GAI-Tronics 12578-003 User Manual

Pub. 42004-715L2C

GAI-TRONICS® CORPORATION

A HUBBELL COMPANY

Model 12578-003

Monitored Input Module (MIM)

Confidentiality Notice

This manual is provided solely as an operational, installation, and maintenance guide and contains
sensitive business and technical information that is confidential and proprietary to GAI-Tronics.
GAI-Tronics retains all intellectual property and other rights in or to the information contained herein,
and such information may only be used in connection with the operation of your GAI-Tronics product or
system. This manual may not be disclosed in any form, in whole or in part, directly or indirectly, to any
third party.

How to Use the Assembly/Model

Application

The 12578-003 Monitored Input Module (MIM) is used in SmartSeries ADVANCE systems.
GAI-Tronics uses the MIM to receive inputs from field devices, monitor the integrity of eight input lines
for trouble conditions or contact activation, and report these conditions to the 69254 Series or
69440 Series Master Control Unit (MCU). The MIM is comprised of two components: the 69613-001
Central Processing Unit (CPU) printed circuit board assembly (PCBA) and the 69251-201 Monitored­In-8 PCBA.

The MIM is designed to be mounted in a Snaptrack that is installed inside an enclosure. Snaptrack is a
grooved plastic channel that is designed to allow PCBAs to securely ‘snap’ into the groove. The
Snaptrack provides flexible installation because the track may be installed inside an enclosure wherever it
is convenient.

The module communicates with the MCU via the 69613-001 CPU PCBA over a FSK modem intended
for use in GAI-Tronics SmartSeries systems. The CPU PCBA interprets and reports the status of the
inputs. The MIM is capable of monitoring up to eight inputs. The MCU identifies a particular MIM on
the page line (FSK link) by its module address. This module address is set by rotary hex switches S1 and
S2 of the MIM (located on the CPU PCBA.) The range of valid settings is from 05 to FE (hex).

GAI-Tronics Corporation 400 E. Wyomissing Ave. Mohnton, PA 19540 USA

610-777-1374  800-492-1212  Fax: [phone]

V

ISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS

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Model 12578-003 Monitored Input Module (MIM) Page 2 of 12

Each input may be independently configured to operate in one of the following five modes:

Input
Mode Description

Comments

0 Deactivate circuit Input is not monitored.

1 IDC line supervision

multiple switch

Detects open circuit, ground faults, and switch actuation from one or
more normally-open dry contact closures.

2 IDC single N.O. switch Detects open circuit, wire-to-wire short circuit, ground faults, and

switch actuation from a single normally-open dry contact closure.

3 IDC single N.C. switch Detects open circuit, wire-to-wire short circuit, ground faults, and

switch actuation from a single normally-closed dry contact closure.

4 IAC line supervision Reserved for 12579-003 Monitored Relay Module

5 IDC non-supervised N.O.

dry switch

5 IDC non-supervised, wet

switch

Detects a switch actuation from one or more normally-open dry
contact closures.

Detects the presence or absence of 24 V dc voltage depending on
applicable onboard jumper settings.

In order to utilize a particular input mode with a particular input, the appropriate external connections
must be made between the MIM and the field devices. Also, the input modes must be added to the MCU
Configuration using the ADVANCE Console System Configuration Software. Refer to the “Installation
Guidelines” section on page 4 for further details.

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Hardware Configuration

Figure 1. Model 12578-003 Monitored Input Module

Interfaces

The Model 12578-003 Monitored Input Module interfaces to a Page/Party® Interface (PPI) card in the
ADVANCE control cabinet via the system page line (FSK link).

Installation Safety Guidelines

Please adhere to all warnings, safety, and operating instructions on the unit and in the installation manual.

DANGER

 Disconnect power before servicing
 Do not disconnect equipment while circuit is energized.
 Avoid servicing the unit during electrical storms.
 Do not touch uninsulated wires.

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Installation Guidelines

1. Notify plant personnel of a system shutdown prior to servicing the unit.

2. Disconnect power before installing or removing the MIM.

Mounting

To install the module into the Snaptrack slide either the right or the left edge of the module into the top
groove on the track. On the opposite side, press firmly on the top and bottom corners of the module until
they snap into the groove. Carefully press from each corner toward the center and simultaneously snap
the edge firmly into place.

