Maple Systems OIT4185A User Manual

24 OIT3185A/4185A
Appendix D
OIT Panel Cutout Dimensions – Front View
stud(s) to control
Connect mounting
0.172" +/-0.01 Dia.,
4.4mm +/-0.3
4 Holes
panel earth ground
5.10" +/-0.03
129.5mm +/-0.8
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INSTALLATION MANUAL
R0.08" max.
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2.0mm
4 Places
4.70" +/-0.03
119.4mm +/-0.8
4.50"
+/-0.01
114.3mm
5.60" +/-0.01
142.2mm +/-0.3
Check Dimension 4.00" [101.6 mm]
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808 134th Street SW, Suite 120 • Everett, WA 98204 • USA • 425/745-3229
Fax: 425/745-3429 • E-mail: maple@maple-systems.com • URL: www.maple-systems.com
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2 OIT3185A/4185A
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 23
Appendix C
Dimensional Outline
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22 OIT3185A/4185A INSTALLATION MANUAL 3
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.
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
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 manual.
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4 OIT3185A/4185A
INSTALLATION MANUAL 21
Introduction
Thank you for purchasing a Maple Systems OIT3185 or OIT4185. 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 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)
OIT3185A Environmental
Operating Temp: +14 to +149°F (-10 to +65°C)
Storage Temp: -22 to +176°F (-30 to +80°C)
OIT4185A 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
OIT3185 Display Type: Backlit Liquid Crystal Display (LCD)—5 x 7 dot matrix with cursor
OIT4185 Display Type: Vacuum Fluorescent Display (VFD)—5 x 7 dot matrix with cursor
Display Character Size: 4 lines of 20 characters, 0.16 inches (4.1 mm) high
Display Viewing Angle: Approximately 90 degrees
Keypad
Key Type: Membrane switch with custom legending (all keys)
Feedback: Audible
Layout: 24 user-definable keys arranged in 3 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
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INSTALLATION MANUAL 5
5.4. Installing a Slide-In Legend
To replace the factory installed legend with your own:
1. Ensure all paints, inks and fixative are thoroughly dry and will not transfer.
2. Place the unit face down on a clean protective surface.
3. Locate the legend access slot along the right side of the cover.
4. Remove the tape from the existing legend and then pull the legend out.
5. Slide in the new legend (refer to Figure 11). be gentle
avoid wrinkling, which makes it hard to push the legend in
if the legend moves around too much, put a curl in the paper
NOTE: The legends are made long to facilitate removal.
6. Once installed, tape the end of the legend to the cover to secure it.
Be careful not to abrade the graphics against the edge of th access slot in the aluminum plate. A paper "shoehorn" may be used to prevent this.
Front of OIT
Aluminum Plate
Gasket
Legend is shown being installed at a 45º angle
Tape legend to the side of the cover once in place
Sectional Side View
Figure 11 Custom Keypad Legend Installation
Legend
(not to scale)
Cover
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. Create Custom Slide-In Legend ..............................10
3.2. Prepare Panel for OIT Mounting..............................10
3.3. Enclosures ...............................................10
3.4. Mount OIT to Panel........................................11
3.5. Connect OIT to Power......................................12
3.6. Connect OIT to PLC/Host ...................................13
4. OIT Configuration Wiring .......................................15
4.1. Connect OIT to PC for Configuration .........................15
5. Custom Keypad Slide-In Legends .................................16
5.1. Predefined Keypad Templates ...............................16
5.2. Blank Legend for Photocopying ..............................16
5.3. Creating a Computer-Generated Slide-In Legend.................19
5.4. Installing a Slide-In Legend .................................20
Appendix A OIT Hardware Specifications..............................21
Appendix B Agency Ratings ........................................22
Appendix C Dimensional Outline.....................................23
Appendix D OIT Panel Cutout Dimensions - Front View ..................24
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INSTALLATION MANUAL 19
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).
5.3. Creating a Computer-Generated Slide-In Legend
The dimensions in Figure 10 can be used to create a computer generated legend.
When creating:
Dimensions are in inches [mm].
Recommended key size is 0.500 inches [12.7 mm] square.
NOTE: Pressing the center of the switch is critical for switch actuation.
Background colorsshould extend to the upper andlower edges of the legendand
• to the 2 vertical lines marked “BACKGROUND.”
All text and graphics should be within the dashed rectangle.
When printing:
Use only non-glossy stock whichis 0.004 - 0.008inches (0.1 - 0.2 mm)thick.
Check printing accuracy with the printed check dimension.
Figure 10 Computer-Generated Legend Dimensions
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WARNING Use only with Class 2 power source limited to 30 VDC open circuit and 8A short circuit.
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18 OIT3185A/4185A
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“Tick” marks indicate
switch centerlines
Check Dimension 4.00” [101.6 mm]
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.
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Figure 9 Photocopy Legend Master
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 OIT3185A/4185A
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.
INSTALLATION MANUAL 17
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• 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.
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Figure 2 Power Line Filter Connection
24 Function Keys
SDF3
SDF2
SDF1
F3
F2
F1
F11
Check Dimension 4.00" [101.6 mm]
F10
F9
3160 Emulation
Figure 8 OIT3185/4185 Predefined Keypad Templates
F4
F1
F5
F2
F6
F3
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16 OIT3185A/4185A
5. Custom Keypad Slide-In Legends
The OIT3185 and OIT4185 have a graphic overlay covering the keypad. This overlay contains a clear window that allows you to insert your own legend to customize the keypad’s text, colors, and graphics. This legend can be inexpensively made and is environmentally sealed when installed.
The slide-in legendcan be madeon anynon-glossy stock between 0.004inches (0.1 mm) and 0.008 inches (0.2 mm) thick by using any of the following methods:
Photocopy one of the predefined keypad templates.
Photocopy the blank legend and hand illustrate.
Use the dimensions to create a computer generated legend.
Use our Legend Generator software to create a computer generated legend.
• Available from out web site at www.maple-systems.com/tech.htm.
5.1. Predefined Keypad Templates
If you have chosen one of the predefined keypad templates in OITware-200, you can photocopy the corresponding slide-in legend from Figure 8.
5.2. Blank Legend for Photocopying
The blank legend in Figure 9 can be photocopied and hand illustrated.
When photocopying:
• Use only non-glossy stock whichis 0.004 - 0.008inches (0.1 - 0.2 mm)thick.
• Check photocopy accuracy with the printed check dimension.
When illustrating:
• Use thetick marksto locate the switch centers. Refer to thecomputer generated legend dimensions if unsure.
NOTE: Pressing the center of the switch is critical for switch actuation.
• Recommended key size is 0.500 inches [12.7 mm] square.
• Background colors should extend to the solid lines.
All text and graphics should be 0.07 inches [1.78 mm] within the solid lines.
NOTE: Do not affix anything to the legend using glue, tape, stickers, etc.
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.
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INSTALLATION MANUAL 15
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. Create Custom Slide-In Legend
Please refer to the “Custom Keypad Slide-in Legends” section for details.
3.2. Prepare Panel for OIT Mounting
The OIT3185 and OIT4185 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.
3.3. 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.
4. OIT Configuration Wiring
The OIT3185 and OIT4185 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
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Figure 7 OIT3185/4185 to PC RS-232 Communication
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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 11
3.4. Mount OIT to Panel
Figure 3 OIT3185/4185 Panel Mounting
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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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12 OIT3185A/4185A
3.5. 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.
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 OIT3185/4185 PLC Connection
NOTE: The power connector on the OIT has M3 slotted screws.
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Figure 4 OIT3185/4185 Power Supply Connection
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).
3.6. 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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