Mettler Toledo ACM500 Installation Manual

ACM500

Communication Module

Installation Manual

Essential Services for Dependable Performance of Your ACM500 Communication Module

Contact METTLER TOLEDO for service

Installation, Configuration, Integration and Training

Initial Calibration Documentation

Periodic Calibration Maintenance

GWP® Verification

life-cycle management of weighing equipment

ACM500 Communication Module

Congratulations on choosing the quality and precision of METTLER TOLEDO. Proper use of your new equipment according to this Manual and regular calibration and maintenance by our factorytrained service team ensures dependable and accurate operation, protecting your investment. Contact us about a service agreement tailored to your needs and budget. Further information is available at www.mt.com/service.

There are several important ways to ensure you maximize the performance of your investment:

www.mt.com/productregistration so we can contact you about enhancements, updates and

important notifications concerning your product.

2. accuracy – an out of specification scale can diminish quality, reduce profits and increase liability. Time ly ser v ice from METTLER TOLEDO will ensure accuracy and optimize uptime and equipment life.

: We invite you to register your product at

: The value of a measurement is proportional to its

trained, weighing equipment experts. We make certain that your weighing equipment is ready for production in a cost effective and timely fashion and that personnel are trained for success.

requirements are unique for every industrial scale so performance must be tested and certified. Our calibration services and certificates document accuracy to ensure production quality and provide a quality system record of performance.

confidence in your weighing process and documentation of compliance with requirements. We offer a variety of service plans that are scheduled to meet your needs and designed to fit your budget.

control and improvement of the entire measuring process, which ensures reproducible product quality and minimizes process costs. GWP (Good Weighing Practice), the sciencebased standard for efficie n t answers about how to specify, calibrate and ensure accuracy of weighing equipment, independent of make or brand.

: A risk-based approach for managing weighing equipment allows for

: The installation environment and application

: A Calibration Service Agreement provides on-going

: Our service representatives are factory-

, gives clear

mechanical, including photocopying and recording, for any purpose without the express written permission of METTLER TOLEDO.

U.S. Government Restricted Rights: This documentation is furnished with Restricted Rights. Copyright 2016 METTLER TO L ED O . This d oc um entation contains proprie t ary i nf or m a ti o n of M ET TLER

TOLEDO. It may not be copied in whole or in part without the express written consent of METTLER TOLEDO.

METTLER TOLEDO reserves the right to make refinements or changes to the product or manual without notice .

METTLER TOLEDO® is a registered tra de mark of Mettler-To l e do , LLC . Al l ot he r br an d or pr od uct names are trademarks or regis t e r ed tr a de marks of their respective companies.

METTLER TOLEDO RESERVES THE RIGHT TO MAKE REFINEMENTS OR CHANGES

WITHOUT NOTICE.

FCC Notice

This device complies with Pa rt 15 of the FCC Rules and the R ad i o Interference Re quirements of the Canadian Department of Communications. Operation is subject to the following conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and fo u nd t o comply with the lim its fo r a Clas s A di gi t al de v i c e, pursuant to P art 15 of FCC R u l e s. Thes e limits are desig ne d to provide reason ab l e pr o te ction agains t harmful interference when the equipment is operated in a commercial environment. This equipment generates, us e s , an d c a n radiate radio fre q ue ncy e nergy and, if not ins t al le d a nd used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his or her expense.

Declaration of Conformity is located in Appendix A.

RoHS Compliance Statement.

§ The majority of o ur pr o d uct s f all within categories 8 and 9. Those categories currently do not fall

within the scope of the Directive 2002/95/EG (RoHS) of January 27, 2003. If our products are intended for use in other products which themselves fall within the scope of the RoHS Directive, compliance requirements have to be separately negotiated contractually.

§ Those products which fall within categories 1-7 and 10 will be in compliance with the EU RoHS

Directive from no later than July 1, 2006.

§ If it is not possible fo r tec h nical reasons t o re pl ac e any non-RoHS-compliant substances in any of

the above products as required, we plan to inform our customers in a timely manner

Statement regarding harmful substances

We do not make direct use of harmful materials such as asbestos, radioactive substances or arsenic compounds. However, we purchase components from third party suppliers, which may contain some of these substances in very small quantities.

DO NOT INSTALL OR PERFORM ANY SERVICE ON THIS EQUIPMENT BEFORE THE AREA IN

Warnings and Cautions

• READ this manual BEFORE operating or servicing this equi pment and FOLLO W thes e instructions carefully.

• SAVE this manual for future reference.

WARNING

WHICH THE IND560x IS LOCATED HAS BEEN SECURED AS NON-HAZARDOUS BY PERSONNEL AUTHORIZED TO DO SO BY THE RESPONSIBLE PERSON AT THE CUSTOMER’S SITE.

WARNING

THE ACM500 COMMUNICATION MODULE IS DESIGNED TO OPERATE IN, AND MUST BE LOCATED IN, A SAFE AREA. ONLY THE FIBER OPTIC OR LOW POWER CURRENT LOOP SERIAL INTERFACE CAN CONNECT INTO THE HAZARDOUS AREA WITHOUT ADDITIONAL BARRIERS OR OTHER PROTECTION.

WARNING

ONLY THE COMPONENTS SPECIFIED IN THIS MANUAL CAN BE USED IN THIS DEVICE. ALL EQUIPMENT MUST BE INSTALLED IN ACCORDANCE WITH THE INSTALLATION INSTRUCTIONS DETAILED IN THIS MANUAL. INCORRECT OR SUBSTITUTE COMPONENTS AND/OR DEVIATION FROM THESE INSTRUCTIONS CAN IMPAIR THE INSTRINSIC SAFETY OF THE TERMINAL AND COULD RESULT IN BODILY INJURY AND/OR PROPERTY DAMAGE.

WARNING

ALLOW ONLY QUALIFIED PERSONNEL TO SERVICE THE ACM500. EXERCISE CARE WHEN MAKING CHECKS, TESTS AND ADJUSTMENTS THAT MUST BE MADE WITH POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS CAN RESULT IN BODILY HARM AND/OR PROPERTY DAMAGE.