Power

After the PCBA is installed onto the Snaptrack, 12 V dc power is brought in from the auxiliary power
supply and terminated on TB9 (PWR IN). The positive leg is connected to TB9-1 (+) and the return leg is
landed on TB9-2 (−). An earth ground is connected to TB9-3 (EGND). TB9 is paralleled with TB10.
TB10 (PWR OUT) may be used to distribute power to additional Snaptrack modules.

OTES:

N

 Although power may be daisy-chained between MIMs and other Snaptrack modules, the preferred

method of delivering power to these modules is by providing a dedicated cable run between each
module and the auxiliary power supply.

 The auxiliary power supply return leg must be connected to earth ground for proper operation. The

physical connection should be made at the auxiliary power supply terminals.

 The ground reference for this assembly must be identical to that of the enclosure.
 The MIM does not contain any current-limiting for power. It is recommended that an external fuse be

provided with the appropriate voltage and current ratings. The selected fuse should be of the slo-blo
variety.

Data Communication Line

Terminal blocks TB11 and TB12 are for the page line connection (FSK data communication) from the
PPI card and to additional MIM and MRM modules.

OTE: The conductor terminated on TB12 should be a twisted pair.

N

FSK Signal Gain

The FSK Signal Gain, R8, adjusts the FSK transmit signal strength. It is set at the factory and should not
be adjusted by the installer.

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Inputs

The MIM contains eight individually configurable inputs, allowing it to interface with field devices.
Connections with these field devices are made at connectors TB1 through TB8. Each connector
corresponds to a single input (TB1 is used for input #1, TB2 is used for input #2, etc.) Each one of these
inputs may be configured to operate in one of five input modes.

Each input mode requires a unique connection scheme between the external field devices and the
appropriate input connector on the MIM. The connection scheme for each input mode is indicated below.
Since the connection scheme is independent of which input is used, only input #1 will be discussed.

N

OTE: To ensure proper termination, ferrules must be crimped on the end of all conductors that are

terminated on the terminal blocks. The size of the ferrule is dependent upon the size of the conductor
used and may be sourced from any supplier such as Phoenix, Altec or Weidmuller. The terminal blocks
may accept conductors between sizes No. 28 AWG to 12 AWG.

Mode 0: Deactivate Circuit

In this mode, input #1 is not used and is not monitored by the MIM. If this mode is used, no external
connections should be made to connector TB1.

Mode 1: IDC Line Supervision Mult iple Switch

In this mode any number of normally-open dry contact closures may be installed on the line. The loop is
monitored for ground faults and open circuits in Mode 1. The end-of-line device is a 20 k, 5% tolerance
resistor.

Figure 2. IDC Line Supervision Multiple Switch

N

OTE: The 20 k, 5% tolerance resistor is not included with the MIM. This resistor is included in a kit

(12509-003), which must be ordered separately.

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Model 2: IDC Single Normally-Ope n (N.O.) Switch

In this configuration, only one normally-open dry contact closure may be installed per supervised line. In
this mode, the loop is monitored for open circuits, wire-to-wire short circuits (across + and −), and ground
faults. When the contact closure is not active (open), the loop appears as 20.1 k load (15 k in series
with 5.1 k). This appears on the input to the MIM and indicates a healthy loop. When the contact
closure is active (closed), the 15 k resistor is bypassed.

Figure 3. IDC Single Normally-Open Switch

The circuit then sees only the 5.1 k load. This changes the value of the input and indicates to the MIM
that the contact closure is active. If there is a short across + and −, if either leg is grounded, or if a break
occurs on either leg, the MIM indicates that a fault has occurred.

OTE: The terminating resistors are not included with the MIM. These resistors are included in a kit

N

(12509-003) that must be ordered separately.

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Mode 3: IDC Single Normally-Closed (N.C.) Switch

In this configuration, only one normally-closed dry contact closure may be installed per supervised line.
In this mode, the loop is monitored for open circuits, wire-to-wire short circuits (across + and −), and
ground faults. When the contact closure is not active (closed), the 15 k is bypassed and the circuit sees
only the 5.1 k load.

