Maple Systems OIT4160B User Manual

INSTALLATION MANUAL

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808 134th Street SW, Suite 120 • Everett, WA 98204 • USA • 425/745-3229

Fax: [phone] • E-mail: [e-mail] • URL: www.maple-systems.com

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2 OIT3160B/4160B

COPYRIGHT NOTICE

This manual is a publication of MapleSystems, Inc.,and is provided for useby its customers only. The
contents of the manualare copyrighted byMaple Systems, Inc.;reproduction in whole orin part, foruse
other thanin support ofMaple Systemsequipment, is prohibited withoutthe specificwritten permission
of Maple Systems.

WARRANTY

Maple Systemswarrants each product tobe free fromelectrical andmechanical defects in materials and
workmanship for a period of two years from the date of shipment. This warranty does not apply to
defects in the Products caused by abuse, misuse, accident, casualty, alteration, negligence, repair not
authorized by Maple Systems, use on current or voltages other than specified by Maple Systems, or
application orinstallation not inaccordance with published instructionmanuals. This warrantyis in lieu
of any other warranty either expressed or implied.

Maple Systems’ liability is limited to the repair or replacement of the Product only, and not costs of
installation, removal, or damage to user’s property or other liabilities. If Maple Systems is unable to
repair or replace a nonconforming Product, it may offer a refund of the amount paid to Maple Systems
for such Product infull satisfaction of its warranty obligation. Maximum liability of Maple Systems is
the cost of the Product.

Information furnished by Maple Systems, Inc., is believed to be accurate and reliable. However, no
responsibility is assumed by Maple Systemsfor the use of this information nor for any infringements of
patents or other rights of third parties which may result from its use. No license is granted by
implication, or otherwise, under any patent or patent rights of Maple Systems, Inc. Maple Systems
retains the right to revise or change its products and documentation at any time without notice.

IF SERVICE IS REQUIRED

Package the unit in its original packaging container or, if unavailable, any suitable rigid container. If a
substitute container is used, surround the unit with shock absorbing material; damagein shipment is not
covered bythe warranty. Include aletter with theunit describing thedifficulty and designatinga contact
person. Send to the following address: Maple Systems, Inc., 808 134th Street SW, Suite120, Everett,
WA 98204.

Only Products that have been issued a Return Material Authorization (RMA) number from Maple
Systems may be returned. All RMAs must be accompanied with a written purchase order for tracking
purposes or, in the case of out-of-warranty repairs, for repair charges on a time and material basis.

All returns will be tested to verify customer claims of noncompliance with the product warranty.
Improper return packaging which makes verification impossible will void the warranty. Products
passing the tests will be returned “AS IS” to the customer.

If noncompliance is verified and is not due to customer abuse or the other exceptions described with
product warranty, Maple Systemswill, at its option, repair or replace the Product returned to it, freight
prepaid, which fail to comply withthe foregoing warranty,provided Maple Systemsis notified of such
noncompliance within the one-year warranty period.

APPLICATIONS ASSISTANCE

This manualis designed to provide the necessary informationfor trouble-free installation andoperation
of your new Operator Interface Terminal (OIT). However, if you need assistance, please call Maple
Systems at 425-745-3229 or visit our web site at www.maple-systems.com.

INSTALLATION MANUAL 19

Appendix D

OIT Panel Cutout Dimensions – Front View

0.172" +/-0.01 Dia.,

4.4mm +/-0.3

4Holes

Connect mounting

stud(s) to control

panel earth ground

5.10" +/-0.03

5.60" +/-0.01

142.2mm +/-0.3

94mm +/-0.8

3.70" +/-0.03

129.5mm +/-0.8

R0.08" max.

2.0mm

4 Places

Check Dimension 4.00" [101.6 mm]

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1010-0105, REV 03

3.50"

+/-0.01

+/-0.3

88.9mm

18 OIT3160B/4160B

Appendix C

Dimensional Outline

6.00 [152.4]

INSTALLATION MANUAL 3

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Read Me First!

Your new Maple Systems OIT comes from the factory without any
communications protocol or operational softwareinstalled; therefore

The OIT will NOT operate until it has been configured using

1.77
[45]

1.60

[40.6]

•

OITware-200 or STEPware-100.

When power is first applied, the OIT’s display will indicate that it

•

needs to be configured.