WARNING

TO PREVENT IGNITION OF HAZARDOUS ATMOSPHERES, DISCONNECT THE IND560x FROM POWER SOURCE BEFORE OPENING ACM500 ENCLOSURE. KEEP COVER TIGHTLY CLOSED WHILE THE CIRCUIT IS ENERGIZED. DO NOT OPEN WHEN AN EXPLOSIVE DUST ATMOSPHERE IS PRESENT.

WARNING

BEFORE PUTTING THE ACM500 INTO SERVICE, MAKE SURE THE PROTECTIVE COVER IS INSTALLED PROPERLY OVER THE INTERFACE BOARD. THIS PROTECTIVE COVER IS PART OF THE SAFETY APPROVAL FOR THE ACM500 CONNECTIONS INTO THE HAZARDOUS AREA. NO WIRES FROM THE COM4 OR COM5 CONNECTION CAN CONTACT THE ACM500 MAIN BOARD OR ANY OF THE OPTION BOARDS.

In conformance with the European Directive 2002/96/EC on Waste Electrical and Electronic

WARNING

FOR CONTINUED PROTECTION AGAINST SHOCK HAZARD, CONNECT TO PROPERLY GROUNDED POWER SOURCE ONLY. DO NOT REMOVE THE GROUNDING CONNECTION.

WARNING

BE CERTAIN THAT THE COMMUNICATION CIRCUITS ARE WIRED EXACTLY AS SHOWN IN THE INSTALLATION SECTION OF THIS MANUAL. IF THE WIRES ARE NOT CONNECTED CORRECTLY, THE IND560x TERMINAL OR INTERFACE BOARD MAY BE DAMAGED.

WARNING

WHEN THIS EQUIPMENT IS INCLUDED AS A COMPONENT PART OF A SYSTEM, THE RESULTING DESIGN MUST BE REVIEWED BY QUALIFIED PERSONNEL WHO ARE FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF ALL COMPONENTS IN THE SYSTEM AND THE POTENTIAL HAZARDS INVOLVED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY HARM AND/OR PROPERTY DAMAGE.

NOTICE

Warnings and Cautions

OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES.

Disposal of Electrical and Electronic Equipment

Equipment (WEEE) this device may not be disposed of in domestic waste. This also applies to countries outside the EU, per their specific requirements.

Please dispos e o f this product in acc or dance with loca l re gu l at ions at the collec t in g po int specified for electrical and electronic equipment.

If you have any questions, please contact the responsible authority or the distributor from which you purchased this device.

Should this dev ic e be pas s ed on to other part ie s (f or private or profess ional use), the content of this r egulation mus t also be related.

Thank you for your contribution to environmental protection.

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Contents

1 Introduction ................................................................................. 1-1

1.1. ACM500 Versions ......................................................................... 1-1

1.1.1. 10BStandard ACM500 Features .................................................................................. 1-1

1.2. 1BWarnings and Precautions ............................................................. 1-2

1.3. 3BOperating Environment .................................................................. 1-3

1.3.1.1. Temperature and Humidity ................................................................................................ 1-3

1.3.1.2. Environmental Protection ................................................................................................... 1-3

1.3.1.3. Hazardous Areas.............................................................................................................. 1-3

1.4. 4BInspection and Contents Checklist ................................................... 1-3

1.5. 5BPhysical Dimensions ..................................................................... 1-4

1.6. 6BSpecifications ............................................................................... 1-4

1.7. 7BMain PCB .................................................................................... 1-5

1.8. 8BIntrinsically Safe Serial Interfaces .................................................... 1-5

1.8.1. Fiber Optic Interface ............................................................................................. 1-5

1.8.2. Intrinsically S afe C u rre n t L oop I nte r face .................................................................. 1-5

1.9. 9BOptions ........................................................................................ 1-6

1.9.1. 11BEthernet/COM2/COM3 Ports .................................................................................. 1-6

1.9.2. 12BPLC Interfaces ..................................................................................................... 1-6

1.9.2.1. Analog Output .................................................................................................................. 1-6

1.9.2.2. Allen-Bradley (A-B) RIO .................................................................................................... 1-6

1.9.2.3. DeviceNet ........................................................................................................................ 1-7

1.9.2.4. EtherNet/IP ...................................................................................................................... 1-7

1.9.2.5. Modbus TCP .................................................................................................................... 1-7

1.9.2.6. PROFIBUS DP .................................................................................................................. 1-7

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

2.1. Testing Standards ......................................................................... 2-1

2.2. Approval Parameters ..................................................................... 2-2

2.2.1. Intrinsically S afe C u rre n t L oop I nte r face .................................................................. 2-2

2.2.2. Fiber Optic Interface ............................................................................................. 2-3

2.3. United States Approval ................................................................... 2-3

2.4. European ATEX Approval ................................................................ 2-3

2.5. IECEx Approval ............................................................................. 2-4

2.6. Entity and Voltage Values, ATEX and IECEx ....................................... 2-4

2.7. Canadian Approval ....................................................................... 2-5

3 Installation .................................................................................. 3-1

3.1. Opening the Enclosure ................................................................... 3-2

3.2. AC Power Considerations ............................................................... 3-3

3.3. Mounting the Enclosure ................................................................. 3-3

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3.4. Installing Cables and Glands .......................................................... 3-4

3.4.1. Ferrites ............................................................................................................... 3-4

3.4.2. Cable Glands ...................................................................................................... 3-5

3.5. Wiring Connections ....................................................................... 3-7

3.5.1. Interface Board Wiring Connections ....................................................................... 3-7

3.5.1.1. Fiber Optic Interface Conne c tions ........................................................................................ 3-7

3.5.1.2. I.S. Serial Interface Connection ........................................................................................... 3-9

3.5.1.3. Creating Cables for the I.S. Current Loop Connection ........................................................... 3-11