Figure 4. IDC Single Normally-Closed Switch

When the contact closure is active (open), the loop appears as a 20.1 k load (15 k in series with 5.1
k). This changes the value of the input and indicates to the MIM that the contact closure is active. If
there is a short across + and −, if either leg is grounded, or if a break occurs on either leg, the MIM
indicates that a fault has occurred.

N

OTE: The terminating resistors are not included with the MIM. These resistors are included in a kit

(12509-003) that must be ordered separately.

Mode 4: IAC Line Supervision

(Reserved for 12579-003 Monitored Relay Module)

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Mode 5: IDC Non-Supervision Multiple Switch (Dry Contact)

In this mode, any number of normally-open dry contact closures can be installed on the line. The loop
will not

be monitored for any faults in Mode 5.

Figure 5. IDC Non-Supervision Multiple Switch (Dry Contact)

Mode 5: IDC Non-Supervision (Wet Contact)

In this wet contact mode, shorting jumpers for each input must be moved from the factory default of
“dry” to “wet” contact mode. When in “wet” contact mode, the input can be activated during a 0 V
condition or a 24 V condition. The factory default setting is “24 V dc input when active” (position 2-3).

If “0 V dc input when active” is desired, move jumper from position 2-3 to position 1-2. The loop will
not

be monitored for any faults in Mode 5. Ensure the polarity of input connection is correct as it is

polarity sensitive.

Figure 6. IDC Non-Supervision (Wet Contact)

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Table 1. Jumper Settings for Mode 5 Input Operation