Use the OITware-200 or STEPware-100 software to create a file

•

(or “project”) that can be downloaded to the OIT.

•

When the project is transferred, both communications protocol
and operational software are automatically loaded and the unit is
ready for operation.

To ensure that the OIT meets UL and CE compliance, it is
necessary to follow all installation procedures described in this

0.16 [4.1]

manual.

SIDE VIEW

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BOTTOM VIEW

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4 OIT3160B/4160B

INSTALLATION MANUAL 17

Introduction

Thank you for purchasing a Maple Systems OIT3160 or OIT4160. You have
selected a rugged, reliable, and powerful operator interface for your application.
This booklet describes the steps necessary to ensure trouble-free OIT system
operation. Please read this booklet carefully!!

Static Awareness

It is best NOT to remove therear coveron the OIT. When the rear cover is removed
the circuitryinside is exposed to possible damage by electrostatic dischargeduring
handling. Minimize the possibility of electrostatic discharge by:

Discharging personal static by grounding yourself prior to handling the OIT.

•

• Handling the OIT at static-free, grounded work station.

• Connecting the chassis of the OIT to a clean ground.

• Placing the OIT into an anti-static bag during transport.

Unpacking the Unit

Carefully unpack the OIT. Please read any instructions or cautions that appear on
the shipping container. Check all material in the container against the enclosed
packing list. Maple Systems, Inc., will not accept responsibility for shortages
against the packing list unless notified within 30 days. The equipment and its
accessories were inspected and tested by MapleSystems before shipment; all of the
equipment should be in good working order. Examine the equipment carefully; if
any shipping damage is evident, notify the carrier immediately. You are
responsible forclaim negotiations with thecarrier. Save the shipping container and
packing material in case the equipment needs to be stored, returned to Maple
Systems, or transported for any reason.

Appendix B

Agency Ratings

UL Class I, Division 2 Groups A,B,C,D hazardous locations.

Environmental Type 4, 4x (indoor), 12

European Union Directive Compliance

If this product is installed within the European Union or EFTA regions, the following regulations apply:

This apparatus is tested to meet Council Directive 89/336 Electromagnetic Compatibility (EMC) Standards:

• EN50081-2 Class A (Industrial) Emissions

• EN50082-2 Class A (Industrial) Immunity

According to these Standard, the factor which determines, for EMC purposes, whether an apparatus is
deemed to be “industrial” or “Residential, commercial and light industrial”, is given in Clause 1 of
EN50081-2 as follows:

Apparatus coveredby thisstandard isnot intended for connection to a public mains
network but is intended to be connected to a power network supplied from a high­or medium-voltage transformer dedicated for the supply of an installation feeding
the manufacturing or similar plant.

The product described in this document is intended for use solely in an industrial environment as defined
above. When installed in Europe, any other application is in contravention of European Union Directives,
and a breach of those laws.

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16 OIT3160B/4160B INSTALLATION MANUAL 5

Appendix A

OIT Hardware Specifications

Mechanical

Material: Aluminum sealed to NEMA 4/12 when panel mounted

Mounting: Panel

Wiring: Unit is field-wired by user to external power plug and shielded RJ-45 communications connectors

Weight: 1 pound (0.45 kg)

OIT3160B Environmental

Operating Temp: +14 to +149°F (-10 to +65°C)

Storage Temp: -22 to +176°F (-30 to +80°C)

OIT4160B Environmental

Operating Temp: +14 to +149°F (-10 to +65°C)

Storage Temp: -40 to +185°F (-40 to +85°C)

Electric Noise Immunity

Emissions: EN55011 (Group 1, Class B)—Generic commercial, light, and heavy industrial environments

EN50081-1—Generic domestic and light industrial environments
EN50081-2—Generic heavy industrial environment

Immunity: EN50082-1—Generic domestic and light industrial environments

EN50082-2—Generic heavy industrial environment

Power Requirements

Input Voltage: +12 to +30 VDC, Class 2

Power Usage: 2.5 watts typical, 3 watts maximum

Display

OIT3160 Display Type: Backlit Liquid Crystal Display (LCD)—5 x 7 dot matrix with cursor

OIT4160 Display Type: Vacuum Fluorescent Display (VFD)—5 x 7 dot matrix with cursor