3.6. Wiring Connections for ACM500 Options ....................................... 3-12

Contents

3.6.1. Ethernet, COM2, and COM3 Connections ............................................................. 3-13

3.6.2. Analog Output Connection .................................................................................. 3-16

3.6.3. PROFIBUS DP Connection .................................................................................. 3-17

3.6.4. Allen-Bradley RIO Connection ............................................................................. 3-18

3.6.5. DeviceNet Connection ........................................................................................ 3-19

3.6.6. EtherNet/IP and Modbus TCP Interface ................................................................. 3-20

3.7. Bonding and Grounding............................................................... 3-20

3.8. PCB Switch and Jumper Settings .................................................. 3-21

3.9. Weights and Measures Sealing ..................................................... 3-22

3.10. Final Steps ................................................................................. 3-22

A Appendix / Apéndice / Anhang / Annexe / Appendice / Anexo .................... A-1

A.1. Overview of Approvals ................................................................... A-1

A.1.1. Un ited States Certificate ........................................................................................ A-1

A.1.2. Canadian Certificate ............................................................................................. A-1

A.1.3. Control Drawing .................................................................................................. A-1

A.1.4. Eu ro pean Certific ate (ATEX) .................................................................................. A-1

A.1.5. IE CEx C er t if ic ate .................................................................................................. A-1

A.2. Generalidades y aprobaciones ........................................................ A-2

A.2.1. Certificado de los Estados Unidos ......................................................................... A-2

A.2.2. Certificado de Canadá .......................................................................................... A-2

A.2.3. Diagrama de control ............................................................................................ A-2

A.2.4. Certificado Eur o pe o (ATEX) ................................................................................... A-2

A.2.5. Certificado IECEx ................................................................................................. A-2

A.3. Überblick der Zula ssungen ............................................................. A-2

A.3.1. US-Zertifikat ........................................................................................................ A-2

A.3.2. Kanadisches Zertifikat .......................................................................................... A-3

A.3.3. Kontrollzeichnung ............................................................................................... A-3

A.3.4. Europäisches Zertifikat (ATEX) .............................................................................. A-3

A.3.5. IECEx Zertifikat .................................................................................................... A-3

A.4. Synthèse des approbations ............................................................ A-3

A.4.1. Cer t if ic a t Ét ats-Unis .............................................................................................. A-3

A.4.2. Certificat canadien ............................................................................................... A-3

A.4.3. Schéma de contrôle ............................................................................................. A-3

A.4.4. Certificat européen (ATEX) .................................................................................... A-4

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A.4.5. Certificat IECEx .................................................................................................... A-4

A.5. Panoramica ................................................................................. A-4

A.5.1. Certificazione degli Stati Uniti ................................................................................ A-4

A.5.2. Autorizzazio ne de l Ca n ad a ................................................................................... A-4

A.5.3. Schema di controllo ............................................................................................. A-4

A.5.4. Certificazione Europea (ATEX) ............................................................................... A-4

A.5.5. Cer t if ic az io ne IE CEx ............................................................................................. A-5

A.6. Visão Geral das Aprovações ........................................................... A-5

A.6.1. Certificado dos Estados Unidos ............................................................................. A-5

A.6.2. Certificado Canadense ......................................................................................... A-5

A.6.3. Desenho de Controle ........................................................................................... A-5

A.6.4. Certificado Europeu (ATEX) ................................................................................... A-5

A.6.5. Certificado IECEx ................................................................................................. A-5

A.7. United States Certificate .................................................................. A-6

A.8. Canadian Certificate ...................................................................... A-8

A.9. Control Drawing .......................................................................... A-10

A.10. European Certificate (ATEX) .......................................................... A-12

A.11. IECEx Certificate .......................................................................... A-15

A.12. Declaration of Conformity ............................................................. A-20

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1-1

This chapter covers

• Options

1 Introduction

Thank you for purchasing the ACM500 communication module. The ACM500

• Versions of the ACM500

• Warnings and Precautions

• Operating Enviro nm ent

• Inspection and Contents Chec k list

• Physical Dimensions

• Specifications

• Main PCB

• Intrinsically Safe Serial Interfaces

1.1. ACM500 Versions

The ACM500 communication module provides a stainless steel enclosure to house additional options for the IND560x terminal. It is available with the fo llo win g in te rface types:

communication module provides housing for the additional serial ports, Ethernet and PLC options of the IND560x terminal. While the IND560 x te rminal is designed to operate within Division 1 and Zone 1/21 areas, the ACM500 module must be located in a safe area. The ACM500 module is approved for connection to the IND560x using either a fibe r optic or an intrinsically safe current loop serial interface.

Information about approvals, configuration, service and maintenance details are included in this manual.

• Harsh enclosure with fiber optic interface

• Harsh enclosure with intrinsically safe current loop interface

1.1.1. 10BStandard ACM500 Features

• Stainless steel enclosure designed for washdown and dust tight protection

• Integral mounting bracket

• Cable glands and blanks to maintain the environmental integrity of the enclosure

• Internal universal power supply

• Dual channel fiber optic or intrin sically safe current loop inte rface

• Supports an optional Ethernet/COM2/ C O M3 in terface for the IND560x

• Support of the following PLC option boards for the IND560x:

• Analog Output • Allen-Bradley (A-B) RIO • DeviceNet

• EtherNet/IP • PROFIBUS

For information regarding METTLER TOLEDO Technical Training contact:



DP • Modbus TCP

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DO NOT INSTALL OR PERFORM ANY SERVICE ON THIS EQUIPMENT BEFORE THE AREA IN

METTLER TOLEDO US

1900 Polaris Parkway Columbus, Ohio 43240 Phone (US and Canada): (614) 438-4511 Phone (International): (614) 438-4888

HUwww.mt.comU

METTLER TOLEDO (Europe)

Postfach 250 D-72423 Albstadt, Germany Phone: (+49-7431) 140

Introduction

HUwww.mt.comU

1.2. 1BWarnings and Precauti ons

Please read these instructions carefully before putting the new ACM500 module into operation. Although the ACM500 communication module is ruggedly constructed, it is nevertheless a precision

instrument. Use care in handling and installing it.