Input No. Dry Contact

Input Selection

1 P1 – Pins 2 & 3

P2 – Pins 2 & 3

P3 – Pins 2 & 3

2 P4 – Pins 2 & 3

P5 – Pins 2 & 3

P6 – Pins 2 & 3

3 P7 – Pins 2 & 3

P8 – Pins 2 & 3

P9 – Pins 2 & 3

4 P10 – Pins 2 & 3

P11 – Pins 2 & 3

24 V DC Wet Contact Input

Selection

P1 – Pins 1 & 2

P2 – Pins 1 & 2

0 V dc – Active: P3 – Pins 1 & 2

24 V dc – Active: P3 – Pins 2 & 3

P4 – Pins 1 & 2

P5 – Pins 1 & 2

0 V dc – Active: P6 – Pins 1 & 2

24 V dc – Active: P6 – Pins 2 & 3

P7 – Pins 1 & 2

P8 – Pins 1 & 2

0 V dc – Active: P9 – Pins 1 & 2

24 V dc – Active: P9 – Pins 2 & 3

P10 – Pins 1 & 2

P11 – Pins 1 & 2

Factory Default
Setting

P1 – Pins 2 & 3

P2 – Pins 2 & 3

P3 – Pins 2 & 3

P4 – Pins 2 & 3

P5 – Pins 2 & 3

P6 – Pins 2 & 3

P7 – Pins 2 & 3

P8 – Pins 2 & 3

P9 – Pins 2 & 3

P10 – Pins 2 & 3

P11 – Pins 2 & 3

P12 – Pins 2 & 3

5 P13 – Pins 2 & 3

P14 – Pins 2 & 3

P15 – Pins 2 & 3

6 P16 – Pins 2 & 3

P17 – Pins 2 & 3

P18 – Pins 2 & 3

7 P19 – Pins 2 & 3

P20 – Pins 2 & 3

P21 – Pins 2 & 3

8 P22 – Pins 2 & 3

P23 – Pins 2 & 3

0 V dc – Active: P12 – Pins 1 & 2

24 V dc – Active: P12 – Pins 2 & 3

P13 – Pins 1 & 2

P14 – Pins 1 & 2

0 V dc – Active: P15 – Pins 1 & 2

24 V dc – Active: P15 – Pins 2 & 3

P16 – Pins 1 & 2

P17 – Pins 1 & 2

0 V dc – Active: P18 – Pins 1 & 2

24 V dc – Active: P18 – Pins 2 & 3

P19 – Pins 1 & 2

P20 – Pins 1 & 2

0 V dc – Active: P21 – Pins 1 & 2

24 V dc – Active: P21 – Pins 2 & 3

P22 – Pins 1 & 2

P23 – Pins 1 & 2

P12 – Pins 2 & 3

P13 – Pins 2 & 3

P14 – Pins 2 & 3

P15 – Pins 2 & 3

P16 – Pins 2 & 3

P17 – Pins 2 & 3

P18 – Pins 2 & 3

P19 – Pins 2 & 3

P20 – Pins 2 & 3

P21 – Pins 2 & 3

P22 – Pins 2 & 3

P23 – Pins 2 & 3

P24 – Pins 2 & 3

0 V dc – Active: P22 – Pins 1 & 2

24 V dc – Active: P22 – Pins 2 & 3

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P24 – Pins 2 & 3

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Model 12578-003 Monitored Input Module (MIM) Page 10 of 12

Operation

The operation of the Model 12578-003 MIM is controlled by the MCU configuration. See the MCU
configuration details in the system manual for all operation information.

How to Diagnose Assembly/Model Faults

Symptom Action

MIM does not
communicate

with MCU

MIM does not
recognize dry
inputs

MIM does not
activate an
alarm with 24 V
dc applied to
input terminal.
(Wet contact
mode ONLY.)

 Verify power is applied to the MIM.
 Verify page line is connected to the MIM.
 Verify address of MIM agrees with the setup configuration.
 Ensure CPU PCBA is correctly connected via J1.
 Call for service of the MIM.

 Verify total loop resistance is less than 100 .
 Verify power is applied to the MIM.
 Verify page line is connected to the MIM.
 Verify end of line resistor(s) properly installed on each input circuit.
 Call for service of the MIM.
 Verify that the jumper that selects the proper “_ V dc when active” mode is in

the correct position for the desired mode. Refer to Mode 5 - IDC Non­Supervision (Wet Contact) information.

 Verify that the applicable input jumpers have been repositioned for WET

operation.

 Verify that the input is within the acceptable dc voltage range (20–30 V dc)
 Verify that the proper voltage polarity has been observed for external

connections to the input terminals.

 Call for service of the MIM.

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Specifications

Electrical

Power requirements ........................................................................................ 9–15 V dc (12 V dc nominal)

Current draw .................................................................... 300 mA maximum @ 12 V dc (no ground faults)

Number of input loops ................................................................................................................. Eight loops

Maximum devices on input loop ..................................................................................... Unlimited (Mode 1)

One (Mode 2)
One (Mode 3)
Unlimited (Mode 5 – Dry)
One (Mode 5 – Wet)

Input/output ....................................................................................................................................... Power in

Power out
Page line (FSK) in
Page line (FSK) out
Eight field inputs

Data communications ............................................................................................................................... FSK

End-of-line device ................................................................................................................ 20 k (Mode 1)

5.1 k in series with 15 k across contact (Mode 2)

5.1 k in series with 15 k across contact (Mode 3)
None (Mode 5)

Field Inputs

Mode 1:

Contact closure resistance (activated) ................................................................................... 1 k maximum

Open fault detection ............................................................................................................ Minimum 65 k

Ground fault detection ......................................................................................... Less than 200  to ground

Modes 2 and 3:

Contact closure resistance (Mode 2: activated/ Mode 3: de-activated) ................................ 3 k maximum

Open fault detection ............................................................................................................ Minimum 65 k

Ground fault detection ......................................................................................... Less than 200  to ground

Wire-to-wire short fault detection ........................................................................................ Less than 200 

Mode 5 (Dry)

Contact closure resistance ................................................................................................... 900  maximum

Mode 5 (Wet)

DC input voltage range ................................................................................. 20–30 V dc (24 V dc nominal)

Limitations:

Cable limitations ........................................................................................ 100  maximum loop resistance

Terminals:

Minimum conductor size ......................................................................................... No. 28 AWG (0.5 mm

Maximum conductor size ......................................................................................... No. 12 AWG (3.0 mm

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2

2

)

)

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Mechanical

Unit dimensions .................................... 4.00 H  10.50 W  1.25 D inches (101.60  266.70  31.75 mm)

Unit weight ....................................................................................................................... 1.00 lb. maximum

Environmental

Temperature range (operating/storage) .................................................. −30 C to 70 C (−22 F to 158 F)

Humidity .......................................................................................... 95% non-condensing relative humidity

Replacement Parts

Model No. Description

69613-001 CPU PCBA

69251-201 Monitored In-8 PCBA

Ref erence Material

REFERENCE TO ASSEMBL Y/MODEL DRAWINGS

Published By Title GAI-Tronics Ref. No.