Display Character Size: 2 lines of 20 characters, 0.19 inches (4.8 mm) high

Display Viewing Angle: Approximately 90 degrees

Keypad

Key Type: Membrane switch with custom legending (all keys)

Feedback: Audible & tactile

Layout: 18 keys with 6 function keys in three rows

Operational Life: Three million operations

Communications

Serial Port: RS-232, RS-422, or RS-485

Baud Rates: 300, 600, 1200, 2400, 4800, 9600, or 19.2k

Internal Features

Memory: 128K x 8 Flash PROM for firmware protocol and configuration data—no battery required

Table of Contents

1. Safety Warnings ................................................6

1.1. Hazardous Locations ........................................6

2. Control Panel Design Guidelines ...................................7

2.1. Control Panel Grounding ....................................7

2.2. Power Supply Selection .....................................8

2.3. OIT Cable Routing .........................................8

2.4. Other Steps to Improve Noise Immunity ........................9

3. OIT Installation ................................................10

3.1. Prepare Panel for OIT Mounting..............................10

3.2. Enclosures ...............................................10

3.3. Mount OIT to Panel........................................11

3.4. Connect OIT to Power......................................12

3.5. Connect OIT to PLC/Host ...................................13

4. OIT Configuration Wiring .......................................14

4.1. Connect OIT to PC for Configuration .........................15

Appendix A: OIT Hardware Specifications .............................16

Appendix B: Agency Ratings ........................................17

Appendix C: Dimensional Outline ....................................18

Appendix D: OIT Panel Cutout Dimensions - Front View .................19

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6 OIT3160B/4160B

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INSTALLATION MANUAL 15

1. Safety Warnings

WARNING Hazardous location environment. This unit is suitable
for use in Class I, Division 2 groups A, B, C and D or Non-Hazardous
locations only.

WARNING All input and output (I/O) wiring must be in accordance
with Class I, Division 2 wiring methods and in accordance with the
authority having jurisdiction.

WARNING Explosion hazard. Do not disconnect equipment unless
power has been switched offor the area isknown to benon-hazardous.

WARNING Explosion hazard. Do not connect more than one main
power supply to any one fuse or circuit breaker.

WARNING Explosion hazard. Substitution of components may
impair suitability for Class I, Division 2.

1.1. Hazardous Locations

Install the MicroOIT terminal using publication NFPA 70E, Electrical Safety
Requirements for Employee Workplaces as a guide. Be certain to follow all
directions for installing and connecting DC power to the MicroOIT.

When used in a hazardous environment, the ultimate enclosure must be in
accordance with Class I, Division 2 wiring methods as described in the National
Electrical Code (ANSI/NFPA 70).

All peripheral equipment must be suitable for the location in which it is used.

Use only a Class 2 power source as described in the National Electrical Code
(ANSI/NFPA 70).

4. OIT Configuration Wiring

The OIT3160 and OIT4160 mustbe configured for a particularprotocol beforeuse.
The OITware-200 or STEPware-100 software (used on a computerwith Windows

3.1 or later) is used for OIT configuration. For detailed instructions on installing
and using the software, please refer to the software documentation.

4.1. Connect OIT to PC for Configuration

To configure the OIT using Maple Systems’ configuration software, remove the
PLC/host cable from the serialport onthe OIT and connect the OIT tothe computer
using an RS-232 serial communications cable (P/N 7431-0096, purchased
separately from Maple Systems). The configuration cable should be connected to
the proper COM port onyour computer, then attached to the serial port on the OIT.
See Figure 7 below for serial port pin assignments.

9S

5

Ground

RXD 2

3

TXD

DCD

1

DTR

4

DSR

6

RTS

7

8

CTS

9

N/C

PC

Printer

Com1

Com2

Maple Systems
OIT to PC cable
(If mouse is using
Com 1, use Com2)

RJ-45

Return

4

TXD

5

RXD

6

N/C

N/C

N/C

N/C

N/C

Top

1TXD+

2TXD-

3CTS

7RXD-

8RXD+

Pin Configuration

RJ-45 Plu

OIT Power Supply

7431-0096

OITPC

1

8

1

8

OIT

Bac

Power

of

OIT

1010-0105, REV 03

WARNING Use only with Class 2 power source limited to 30 VDC
open circuit and 8A short circuit.