WARNING

WHICH THE IND560x IS LOCATED HAS BEEN SECURED AS NON-HAZARDOUS BY PERSONNEL AUTHORIZED TO DO SO BY THE RESPONSIBLE PERSON AT THE CUSTOMER’S SITE.

WARNING

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1.3. 3BOperating Environment

ACM500 Communication Module

Bag of miscellaneous parts

When selecting a location:

• Choose a stable, vibration-free surface to mount the module

• Ensure there are no excessive fluctuations in temperature

• Be certain the cable glands and blanks are properly sealed to maintain the integrity of the

enclosure.

1.3.1.1. Temperature and Humidity

The ACM500 can be operated at temperatures and relative humidity conditions as listed under Operating Environment in to 60° C (–4° to 140° F) at 10 to 95% relative humidity, non -condensing

1.3.1.2. Environmental Protection

The stainless steel enclosu r e is certified as IP66 and TYPE 4 and is designed to provide washdown and dust-tight protection.

1.3.1.3. Hazar do us Ar e as

The ACM500 communication module must be located in a safe area. It is designed to connect to the intrinsically s a fe IND5 6 0x te rm in a l o pe rating within an area classified as Division 1, Zone 1 or Zone 21. Connection to the IND560x terminal is made with either a fibe r optic or intrinsically safe current loop interface.

XTable 1-1X. The module can be stored at temperatures ranging from –20°

1.4. 4BInspection and Contents Checklist

Verify the contents and inspect the package immediately upon delivery. If the shipping container is damaged, check for internal damage and file a freight claim with the carrier if necessary. If the container is not damaged, remove the ACM500 module from its protective package, noting how it was packed, and inspect each component for damage.

If re-shipping of the module is required, it is best to use the original shipping container. The ACM500 communication module must be packed correctly to ensure its safe transportation.

The package should include:

•

• Printed Installation Manual

•

• Documentation CD (all documentation)

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Enclosure Type

Dimensions (H × W × D)

Overall (Y x Z) Shipping Weight

Environmental Protection

Operati n g Environmen t

Hazardo us Ar e as

Power

IND560x C om munications

1.5. 5BPhysical Dimensions

The physical dimensions for the ACM500 communication module, for use with the IND560x, are listed in

XTable 1-1X. The mounting measurements are shown in XFigure 1-1X in mm and inches.

Introduction

Figure 1-1: ACM500 Communication Module Dimensions

1.6. 6BSpecifications

The ACM500 communication module, for use with the IND560x terminal conforms to the specifications listed in

XTable 1-1X.

Table 1-1: ACM500 Specifications

ACM500 Specifications

Type 304L stainless steel enclosure 208 mm × 263 mm × 116 mm

(8.2 in. × 10.4 in. × 4.6 in.) 320 mm × 217 mm

(12.6 in. x 8.5 in.)

5.5 kg (11.2 lb) IP66, TYPE 4 Can be operated at temperatures ranging from −10° to 40° C (14° to 104°

F) at 10% to 95% relative humidity non-condensing.

Not designed for us e wi th in hazardous are as . T he ACM 5 0 0 m us t be located in a non-hazardous environment.

Operates at 100-240 VAC, 50–60 Hz, 250 mA and includes power cord for country of use.

Two fiber optic or intrinsically safe current loop interface circuits required for full communication, but only 1 may be required for some applications. One circuit is required for optional PLC and COM2/COM3 communications. The other circui t is re q ui r ed for Ethernet .

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ACM500 Specifications

Ethernet/COM2/COM3 PLC

Optional Ethernet/COM2/COM3 ports: Ethernet 10 Base-T with two additional serial ports COM 2 (R S-232) and COM3 (RS-232/RS-422/RS-485) avai lab le using an expansion slot.

Optional A-B RIO, PROFIBUS DP, DeviceNet, EtherNet/IP, Modbus TCP or Analog outpu t av a il a ble us i n g an ex p a nsion slot.

1.7. 7BMain PCB

The ACM500 communication module’s main printed circuit board (PCB) provides expansion slots for the IND560x serial/Ethernet and PLC options. The main board also contains power connections from the power supply and data connections from the fiber optic or intrinsically safe serial interface board. Some diagnostic LEDs are also provided.

1.8. 8BIntrinsically Safe Serial Interfaces

A fiber optic interface or an intr in s ically safe serial interface ma y be use d to co n nec t an IN D5 6 0x terminal to the ACM500. If a du a l-channel fiber optic converter (from a previous 8141, 8525, Puma, or ID3sTx installation ) is to be connected to an IND560x, the fibe r o p tic in terfac e must be used.

1.8.1. Fiber Optic Interface

The fiber optic interface provides one or two channels of communication designed to use a hard clad silica or a plastic optic a l fib e r cable. High speed transmitters and receivers are used to increase the throughput of data. When combined with the ACM500 communication module and its options, this permits remote (safe area) operation of COM2 and COM3 serial ports, Ethernet and PLC interfaces, at distances up to 300 meters (1000 ft.). When used with the standard dualchannel fiber optic converter, this interface provides one or two additional bi-directional serial ports (COM2 and COM3) at the same distance. If the plastic optical fiber cab le is used, the distance is reduced to 40 meters (130 ft.).

1.8.2. Intrinsically Safe Current Loop Interface

The intrinsically safe current loop interface provides one or two channels of communication designed to use standard multi-strand copper wire. Low power, high speed circuitry is used to extend the distance of each circuit up to 300 meters (1000 ft.) when using two twisted pair 0.5

(20 GA) cable. When combined with the ACM500 communication module and its options,

mm this permits remote (safe area) operation of COM2 and COM3 serial ports, Ethernet and PLC interfaces.

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1.9. 9BOptions

The following options are available for use in the ACM500.

