﬁcations.

8. Device mounting bolts and ground braid termination bolts should be #10 copper bolts or equivalent. Tapped holes instead of nut-bolt arrangements should be used whenever possible. To ensure good contact on termination areas impediments such as, paint, other coating or corrosion should be removed in the area of contact.

9. The system is designed to be powered by 110/220 VAC or 24VDC normally available throughout an industrial environment. Isolation transformers and noise suppression devices are not normally necessary, but may be helpful in eliminating/reducing suspect power problems.

Enclosures

Your selection of a proper enclosure is important to ensure safe and proper operation of your Terminator I/O system. Applications of Terminator I/O systems vary and may require additional features. 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 equipment

• Security or restricted access

• Sufﬁcient space for proper installation and maintenance of equipment

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter 2: Installation and Wiring

Environmental Speciﬁcations

The following table lists the environmental speciﬁcations that apply to the Terminator I/O modules. Be sure to check the speciﬁcations of the controller you are using. Also refer to the appropriate I/O module speciﬁcations in Chapter 3 for the temperature derating curves for the speciﬁc module.

Speciﬁcation Rating

Storage temperature -4°F to 158°F (-20°C to 70°C) Ambient operating temperature 32°F to 131°F (0°C to 55°C) Ambient humidity* 5%–95% relative humidity (non-condensing Vibration resistance MIL STD 810C, Method 514.2 Shock resistance MIL STD 810C, Method 516.2

Noise Immunity

Atmosphere

*Equipment will operate at low humidity. However, static electricity problems occur much more frequently at lower humidity levels. Make sure you take adequate precautions when you touch the equipment. Consider using ground straps, anti-static ﬂoor coverings, etc., if you use the equipment in low humidity environments.

Power

The power source must be capable of supplying voltage and current complying with the base power supply speciﬁcations.

NEMA (ICS3-304) Impulse noise 1µs, 1000V FCC class A RFI (144MHz, 430MHz 10W, 10cm

No corrosive gases. The level for the environmental pollution = 2. (UL840)

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Speciﬁcation AC Power Supply DC Power Supply

Part Number T1K-01AC T1K-01DC

Input Voltage Range

Maximum Inrush Current 20A 10A Maximum Power 50VA 20W Voltage Withstand (dielectric) 1 minute @ 1500VAC between primary, secondary, ﬁeld ground Insulation Resistance > 10Mq at 500VDC

Auxiliary 24VDC Output

110/220 VAC (85–264 VAC) 50/60 Hz (47–63 Hz)

20–28 VDC, 10% ripple max. 300mA. Max. 500mA @ 24VDC can be achieved if the 5VDC power budget rating of 2000mA is reduced to 1500mA. See power budget section.

12/24 VDC (10.8–26.4 VDC) with less than 10% ripple

None

Agency Approvals

Some applications require agency approvals. Typical agency approvals which your application may require are:

• UL (Underwriters’ Laboratories, Inc.)

• CSA (Canadian Standards Association)

• FM (Factory Mutual Research Corporation)

• CUL (Canadian Underwriters’ Laboratories, Inc.)

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Assembling the Components

Chapter 2: Installation and Wiring

Assembling the I/O Modules and Bases

INSERT MODULE INTO BASE

1. Pull base arm back to allow space for module to enter base.

2. Align module slides with base track.

3. Press module ﬁrmly into base.

Mounting the Components on DIN Rail

NOTE: Do not force the base controller on the DIN rail. Due to slight size variations in different manufacturers’ DIN rail, it may be necessary to ﬁrst unlatch the locking tab, rotate the module into place, then latch the locking tab.

INSTALL ON DIN RAIL

1. Make sure the locking tab is in the latched position (pushed in).

2. Hook upper tab over upper ﬂange of DIN rail.

3. Tilt the unit toward DIN rail until it snaps securely to DIN rail.

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Chapter 2: Installation and Wiring

Connecting the Components on the DIN Rail

SLIDE ASSEMBLY INTO POSITION ON THE DIN RAIL

Slide the module assembly on the DIN rail until the clip arm attaches securely to the adjacent module.

NOTE: One power supply is required in the leftmost component position followed by the base controller. Additional power supplies should be added between I/O modules as necessary to meet power budget requirements (see ch 3, page 3-18). Each power supply powers the modules to its right, but is interrupted by the next power supply.

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Removing I/O Modules from the Base

To remove a module from the base, grip the center of the base arm and rotate outward releasing the module. Lift the module from the base.

To remove a module assembly from the DIN rail, lift the clip arm up and slide the module assembly away from the adjacent module. Pull the locking tab down (out) and lift the assembly off the DIN rail. Refer to the “I/O Module Hot Swap Feature” section in Chapter 3 to remove an I/O module with Terminator I/O system power ON.

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Chapter 2: Installation and Wiring

Multiple Power Supplies / Local Expansion Conﬁgurations

Multiple Power Supply Conﬁguration

It is possible to have multiple power supplies in a single slave (node) system to meet power budget requirements. One power supply is required in the leftmost component position followed by the base controller. Additional power supplies should be added between I/O modules as necessary to meet power budget requirements. There are some restrictions on where power supplies can be placed in the system when using the T1K-05CBL-RR(-1) expansion base cable. Each power supply powers the modules to its right, but is interrupted by the next power supply. Each slave (node) system can be divided into one row of base I/O plus two rows of local expansion I/O up to a total of 16 I/O modules.

Expansion cables are available in two conﬁgurations: one that allows 24VDC base power to pass and one that does not (both cables pass the 5VDC base power). The “-1” version of the expansion cables, pass 24VDC on an isolated wire. Any local expansion DC input modules conﬁgured for “internal power” (current sourcing) must either have a power supply preceding it on the same base or have a “-1” version cable pass 24VDC from a power supply on the preceding base.