Figure 7 OIT3160/4160 to PC RS-232 Communication

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14 OIT3160B/4160B

f

3. Route the communication cable to the PLC/host. Refer to the “OIT Cable
Routing” section for more information.

4. Connect the other end of the cable to the PLC/host and tighten the cable screws.

PIN# FUNCTION

1 TXD+
2 TXD­3 CTS
4 RETURN
5 TXD
6 RXD
7 RXD­8 RXD+

Figure 6 Port 1 Pin Outs

5. Connect the green shield wire from the cable to earth ground (chassis
ground) on the PLC. If this wire is not present, the ground connection was
made inside the connector.

INSTALLATION MANUAL 7

2. Control Panel Design Guidelines

The following guidelines are intended to illustrate proper installation of the OIT to
help minimize electrical noise, which may hamper normal operation. It is the

responsibility of the customer to ensure that all wiring and other components
used in the control system meet Class I, Division 2 requirements. This
installation manual is intended only as a general guideto be used in conjunction
with the appropriate Class I, Division 2 installation and wiring requirements.
The customer is ultimately responsible for proper installation.

Pay careful attention to the placement of system components and associated cable
routing. These items can significantly enhance the performance and integrity o
your control application.

1010-0105, REV 03

Figure 1 Control Panel Example

2.1. Control Panel Grounding

•

The control panel should be connected to a good, high-integrity earth ground
both for safety considerations and shielding purposes. This must be a reliable
earth ground with a low-resistance path. The ideal earth ground would be a
copper grounding rod located close to the OIT and the control panel.

•

Hinged doors on control panels do notprovide a long term electrical connection
to the rest of the enclosure. Corrosion develops over time and prevents good
electrical contact. For this reason,a separate wire braid should be installed from
the hinged control panel to the rest of the enclosure.

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8 OIT3160B/4160B

2.2. Power Supply Selection

The power supply used to power the OIT should have an output between +12

•

and +30 VDC, meeting Class 2 power requirements. The voltage should
measure between +12 and +30V at the OIT between Pins 1 and 2 of the power
connector. A 24 VDC, 1.2 amp linear power supply dedicated to the OIT is
recommended.

The powercable for the OIT should be 18AWG 2-conductor stranded wire with

•

a shield wire and protective shield (foil or braid). The shield of the OIT power
cable must be connected toearth ground at both endsof thecable. Please refer to
the “Connect OIT to Power” section for more information.

A power line filter installed at the AC input to the OIT power supply is highly

•

recommended as a safeguard againstconducted RFnoise, which is often present
on factory power lines. The wires connecting the output of the power linefilter
to the power supply should be kept as short as possible to minimize any
additional noisepickup. The caseof thepower linefilter should be connected to
a quiet earth ground. The power line filtershould havea current rating of atleast
three amps with common mode and differential mode attenuation.

Figure 2 Power Line Filter Connection

• The power supply that provides power to the OIT should not be used to power

switching relays orsolenoids unless noise filter capsare connected to eachrelay.

2.3. OIT Cable Routing

•

Input and output (I/O) wiring must be in accordance with Class I, Division 2
wiring methods and in accordance with the authority having jurisdiction.

•

Always route the OIT communicationcable and power cable awayfrom any AC
voltage or PLC/host control wires.

•

Never bundle the OIT cables together with 120 VAC power wires or with relay
wiring.

•

Try to keep at least 8 inches (20 cm) of separation between the OIT cables and
other power wiring. If voltages greater than 120 VAC are used in the system,
greater separation is required.

•

If the OITcables must comenear AC wiring,make sure theycross at 90degrees.

•

Running AC power wires ina separate grounded conduitis the preferred method
for electrical noise reduction.

1010-0105, REV 03

INSTALLATION MANUAL 13

2. Install the wires into the Class 2 power supply as follows (colors shown are
for Maple Systems Cable P/N 6030-0009):

COLOR POWER SUPPLY OIT

Red + Output (+)

Black - Output (-)

Shield Wire Case Ground Shield

Figure 5 OIT3160/4160 PLC Connection

NOTE: The power connector on the OIT has M3 slotted screws.