1.9.1. 11BEthernet/COM2/COM3 Ports

The Ethernet/COM2/COM3 port option provides two additional serial ports and a TCP/IP Ethernet port. The Ethernet TCP/IP port can be used to transmit a demand template or continuous data to other devices. It can also be used for remote configuration and updating the firmware using the METTLER TOLEDO InSite transfer of tare and target tables and complete setup files is also supported.



program, and for direct access to data via a shared dat a server. FTP

Introduction

The COM2 port provides RS-232 communication at rates from 300 to 115.2k baud and the COM3 port supports the same baud rates and provides an RS-232, RS-422, or RS-485 connection.

When using COM2 or COM3 serial ports in the ACM500, it is recommended to use a network transmission baud rate of at least 9,600 Baud. Using COM2 or COM3 serial ports with network transmission baud rates of 4,800 Baud or less may result in continuous data lagging behind real time conditions, or a delayed response to on-demand data requests (e.g., SICS requests).

1.9.2. 12BPLC Interfaces

The IND560x PLC interface options available through the ACM500 include Analog Output, A-B RIO, DeviceNet, EtherNet/IP, Modbus-TCP and PROFIBUS DP.

1.9.2.1. Analog Output

Analog Output refers to the representation of an internal system variable using a proportional electrical signal. Analog Output can be used to transmit a measured value, such as the gross or net weight or a rate. Another use for the Analog Output is as a control signal for some external device, such as a control valve, where the amount of valve opening is proportional to the analog signal commanding its operation. Such outputs are usually used to control the flow rate of material into or out of a vessel.

Both 0-10 volt DC and 4-20 mA signals are provided. Additional details of this interface can be found in the PLC Interface Manual on the ACM500 Documentation CD.

1.9.2.2. Allen-Bradley (A-B) RIO

The A-B RIO option enables data exchange by bi-directional communications using the Discrete Data Transfer or Block Transfer mode. The terminal provides a communication exchange with the PLC approximately 20 tim es p er se c ond u tiliz in g th e Allen-Bradley Discrete Data Transfer protocol. This communication is a high-sp eed, real-time message interface between the terminal and the PLC for process control. Division, integer, and floating point values are supported.

The A-B RIO interface also supports Block Transfer mode for transmission of larger amounts of data. Additional details of this interface can be found in the PLC Interface Manual on the ACM500 Documentation CD.

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1.9.2.3. DeviceNet

DeviceNet is an RS-485 based network utilizing CAN chip technology. The network can be configured to run up to 500Kbits per second depending on cabling and distances. Messages are limited to 8 un-fragmented bytes. The IND560x implementation of DeviceNet does not support fragmented messages - all messages are 8 bytes or shorter. The network is capable of supporting up to 64 nodes including the master.

1.9.2.4. EtherNet/IP

EtherNet/IP, short for "EtherNet Industrial Protocol," is an open industrial networking standard that takes advantage of commercial, off-the-shelf EtherNet communication chips and physical media. This networking standard supports both implicit messaging (real-time I/O messaging) and explicit messaging (message exchange). The protocol is supported by ControlNet International (CI), the Industrial Ethernet Association (IEA) and the Open DeviceNet Vendor Association (ODVA).

1.9.2.5. Modbus TCP

Modbus/TCP is used to establish master-slave/client-server communication between intelligent devices. It is an open standard network protocol, widely used in the industrial manufacturing environment. The ModbusTCP protocol takes the Modbus instruction set and wraps TCP/IP around it.

1.9.2.6. PROFIBUS DP

The IND560x Terminal communicates to a PROFIBUS-DP master according to DIN 19 245. The PROFIBUS option consists of software that resides in the IND56 0x Terminal and a printed circ u it board that installs in the ACM500 communication module to implement the data exchange.

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2-1

This chapter covers

2 Approvals

This chapter provides information about safety approvals for the ACM500

• Overview

• Testing Standar ds

• Approval Parame ters

• U.S. Approval

• European ATEX Approval

• IECEx Approval

• Entity and Volt age Values, ATEX and IECEx

• Canadian Approval

2.1. Testing Standards

Table 2-1 shows the list of standards to which the ACM500 has been tested. The date of each standard is also included.

communication module with intrinsically safe connections. Please read this chapter thoroughly before beginning installation.

Appendix A at the end of this manual contains the approval certificates and control drawings for the approvals. These documents should also be reviewed before beginning the installation.

Table 2-1: Testing Standards

Directive Standard Description Date

Class 3600

Class 3610

Class 3810

ANSI/IEC 60529

C22.2.No. 157 C22.2.No. 142 Process control equipment 1990

C22.2.No. 1010.1

C22.2.No. 60529

Electrical equipment for us e in H az ar dous (Classified) Locations, general requirements

Intrinsically safe apparatus and associated apparatus for use in Cl ass I, II, and III, Division 1 and Clas s I Zone 0 an d 1 Hazardous (Classified) locations

Electrical and electronic test, measuring and process equipment

Degrees of prote ction provided by enclosur es (IP Code)

Intrinsically safe and non-incendive equipment for use in hazardous locations

Safety requirements for electrical equipment for measureme nt , co n tr o l an d la b oratory use – Part 1: General requirements

Degree of protection provided by enclosur e s (IP Code)

1998

1999

2005

2004

1992

2004

2005

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Directive Standard Description Date

94/9/EC Directive EN60079-0:2006

94/9/EC Directive EN60079-11:2007 2006/95/EC Low

Voltage Directive

2004/108/EC EMC

Approvals

Directive

2004/108/EC EMC

Directive

2004/108/EC EMC

Directive

2004/108/EC EMC

Directive

2002/95/EC RoHS

Directive

EN61010-1:2001 General requirements 2001

EN61010-6-2 Immunity for industrial environments

EN61010-6-3

EN61000-4-3 (10V/m)

EN61000-4-6 (10V/m)

2.2. Approval Parameters

Electrical apparatus for explosive gas atmospheres – Part 0: General requirements

Explosive atmospheres – Par t 11 : Eq u ipm ent protection by intrinsic safety “i”

Emission standard for residential, commercial and light indus trial environments

Radiated, ra di o -frequency, electromagnetic field immunity te s t

Immunity to conducted disturbances, induced by radio-frequency fields

Restriction of the use of certain hazardous substances in electrical and electronic equipment

2006

2007

2.2.1. Intrinsically Safe Current Loop Interface

The ACM500 intrinsically safe current loop interface is approved using the entity value method of evaluation. The entity parameters for each ACM500 approval can be found in the following sections and also in the approval certificates in Appendix A. Refer to the approval documentation of the device to be connected to the A C M50 0 for its entity parameters.