GAI-Tronics Monitored Input Module Assembly Drawing 73567

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Warranty

Equipment. GAI-Tronics warrants for a period of one (1) year from the date of shipment, that any

GAI-Tronics equipment supplied hereunder shall be free of defects in material and workmanship, shall
comply with the then-current product specifications and product literature, and if applicable, shall be fit
for the purpose specified in the agreed upon quotation or proposal document. If (a) Seller’s goods prove
to be defective in workmanship and/or material under normal and proper usage, or unfit for the purpose
specified and agreed upon, and (b) Buyer’s claim is made within the warranty period set forth above,
Buyer may return such goods to GAI-Tronics nearest depot repair facility, freight prepaid, at which time
they will be repaired or replaced, at Seller’s option, without charge to Buyer. Repair or replacement shall
be Buyer’s sole and exclusive remedy. The warranty period on any repaired or replacement equipment
shall be the greater of the ninety (90) day repair warranty or one (1) year from the date the original
equipment was shipped. In no event shall GAI-Tronics warranty obligations with respect to equipment
exceed 100% of the total cost of the equipment supplied hereunder. Buyer may also be entitled to the
manufacturer’s warranty on any third-party goods supplied by GAI-Tronics hereunder. The applicability
of any such third-party warranty will be determined by GAI-Tronics.

Services. Any services GAI-Tronics provides hereunder, whether directly or through subcontractors,

shall be performed in accordance with the standard of care with which such services are normally
provided in the industry. If the services fail to meet the applicable industry standard, GAI-Tronics will re­perform such services at no cost to buyer to correct said deficiency to Company's satisfaction provided
any and all issues are identified prior to the demobilization of the Contractor's personnel from the work
site. Re-performance of services shall be Buyer's sole and exclusive remedy, and in no event shall GAI­Tronics warranty obligations with respect to services exceed 100% of the total cost of the services
provided hereunder.

Warranty Periods. Every claim by Buyer alleging a defect in the goods and/or services provided

hereunder shall be deemed waived unless such claim is made in writing within the applicable warranty
periods as set forth above. Provided, however, that if the defect complained of is latent and not
discoverable within the above warranty periods, every claim arising on account of such latent defect shall
be deemed waived unless it is made in writing within a reasonable time after such latent defect is or
should have been discovered by Buyer.

Limitations / Exclusions. The warranties herein shall not apply to, and GAI-Tronics shall not be

responsible for, any damage to the goods or failure of the services supplied hereunder, to the extent
caused by Buyer’s neglect, failure to follow operational and maintenance procedures provided with the
equipment, or the use of technicians not specifically authorized by GAI-Tronics to maintain or service the
equipment. THE WARRANTIES AND REMEDIES CONTAINED HEREIN ARE IN LIEU OF AND
EXCLUDE ALL OTHER WARRANTIES AND REMEDIES, WHETHER EXPRESS OR IMPLIED BY
OPERATION OF LAW OR OTHERWISE, INCLUDING ANY WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Return Policy

If the equipment requires service, contact your Regional Service Center for a return authorization number
(RA#). Equipment should be shipped prepaid to GAI-Tronics with a return authorization number and a
purchase order number. If the equipment is under warranty, repairs or a replacement will be made in
accordance with the warranty policy set forth above. Please include a written explanation of all defects to
assist our technicians in their troubleshooting efforts.

Call 800-492-1212 (inside the USA) or 610-777-1374 (outside the USA) for help identifying the
Regional Service Center closest to you.

(Rev. 10/06)