Example Using T1K-10CBL and T1K-10CBL-1 Expansion Cables

CPU

T1H-DM1E

TERM

RUN

RUNSTOP

USB

I/O

STAT

USB

PGM

Power Supply #1

(The power supply must be the left most component in a system followed by the base controller.)

I/O Addressing

PORT

Local Base I/O

Power Supply #2

T1K-10CBL-1

I/O Addressing

1st Local Expansion I/O

T1K-10CBL

Power Supply #3

2nd Local Expansion I/O

I/O Addressing

System shown above: The ﬁrst power supply powers the base controller and the two I/O modules to its right. The second power supply powers the two modules to its right and the three I/O modules on the ﬁrst local expansion base. Power Supply #3 powers the three I/O modules to its right on the second local expansion base. This serves as an example only, your power budget requirements will vary depending on the I/O modules used.

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter 2: Installation and Wiring

Example Using T1K-05CBL-RR-1 and T1K-05CBL-LL Expansion Cables

NOTE: The T1K-05CBL-RR-1 expansion cable with an isolated 24VDC lead was discontinued in 2015 and is no longer available. The following examples show this cable. As an alternative, consider using the T1K-10CBL(-1) cables as shown in the example on the preceding page.

Power Supply #1

(The power supply must be the left most component in a system followed by the base controller.)

Do not connect a T1K-05CBL-LL to the left side of the local I/O base.

T1K-05CBL-LL

System shown above: The ﬁrst power supply powers the base controller and the two I/O modules to its right. The second power supply powers the two modules to its right and the three I/O modules on the ﬁrst local expansion base. When a T1K-05CBL-RR-1 is used, the expansion I/O assignments are from right to left (reversed). A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1. Power Supply #3 powers the three I/O modules to its right on the second local expansion base. This serves as an example only, your power budget requirements will vary depending on the I/O modules used.

Base Controller

I/O Addressing

Power Supply #3

I/O Addressing

Local Base I/O

Power Supply #2

T1K-05CBL-RR-1

1st Local Expansion I/O

A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1.

2nd Local Expansion I/O

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Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Chapter 2: Installation and Wiring

Example Using T1K-10CBL and T1K-05CBL-RR-1 Expansion Cables

Base Controller

Power Supply #1

(The power supply must be the left most component in a system followed by the base controller.)

I/O Addressing

Power Supply #3

I/O Addressing

Power Supply #2

T1K-10CBL

1st Local Expansion I/O

T1K-05CBL-RR-1

A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1.

Local Base I/O

2nd Local Expansion I/O

I/O Addressing

System shown above: The ﬁrst power supply powers the base controller and the two I/O modules to its right. The second power supply powers the two modules to its right. Power Supply #3 powers the three I/O modules to its right on the ﬁrst local expansion base and the three I/O modules on the second local expansion base. When a T1K-05CBL-RR-1 is used, the expansion I/O assignments are from right to left (reversed). A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1. This serves as an example only, your power budget requirements will vary depending on the I/O modules used.

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

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Chapter 2: Installation and Wiring

Example Using T1K-05CBL-RR-1 Expansion Cables

Base Controller

Power Supply #1

(The power supply must be the left most component in a system followed by the base controller.)

System shown above: The ﬁrst power supply powers the base controller and the two I/O modules to its right. The second power supply powers the two modules to its right and the ﬁve I/O modules on the ﬁrst local expansion base. When a T1K-05CBL-RR-1 is used, the expansion I/O assignments are from right to left (reversed). A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1. This serves as an example only, your power budget requirements will vary depending on the I/O modules used.

I/O Addressing

Power Supply #2

I/O Addressing

Local Base I/O

T1K-05CBL-RR-1

A power supply cannot be used on a base that is connected to a system by a T1K-05CBL-RR-1.

1st Local Expansion I/O

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Terminator Installation and I/O Manual, 3rd Edition, Rev. C

Power Supply Wiring Guidelines

Power Wiring

The diagram below shows the terminal connections located on the Terminator I/O AC and DC power supplies. The table below shows the wire size and the recommended power supply terminal screw torque.

Chapter 2: Installation and Wiring

110/220 VAC Terminal Strip

Power Supply T1K-01AC T1K-01DC

Wire Size

Recommended Torque

Solid: 24–12 AWG Stranded: 24–12 AWG

4.43–5.31 lb·in (0.5–0.6 N·m)

12/24 VDC Terminal Strip

Solid: 24–12 AWG Stranded: 24–12 AWG

4.43–5.31 lb·in (0.5–0.6 N·m)

Terminator Installation and I/O Manual, 3rd Edition, Rev. C

2-28

Chapter

I/O WIrIng and SpecIfIcatIOnS

In This Chapter...

I/O Wiring Strategies ................................................................................................ 3-3

I/O Modules Position, Wiring and Speciﬁcations ................................................... 3-15

I/O Module Hot Swap Feature ................................................................................ 3-22

Calculating the Power Budget ................................................................................ 3-23

I/O Speciﬁcation Terms ........................................................................................... 3-27

T1K-01AC, T1K-01DC Power Supply ....................................................................... 3-29

T1H-EBC Ethernet Base Controller (Obsolete) ....................................................... 3-31

T1H-EBC100 Ethernet Base Controller .................................................................... 3-33

T1K-DEVNETS .......................................................................................................... 3-35

T1K-MODBUS Base Controller ................................................................................ 3-37

T1K-RSSS Remote I/O Base Controller ................................................................... 3-39

T1H-PBC Proﬁbus Base Controller .......................................................................... 3-41