The following conditions must be met. Note that the input values on the left side of the equations

, V

below (U

• U

• I

• P

• C

• L

As an alternative to the direct Inductance calculation, the following inductance to resistance formula may be substituted:

• L

, etc.) are associated with the ACM500 module.

max

or V

or I

≥ Po or Pt

+ C

+ L

a max.

Where L

≥ Uo or Voc

max

≥ Io or Isc

max

≤ Co or Ca

cable

≤ Lo or La

cable

/ Ra < L

cable

/ R

cable

is the length-based inductivity value and R

of the cable used.

is the length-specific resistance

cable

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2.2.2. Fiber Optic Interface

The ACM500 fiber optic interface is approved by limiting the maximum power applied to the fiber optic cable. The power is restricted by design to 5mW maximum. This restriction is shown in the approval certificates and control drawings in the Appendix.

2.3. United States A ppr ov al

This section lists appr o val de ta ils fo r the ACM500 when installed according to United States requirements. The U.S. safety approvals are based upon entity values.

The ACM500 communication module has been evaluated and approved as:

Associated apparatus with intrinsically safe connections to Class I, Division 1, Groups A, B, C, D, Class II, Division 1, Groups E, F, and G, Class III hazardous locations in accordance with Entity Requirements and METTLER TOLEDO Control Drawing #72191600.

• AIS / I, II, III / 1 / ABCDEFG – 72191600; Entity; IP66

The approved entity parameters for the U.S. approval for the ACM500 module are listed in Table 2-2.

Table 2-2: Entity Values - U.S.

Entity Values for U.S. Approval

Ui 10 VDC

Ii 300 mA

Pi 500 mW Ci 120 nF

Li 0 mH

2.4. European ATEX Approval

Approval details for the ACM500 communication module when installed according to European ATEX requirements are listed in this section. The European safety approvals are based upon entity values.

The ACM500 module has been evaluated and issued certificate BVS 08ATEX E 100 for certificatio n as:

With Current Loop (CL) Interface

• II (2) G [Ex ib Gb] IIC

• II (2) D [Ex ib Db] IIIC

With Fiber Optic (FO) Interface

• II (2) G [Ex op is Gb] IIC

• II (2) D [Ex op is Db] IIIC

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The approved entity parameters for European ATEX approval for the ACM500 intrinsically safe communication module are listed in The approved entity parameters for IECEx approval for the ACM500 intrinsically safe communication module are listed in reference..

Table 2-3.

Error! Not a valid bookmark self-

2.5. IECEx Approval

Approvals

The ACM500 module has been evaluated for certification as:

With Current Loop (CL) Interface

• [Ex ib Gb] IIC

• [Ex ib Db] IIIC

With Fiber Optic (FO) Interface

• [Ex op is Gb] IIC

• [Ex op is Db] IIIC

2.6. Entity and Voltage Values, ATEX and IECEx

The approved entity parameters for IECEx approval for the ACM500 intrinsically safe communication module are listed in

Error! Not a valid bookmark self-reference..

Table 2-3: Entity Values – ATEX and IEC Ex Entity Values for ATEX and IECEx Approval

Ui 10 VDC

Ii 300 mA

Pi 500 mW Ci 120 nF Li 0 mH

The maximum voltage that can be applied to the ACM500 communication module is shown below in Table 2-4. This is noted as the U

value on the label as part of the approval.

Table 2-4: Maximum Voltage

Maximum Voltage Listing for ATEX and IECEx Approval

Um 250 VAC

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2.7. Canadian Approval

This section lists approval details for the ACM500 when installed according to Canadian requirements. The Canadian safety approvals are based upon entity values.

The ACM500 communication module has been evaluated and approved as:

• AIS / I, II, III / 1 / ABCDEFG - 72191600; Entity; IP66

The approved entity parameters for the Canadian approval for the ACM500 module are listed in Table 2-5.

Table 2-5: Entity Values - Canada

Entity Values for Canadian Approval

Ui 10 VDC

Ii 300 mA

Pi 500 mW Ci 120 nF Li 0 mH

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This chapter covers

3 Installation

This chapter provides installation instructions for the ACM500 communication

• Opening the Enclosure

• AC Power Considerations

• Mounting the Enclosure

• Installing Cables and Glands

• Interface Wiring Connections

• Wiring ACM500 Options

• Bonding and Grounding

• Switch Settings

• Weights and Measures Sealing

•

Final Steps

module, including wiring connections for the module and its options. Please read this chapter thoroughly before beginning installation.

An illustration of a typic a l ACM50 0 in s ta lla tio n with an IND560x is shown in Figure 3-1. Note that the ACM500 must be located in the safe area. Refer to the approval documents for additional information.

Figure 3-1: Typical ACM500 Installation

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DO NOT INSTALL OR PERFORM ANY SERVICE ON THIS EQUIPMENT BEFORE THE AREA IN

3.1. Opening the Enclosure

WARNING

WHICH THE IND560x IS LOCATED HAS BEEN SECURED AS NON-HAZARDOUS BY PERSONNEL AUTHORIZED TO DO SO BY THE RESPONSIBLE PERSON AT THE CUSTOMER’S SITE.

WARNING

Installation

The front panel of the ACM500 is locked in place by four spring clips attached to the enclosure body. To gain access for internal wiring and setting switches, separate the front panel from the enclosure as follows:

1. Insert the tip of a flat-blade screwdriver into one of the two slots (toward the bottom of the slot) located on the bottom of the front panel assembly (refer to Figure 3-2) and gently push in toward the enclosure. A “pop” sound indicates when the cover is released.