3.5. Connect OIT to PLC/Host

Each PLC/host supported by Maple Systems has its own wiring requirements.
Maple Systems offers pre-constructed OIT-to-PLC communication cables for
most PLCs. Most cables areavailable for same day shipment from Maple Systems.
They arebuilt andtested forhigh reliabilityand arestrongly recommended. Maple
Systems also builds custom cables—contact the factory for information.
Components and instructions necessary to construct your own OIT-to-PLC
communications cables are also available. Refer to Maple Systems’ Price List or
web site (www.maple-systems.com).

NOTE: Refer tothe ASCII Slave Protocol Guideor the STEP1 ProtocolOperation
Manual for information on constructing OIT-to-ASCII host communication
cables.

STEPS

1. Connect the RJ-45 plug end of the communication cable into the serial port
on the OIT.

2. Ensure that the locking tab has secured the plug.

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12 OIT3160B/4160B

3.4. Connect OIT to Power

WARNING Use only with Class 2 power source limited to 30 VDC
open circuit and 8A short circuit.

The power cable for the OIT should be 18AWG 2-conductor wire with a shield
wire and protective shield foil. Maple Systems sells cable P/N 6030-0009 by the
foot for user-built power cables.

Figure 4 OIT3160/4160 Power Supply Connection

INSTALLATION MANUAL 9

Keep thelengths of the OIT cables as short as possible. Do not coilexcess cable

•

and place it next to AC powered equipment.

2.4. Other Steps to Improve Noise Immunity

Always install the OIT’s rear cover. This provides a shield against electrical

•

noise which can be generated in thecontrol panel by relays, motors,power lines,
and/or high frequency equipment. Ensure that all rear cover mounting screws
are properly secured.

Any equipment used in the enclosure that operates at high frequency or high

•

current levels can be covered with a grounded metal shield.

1010-0105, REV 03

STEPS

1. The power cable should not be any longer than necessary. Prepare the
cable as follows:

a) Cut the power cable to the appropriate length.

b) Strip the cable shield back to expose the two insulated wires and the
bare shield wire on both ends of the power cable.

c) Strip the insulation from the two insulated wires. For the OIT end, this
is 0.27 inch (7 mm).

1010-0105, REV 03

10 OIT3160B/4160B

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INSTALLATION MANUAL 11

3. OIT Installation

It is necessary to follow all installation procedures described in this chapter for
electrical noise immunity and CE compliance.

Your Maple Systems OIT is designed to connect easily to your PLC. External
connectors provide quick connection for power and communications wiring.

There isone serialport withan RJ-45 shielded jack. This port is used to connect

•

to the PLC and to configure the OIT.

A separate three-position terminal block is supplied to provide power to the

•

OIT.

3.1. Prepare Panel for OIT Mounting

The OIT3160 and OIT4160 are mounted to a control panel from the front. For a
proper NEMA 4/12 seal, you will need:

• A panel with a maximum thickness of 0.125 inches (3.2 mm).

• A panel with a minimum thickness of 16-gauge (0.059 inches; 1.5 mm) steel or

10-gauge (0.102 inches;2.6 mm) aluminum. Thinner panels may bow between
the mounting studs, requiring the use of a stiffener on the rear.

• The surface of the panel, where the panel comes into contact with the gasket,

must be free of scratches, pits, and other features that prevent the gasket from
sealing properly.

The diagram in Appendix D shows the dimensions of the panel cutout required for
proper installation. This panel cutout illustration is shown actual size and can be
photocopied to be used as a template. Check photocopy accuracy with the printed
check dimension. The panel cutout should be cleaned and deburred before the OIT
is installed.

3.2. Enclosures

Allow enough spacing within an enclosure for adequate ventilation. For some
applications, you may have to consider heat produced by other devices within a
panel. The ambient temperature around the terminal must be maintained as
specified.

3.3. Mount OIT to Panel

Figure 3 OIT3160/4160 Panel Mounting

STEPS

1. Gently position the OIT with the studs through the panel mounting holes.

2. Secure the OIT by installing the four #6-32UNC mounting nuts using a
5/16 inch socket wrench or nut driver.

CAUTION: Do not torque the 4 mounting nuts to over 15 pound-inches. Ove
torquing can strip the threads or pull the studs loose.

RE-INSTALLING: Because the gasket will take a “set” to the panel, be sure to
re-install any OIT to the same panel cutout when a NEMA 4/12 seal is required.

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