If the clip does not release easily, apply a small amount of force/pressure to the front cover

of the ACM500 and repeat Step 1.

Figure 3-2: Ope ning the Enclos ure

2. Repeat Step 1 for the other slot.

3. With the two spring clips re lea s e d, lift th e b o tto m o f th e fron t p a nel firmly up and out until it

completely clears the top edge of the bottom enclosure.

4. Squeeze the top of the front panel to the enclosure slightly and push upward to unsnap the two remaining clips, then lift the panel to clear them. The panel will swing down, hinged by two wire cables at the bottom.

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3.2. AC Power Con s iderations

No internal wiring is required for AC power, since the ACM500 is supplied with an integra l p o wer cord. When installing the ACM500, make sure the unit is near a properly grounded socket-outlet and that the outlet is easily acc essible.

Make sure that the AC power source is within the operating range of the ACM500, 100 to 240 VAC.

3.3. Mounting the Enclosure

The ACM500 enclosure is designed to mount to a flat, vertical surface such as an instrument panel or industrial enclosure or wall. Observe location and environment considerations as described in Chapter 1 of this manual,

To mount the enclosure, follow these steps:

1. Mark the position of the mounting holes on the vertical surface using the dimensions shown in Figure 3-3, or by holding the enclosure up to the surface and marking through the bracket holes on the sides of the enclosure. Measurements are provided in mm and inches.

Introduction.

2. The hardware to mount the enclosure to the vertical surface is not included with the terminal – it must be supplied locally. Ensure that the mounting hardware is capable of supporting the weight of the terminal, wh ich is a pproximately 6 kg (13 lb). Using the lo c a lly-supplied hardware, mount the ACM500 to the vertical surface.

Figure 3-3: Mounting Hole Pattern

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3.4. Installing Cables and Glands

This section provides information for installing cables and connections to the ACM500 communication module, including:

• Ferrites

• Cable Glands

• Interface Board Wiring Connections

Installation

3.4.1. Ferrites

• Cable Preparation for Intrinsically Safe Current Loop Interface

• Wiring Connections for Options

WARNING

In order to meet certain electrica l n o is e emission limits and to protect the AC M5 00 from ex te rn a l influences, it is nece ssa ry to ins ta ll a ferrite core on the connection cab le between the interface board and the main board of the ACM500.

Ferrites are not required on the incoming intrinsically safe current loop or fibe r o p tic interfaces.

Do not attempt to use ferrites on the fiber op tic c a b le for th e in te rface board. Attempting to

do so will damage the fiber optic cable

Additional ferrites are not required for the Ethernet TCP/IP, COM2/COM3 and PLC

connections running from the ACM500.

To install ferrites, simply pass the cable through the center of the core and then take one wrap around the outside of the core and pass it through again. Either the complete cable or the individual wires can be wrapped through the ferrite. This should be done on the inside of the enclosure as close to the outside wall as pos s ib le . R e fer to Figure 3-4 for examples of acceptable methods of installation.

Figure 3-4: Installing the Ferrite Cores

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3.4.2. Cable Glands

The ACM500 stainless steel enclosure is designed to withstand wet and dusty environments. In order to maintain the sealing integrity of the enclosure, care must be taken when installing cables that enter the enclosure. To ensure a watertight and dust tight seal:

• Pass any cables through an appropriately sized cable grip before connecting the wires inside

the ACM500.

The intrinsically safe current loop interface cables and the fiber optic interface cable always

pass through the two cable glands “A” and “B” to the far left (Figure 3-5). Note that only ATEX certified cable glands should be used on COM4 and COM5. Only the certified inserts supplied with the ATEX glands can be used for securing cables. Do not use rubber sleeve grommets with the ATEX certified glands.

A: COM4

B: COM5

Figure 3-5: Cable Glands

•

When making a connection with fiber optic interface cable, a special split grommet (Figure 3-6) will be provided. Each of the two fiber cables fits into one of the two holes in the grommet.

Figure 3-6: Installing Fiber Optic Cables in Cable Grip

•

For all other ACM500 connections (Ethernet, serial, PLC), depending upon the diameter of the cable used for a specific connection, a rubber sleeve grommet may be needed to properly seal

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around the cable. Use one of the 2 different sized rubber sleeved grommets supplied with the option kit to properly seal around the cable (Table 3-1).

Table 3-1: Grommet Cable Sizes

Grommet Cable Diameter

None 7–10 mm (0.28–0.39 in.) Larger size hole 5– 6 mm (0.20–0.24 in.) Smaller size hole 3–4 mm (0.12–0.16 in.)

Installation

Note that the rubber sleeve grommets provided in accessory kits cannot be used with ATEX

certified cable glan d s req u ire d fo r C OM4 and CO M5. O nly th e special split grommet provided with the fiber optic interface is permitted.

• All cables that include shields (except the current loop interface cabling) should have the shield

terminated at the gland as shown in Figure 3-7. Spread the shield wires out and make sure enough shield wire is present to make good contact with the metal part of the gland.

Note that the shield of the cable fr om th e IND5 6 0x to the ACM500 must not be terminated

at the ACM500 end. The shield must be left open at the ACM500 end of the cable.

•

After making the wiring connections as described in the next section, ensure the nut on the cable gland is tightened properly to seal around the cable.

Figure 3-7: Shield Termination at Cable Gland

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3.5. Wiring Connections

The following sections describe how to make wiring connections to the ACM500 communication module. Follow all instr u c tions carefully.

3.5.1. Interface Board Wiring Connections

Depending on the model ordered, each ACM500 will have either the fiber optic serial interface board or the intrinsically safe current loop interface board installed. After the ACM500 enclosure is open, the interface board can be removed and connections made as described in the next sections.

Each interface board provides two circuits for communication to the IND560x. Depending upon the options used, it may not be necessary to provide connections to both circuits. Refer to Table 3-2 to determine if both the COM4 and th e COM5 c irc u its must be connected.

Table 3-2: ACM500 Interface Port Usage

ACM500 Option Used COM4 Required COM5 Required

COM2 Port COM3 Port

Ethernet --

PLC Option

3.5.1.1. Fiber Optic Interface Connections

When using fiber optic cable to connect the IND560x to the ACM500 communications

module, care must be taken not to bend the cable sharply or it could be permanently damaged

The ACM500 does not include fiber optic cables to connect to the IND560x terminal. Fiber optic cable is available separately from METTLER TOLEDO with pre-terminated connectors in various lengths.

Two types of cable are offered for use with the ACM500:

• Plastic core

• Hard clad silica (glass) core

The plastic core fiber optic cable can be used for short cable runs up to 40m (125 ft.). For longer cable runs, up to 300m (1000 ft.), the hard clad silica (glass) core cable must be used. Various cable lengths for each type of cable are available. Please refer to your price pages and appropriate catalogs for available lengths and part numbers.

ü ü

-ü

If necessary, two glass core fiber optic cables can be coupled using a special optic coupler, but the coupler signal loss is equivalent to 150 m (500 ft.) of cable. When one coupler is used the useable distance of the glass core cable is reduced to 150 m (500 ft.)

It is possible to cut the plas tic c o re fib er o p tic ca b le in the fie ld a n d ins ta ll th e connectors using the available terminatio n k it. The glass core fiber optic cable re q u ires special tools to install the connectors and field termination of this cable is not recommended.

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Two fiber optic cables are required for bidirectional communication to each port on the ACM500 (COM4 and COM5). If both ports are required, then a total of four cables will be required.

The fiber optic cable connectors and the sockets on the interface board are color-co ded. Each cable has one blue and one gray end, which should be connected to the same color on the interface board, as shown in Figure 3-8.

Installation

Figure 3-8: Color-Coded Fiber Optic Cable Connections

The following instructions assume that the fiber optic cables are already connected to the fiber optic interface board in the IND560x and the other ends of the cables are available at the ACM500. Depending upon the country of installation, special protection such as conduit seals may be required. Refer to the control drawing, the approval certificates and local regulations to determine what is required.

1. Make certain that power is removed from the ACM500 communication module and the IND560x terminal.

2. Feed the ends of the fiber optic cables through the split bushing of the correct cable gland (identified in (Figure 3-5) until the cable reach es the fiber optic interface bo ar d (a pproximately 90 mm/3.5 in.). The COM4 cables should enter through the upper cable gland “A”, the COM5 cables through cable gland “B” just below.

Be sure the fiber optic cable is not bent to less than a 13 mm (1/2 inch) radius. Any sharp

kinks in the fiber optic cable will damage it, requiring that the cable be replaced. Coil any excess cable neatly in large loops close to the ACM500 and secure it so it does not get damaged.

3. When connecting fiber optic cables to COM4, determine which two fiber optic cables come from the COM4 port of the IND560x. Plu g the fiber optic cable from the IND560x COM4 transmitter (U1) into the ACM500 COM4 receiver (U3) and the cable from the IND560x CO M4 receiver (U3) into the ACM500 COM4 tran sm itte r (U1). Refer to Figure 3-9 to help identify the transmitters and receivers on the ACM500 fiber optic interface board. Figure 3-10 shows correct wiring between the IND560x and the ACM500.

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U1- COM4 Tx

U3- COM4 Rx

U2- COM5 Tx U4- COM5 Rx

Figure 3-9: Fiber Optic Interface Board

4. When installing a connection to COM5, determine which two fiber optic cables come from the COM5 port of the IND560x . Plug the fib er optic cab le fr om the IND560 x COM5 transmitte r into the ACM500 COM5 receiver the ACM500 COM4 transmitter

(U4) and the cable from the IND560x COM5 receiver (U4) into

(U2). Figure 3-10 shows correct wiring between the IND560x

(U2)

and the ACM500.

IND560x ACM500

U1 – Tx

COM4

U3 - Rx

U2 – Tx

COM5

U4 - Rx

Figure 3-10: Fiber Optic Cable Connection Diagram

5. When all fiber optic cables are connected, tighten the compression nuts on the outside of the cable glands to secure the cables in place.

6. Reinstall the protec tiv e cover and interface board assembly to the side of the ACM500.

3.5.1.2. I.S. Serial Interface Connection

U1 – Tx

COM4

U3 - Rx

U2 – Tx

COM5

U4 - Rx

WARNING

The ACM500 does not include cables to connect to the IND560x terminal. One length of cable is required for each circuit used. Refer to Table 3-2 to determine if one or two

circuits are required for your application. Connection cables are available separately from METTLER

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TOLEDO in various lengths. Please refer to your price pages and appropriate catalogs for available lengths and part numbers. Maximum connection length is 300 m (985 ft).

The following instr uctio n s assume that pre-made connection cables are already available, and describe how to connect the ACM500 end of the intrinsically safe interface cable. Refer to the IND560x installation manual for details on the terminal end of the cable. Depending upon the country of installation, special cable protection such as conduit seals may be required. Refer to the control drawing, the approval certificates and local regulations to determine what is required.

1. Make certain that power is removed from both the IND560x terminal and the ACM500 communication module.

Installation

2. Feed the cables through the correct cable gland (identified in Figure 3-5) until the wires re a ch the intrinsically s a fe cur re n t loop interface board (approximately 90 mm – 3.5 in.). The COM4 cable should enter through the upper cable gland “A” and the COM5 cable should enter through cable gland “B” just below.

WARNING

Figure 3-11: Current Loop Interface Board

3. When installing a connection to COM4, determine which cable comes from the COM4 port (J4) of the IND560x. This cable will con n ect to COM4 (

4. Follow the wiring connections shown in Figure 3-12 and Table 3-3. Refer to Figure 3-11 to help identify the terminal positions. Keep the internal wiring as short as practical.

J4) of the ACM500.

+ 252 hidden pages

Mettler Toledo ACM500 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual