Mitsubishi Electric E1151 Installation Manual

MITSUBISHI ELECTRIC

E1151

Installation manual

MA00780C 2008-07

English

Foreword

Mitsubishi Electric, MA00780C

Installation manual for the E1000 series operator panels

Foreword

The E1000 operator panel is developed to satisfy the demands of human-machine
communication. Built-in functions such as displaying and controlling text, dynamic
indication, time channels, alarm and recipe handling are included.

The operator panel work, for the most part, in an object-oriented way, making it easy
to understand and use. The configuration operation of the panel is made in a person­al computer, using the configuration tool E-Designer. The project is then transferred
and stored in the operator panel.

The operator panel can be connected to many types of automation equipment, such
as PLCs, servos or drives. In this manual the expression “the controller“ is used as a
general term for the connected equipment.

This manual explains how to install the operator panel. Please refer to the reference
manual for further information.

© Mitsubishi Electric, MA00780C, 2008-07

The information in this document is subject to change without notice and is provided as available at the time
of printing. The manufacturer reserves the right to change any information without updating this publication.
The manufacturer assumes no responsibility for any errors that may appear in this document.
Read the entire installation manual prior to installing and using this equipment.
Only qualified personnel may install, operate or repair this equipment. The manufacturer is not responsible
for modified, altered or renovated equipment.
Because the equipment has a wide range of applications, users must acquire the appropriate knowledge to use
the equipment properly in their specific applications.
Persons responsible for the application and the equipment must themselves ensure that each application is in
compliance with all relevant requirements, standards and legislation in respect to configuration and safety.
Only parts and accessories manufactured according to specifications set by The manufacturer may be used.
THE MANUFACTURER SHALL NOT BE LIABLE TO ANYONE FOR ANY DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE
INSTALLATION, USE OR REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT,
CONTRACT, OR OTHERWISE. BUYER'S SOLE REMEDY SHALL BE THE REPAIR,
REPLACEMENT, OR REFUND OF PURCHASE PRICE, AND THE CHOICE OF THE APPLICABLE
REMEDY SHALL BE AT THE SOLE DISCRETION OF THE MANUFACTURER.

Table of Contents

Mitsubishi Electric, MA00780C

Table of Contents

1 Safety Precautions................................................................................. 5

1.1 UL and cUL Installation ................................................................... 5

1.2 General ............................................................................................. 6

1.3 During Installation............................................................................ 6

1.4 During Use ....................................................................................... 7

1.5 Service and Maintenance................................................................... 7

1.6 Dismantling and Scrapping............................................................... 7

2 Installation ........................................................................................... 9

2.1 Space Requirements .......................................................................... 9

2.2 Installation Process............................................................................ 9

2.2.1 Mode Switches ................................................................................................ 11

2.2.2 Connections to the Controller ......................................................................... 11

2.2.3 Other Connections and Peripherals ................................................................. 11

3 Technical Data ................................................................................... 13

4 Chemical Resistance ........................................................................... 15

4.1 Metal Casing................................................................................... 15

4.2 Touch Screen and Overlay.............................................................. 15

4.2.1 Autotex F157/F207......................................................................................... 15

4.2.2 Touch Screen Surface ...................................................................................... 16

4.2.3 Autoflex EB..................................................................................................... 16

5 Operator Panel Drawings ................................................................... 17

5.1 Communication Ports..................................................................... 17

5.2 E1151 Outline................................................................................ 18

6 Additional Installation Tips................................................................ 19

6.1 Grounding the Operator Panel ....................................................... 19

6.2 Ethernet Connection in the Panel................................................... 20

6.3 To Achieve Better EMC Protection ................................................ 21

6.4 Ambient Temperature..................................................................... 22

6.5 Safety .............................................................................................. 23

6.6 Galvanic Isolation ........................................................................... 24

6.7 Cable and Bus Termination RS485................................................. 25

Table of Contents

Mitsubishi Electric, MA00780C

Safety Precautions

Mitsubishi Electric, MA00780C 5

1 Safety Precautions

Both the installer and the owner and/or operator of the operator panel must read and
understand this installation manual.

1.1 UL and cUL Installation

– This equipment is suitable for use in Class I, Division 2, Groups A, B, C and D

OR non-hazardous locations only. [Combinations of equipment in your system
are subject to investigation by the local Authority Having Jurisdiction at the time
of installation.]

– Maximum ambient temperature 40 °C when mounted horizontal or 50 °C when

mounted vertical.

– WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless

power has been removed or the area is known to be non-hazardous.

– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE

DECONNECTER L’EQUIPEMENT, COUPER LE COURANT OU
S’ASSURER QUE L‘EMPLACEMENT EST DESIGNE NON DANGEREUX.

– WARNING – EXPLOSION HAZARD - Substitution of components may

impair suitability for Class I, Division 2.

– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – LA

SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATERIEL
INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I,
DIVISION 2.

– WARNING – EXPLOSION HAZARD – only UL and cUL approved expansion

units are allowed to be connected to the port designated “EXPANSION”. At the
moment there are no such units evaluated or allowed.

– WARNING – EXPLOSION HAZARD - Do not replace expansion unit unless

power has been switched off or the area is known to be non-hazardous.

– This product contains battery, this must only be changed in an area known to be

non-hazardous. Permitted types are shown in the section Technical Data.

– For use on a flat surface of a type 4X enclosure indoor use only.

– To make wiring connections to the power supply connector, use an AWG 28-12

cable and a tightening torque of min. 0.5 Nm.

Safety Precautions

6 Mitsubishi Electric, MA00780C

1.2 General

– Read the safety precautions carefully.

– Check the delivery for transportation damage. If damage is found, notify the

supplier as soon as possible.

– Do not use the operator panel in an environment with high explosive hazards.

– The supplier is not responsible for modified, altered or reconstructed equipment.

– Use only parts and accessories manufactured according to specifications of the

supplier.

– Read the installation and operating instructions carefully before installing, using

or repairing the operator panel.

– Never allow fluids, metal filings or wiring debris to enter any openings in the

operator panel. This may cause fire or electrical shock.

– Only qualified personnel may operate the operator panel.

– Storing the operator panel where the temperature is lower/higher than

recommended in this manual can cause the LCD display liquid to congeal/become
isotopic.

– The LCD display liquid contains a powerful irritant. In case of skin contact, wash

immediately with plenty of water. In case of eye contact, hold the eye open, flush
with plenty of water and get medical attention.

– The figures in this manual serves an illustrative purpose. Because of the many

variables associated with any particular installation, the supplier cannot assume
responsibility for actual use based on the figures.

– The supplier neither guarantees that the operator panel is suitable for your

particular application, nor assumes responsibility for your product design,
installation or operation.

1.3 During Installation

– The operator panel is designed for stationary installation on a plane surface, where

the following conditions are fulfilled:

• no high explosive risks

• no strong magnetic fields

• no direct sunlight

• no large, sudden temperature changes

– Install the product according to the accompanying installation instructions.

– Ground the product according to the accompanying installation instructions.

– Only qualified personnel may install the operator panel.

– Separate the high voltage, signal and supply cables.

– Make sure that the voltage and polarity of the power source is correct before

connecting the product to the power outlet.

– Peripheral equipment must be appropriate for the application and location.

Safety Precautions

Mitsubishi Electric, MA00780C 7

1.4 During Use

– Keep the operator panel clean.

– Emergency stop and other safety functions may not be controlled from the

operator panel.

– Do not use too much force or sharp objects when touching the keys, touch screen

etc.

1.5 Service and Maintenance

– Only qualified personnel should carry out repairs.

– The agreed warranty applies.

– Before carrying out any cleaning or maintenance operations, disconnect the

equipment from the electrical supply.

– Clean the display and surrounding front cover with a soft cloth and mild

detergent.

– Replacing the battery incorrectly may result in explosion. Only use batteries

recommended by the supplier.

1.6 Dismantling and Scrapping

– The operator panel or parts thereof shall be recycled according to local regulations.

– The following components contain substances that might be hazardous to health

and the environment: lithium battery, electrolytic capacitor and display.

Safety Precautions

8 Mitsubishi Electric, MA00780C

Installation

Mitsubishi Electric, MA00780C 9

2 Installation

2.1 Space Requirements

– Installation plate thickness: 1.5 - 9.0 mm (0.06 - 0.35 inch)
– Space requirements when installing the operator panel:

Caution

The openings on the enclosure are for air convection. Do not cover these
openings.

2.2 Installation Process

1. Unpack and check the delivery. If damage is found, notify the supplier.

Note:

Place the operator panel on a stable surface during installation.
Dropping it or letting it fall may cause damage.

2. Place the panel cut out where the operator panel is to be situated, draw along the
outer sides of the holes and cut according to the markings.

50 mm

100 mm

60 mm

304 mm

398 mm

100 mm
(4.0 inch)

100 mm
(4.0 inch)

(4.0 inch)

(2.0 inch)

50 mm

(2.0 inch)

(11.97 inch)

(15.67 inch)

(2.36 inch)

x14

Panel cut out 355.5 x 278.5 mm

(14.0 x 10.96 inch)

Installation

10 Mitsubishi Electric, MA00780C

3. Secure the operator panel in position, using all the fastening holes and the
provided brackets and screws:

4. Connect the cables in the specified order.

Use an M5 screw and a grounding conductor (as short as possible)

with a cross-section of minimum 2.5 mm

2

.

5. Carefully remove the laminated film over the operator panel display, to avoid
static electricity that could damage the panel.

x14

0.5 - 1.0 Nm

B

C

D

A

Caution

Ensure that the operator panel and the controller system have the
same electrical grounding (reference voltage level), otherwise errors
in communication may occur .

Caution

- Use only shielded communication cables.

- Separate high voltage cables from signal an d su pply cab l e s.

Caution

- The operator panel must be brought to ambient temperature
before it is started up. If condensation forms, ensure that the
operator panel is dry before connecting it to the power outlet.

- Ensure that the voltage and polarity of the power source is correct.

24V DC

RS422/RS485

24V DC

1

CFCARD

B

A

C

D

RS232

Controller

Power

Ethernet

Installation

Mitsubishi Electric, MA00780C 11

2.2.1 Mode Switches

All mode switches must be in OFF position during operator panel use.

The mode switches should not be touched unless by qualified personell.

2.2.2 Connections to the Controller

For information about the cables to be used when connecting the operator panel to
the controller, please refer to the help file for the driver in question.

2.2.3 Other Connections and Peripherals

– Cables, peripheral equipment and accessories must be suitable for the application

and its environment. For further details or recommendations, please refer to the
supplier.

Caution

When using a compact flash card, do not remove the card when the busy
indicator is illuminated.

1

24V DC

CF CARD

COM 1

RS422

RS485

COM 2

RS232

10/100

EXPANSION

BUSY

MODE

1234

ON DIP

MODE

1234

ON DIP

Installation

12 Mitsubishi Electric, MA00780C

Technical Data

Mitsubishi Electric, MA00780C 13

3Technical Data

Parameter E1151

Front panel, W x H x D 398 x 304 x 6 mm
Mounting depth 60 mm (160 mm including clearance)
Front panel se a l IP 66
Rear panel seal IP 20
Keyboard material/

Front panel

Touch screen: Polyester on glass, 1 million finger touch

operations. Overlay: Autotex F157 or F207 *.
Reverse side material Powder-coated aluminum
Weight 3.7 kg
Serial port RS422/

RS485

25-pin D-sub contact, chassis-mounted female with

standard locking screws 4-40 UNC.
Serial port RS232C 9-pin D-sub contact, male with standard locking screws 4-40

UNC.
Ethernet Shielded RJ 45
USB Host type A (USB 1.1), max output current 500mA

Device type B (USB 1.1)
CF-slot Compact flash, type I and II
Flash memory for

application

12 MB (incl. fonts)

Real time clock ±20 PPM + error because of ambient temperature and supply

voltage. Total maximum error: 1 min/month at 25 °C

Temperature coeff icient: 0.004 ppm/°C

2

Real time cl ock
battery

CR2450 (UL and cUL: Sanyo or Panasonic)

Minimum lifetime: 3 years
Power consumption at

rated voltage

Normal: 1.2 A

Maximum: 1.7 A
Display TFT-LCD. 1024 x 768 pix e ls, 64K color.

CCFL backlight lifetime at the ambient temperature of

+25 °C: >35,000 h.
Active area of display,

W x H

304.1 x 228.1 mm

Fuse Internal DC fuse, 3.15 AT, 5 x 20 mm
Power supply +24V DC (20 - 30V DC). Power supply connector.

CE: The power supply must conform with the requirements

according to IEC 60950 and IEC 61558-2- 4.

UL and cUL: The power supply must conform with the

requirements for class II power supplies.
Ambient temperature Vertical installation: 0 ° to +50 °C

Horizontal installation: 0 ° to +40 °C
Storage temperature -20 ° to +70 °C
Relative humidity 5 - 85 % non-condensed
CE approvals Noise tested according to EN61000-6-4 emission and

EN61000-6-2 immunity.
UL, cUL approvals

(when procuct or
packing is marked)

UL 1604 Class I, Div 2 / UL 508 / UL 50 4x indoor use only

DNV Yes
NEMA 4x indoor use only
* See section Chemical Resistance for more information.

Technical Data

14 Mitsubishi Electric, MA00780C

Chemical Resistance

Mitsubishi Electric, MA00780C 15

4 Chemical Resistance

4.1 Metal Casing

The frame and casing material is powder-coated aluminum. This powder paint
withstands exposure to the following chemicals without visible change:

The powder paint shows limited resitance to the following chemicals at room
temperature:

The powder paint shows little or no resistance to the following chemicals at room
temperature:

4.2 Touch Screen and Overlay

4.2.1 Autotex F157/F207

Autotex F157 or F207 covers the overlay surrounding the touch screen.

Solvent Resistance

Autotex F157/F207 withstands exposure of more than 24 hours duration under DIN
42 115 Part 2 to the following chemicals without visible change:

Acetic acid 10% Phosphoric acid 4%
Citric acid 10% Phosphoric acid 10%
Diesel Sea water
Distilled water Sodium chloride 2%
Edible oil Sodium chloride 20%
Fuel oil Sulphuric acid 20%
Hydrogen peroxide 3% Tap water

Butanol Nitric acid 3%
Hydrochloric acid 5% Nitric acid 10%
Isopropyl alcohol Phosphoric acid 43%
Na-hypochlorite 10% Turpentine

Note:

If exposure to any of the above chemicals is dema nded, it is recommended to firs t test
the chemical on an “invisble” spot of the metal casing.

Acetic acid, conc. Methyl-ethyl ketone Toluene
Acetone Nitric acid 30% Trichlorethylene
Ammonia 5% Phenol Xylene
Ammonia, conc. Sodium hydroxide 5% 97 octan unleaded petrol
Ethyl acetate Sodium hydroxide 30% 98 octan leaded petrol

Acetonitrile

Diesel Downey / Lenor

1

Phosphoric acid (<30%)
Ajax / Vim in solution Ethanol Potassium ferricyanide
Alkalicarbonate solution

1

Glycerine Potassium hydroxide (<30%)

Ammonia (<40%)

1

Glycol Pure Turpentine

Chemical Resistance

16 Mitsubishi Electric, MA00780C

Autotex withstands DIN 42 115 Part 2 exposure of up to 1 hour duration to glacial
acetic acid without visible change.

Autotex is not resistant to high pressure steam at over 100 °C or the following
chemicals:

Outdoor Use

In common with all polyester based films Autotex F157/F207 is not suitable for use
in conditions of long term exposure to direct sunlight.

4.2.2 Touch Screen Surface

The touch screen surface on the panel withstands exposure to the following solvents
without visible change:

4.2.3 Autoflex EB

It is recommended to use the Autoflex EB touch display protection film, that can be
ordered from the manufacturer.

Solvent Resistance

Autoflex EB withstands exposure to the same chemicals as Autotex F157 or F207
according to section Autotex F157/F207.

Outdoor Use

In common with all polyester based films Autoflex EB is not suitable for use in
conditions of long term exposure to direct sunlight.

Acetic acid (<50%)

Gumption

1

SBP 60/95

1

Ariel powder in solution

1

Hydrochloric acid (<36%) Sulfuric acid (<10%)

Bleach

1

Linseed oil Tomato ketchup
Castor oil Methanol Trichloroacetic acid (<50%)
Caustic soda (<40%)

1

Nitric acid (<10%) White Spirit
Cutting oil Paraffin oil

Windex

1

Cyclohexanol

Persil powder in sol u tion

1

Wisk

Diacetone alcohol

Petroleum spirit

1

-

1

Extremely faint glossing of the texture was noted.

Concentrated mineral acids Benzyl alcohol
Concentrated caustic solution Methylene chloride

Solvents Time

Acetone 10 minutes
Isopropanol 10 minutes
Toluene 5 hours

Operator Panel Drawings

Mitsubishi Electric, MA00780C 17

5Operator Panel Drawings

5.1 Communication Ports

Drawing No. S-5005, Date 2004-10-27

RS-232

RS-422

RS-422/485

RS-485

Ethernet

USB

Operator Panel Drawings

18 Mitsubishi Electric, MA00780C

5.2 E1151 Outline

Drawing No. S-5141, Date 2004-10-26

Additional Installation Tips

Mitsubishi Electric, MA00780C 19

6 Additional Installation Tips

When experiencing communication problems in for example noisy environments or
when operating close to temperature limits, the following recommendations are to be
noticed.

6.1 Grounding the Operator Panel

1. The operator panel’s mounting clamps do not provide a secure grounding con­nection between the panel and the device cabinet.

2. Connect a 2.5 mm

2

wire between the operator panel’s quick-connect plinth and

the panel chassis.

3. Connect a 6 or 4 mm

2

wire or grounding braid between the panel’s chassis and

the closest grounding point on the door.

4. Connect a strong but short grounding braid between the door and the device
cabinet.

5. Twist the cables onto the 24 V DC feed.

6. A ferrite core suppresses disturbances to the 24 V feed.
2 turns around the ferrite core provide 4 times the suppression of 1 turn.
3 turns around the ferrite core provide 9 times the suppression of 1 turn.

Remember:

The grounding wires should be short and the conductor should have a large area.
A long, thin grounding wire has a very high impedance (resistance) at high frequencies
and will not guide disturbances to the ground.
Multi-wire conductors are better than single wire conductors with the same area.
A braided conductor wire with the same area is even better.
The best is a short, thick grounding braid.

1

2

3

4

5

6

Door

Operator panel

Ferrite core

Mounting plate in the cabinet

Power supply

24 V DC

Additional Installation Tips

20 Mitsubishi Electric, MA00780C

6.2 Ethernet Conn ection in the Panel

1. In some industrial units for Ethernet, the RJ45 contact’s shield is connected to
the chassis via a capacitor.

2. The operator panel’s Ethernet shield is directly connected to the chassis.

Check whether the other Ethernet unit has its shield directly grounded or grounded
via a capacitor.

In many cases, connecting the shielded Ethernet cabling to the chassis at both ends
is inappropriate. Hum or grounding loops can occur. Unshielded cabling may even
result in fewer communication errors.

A good solution may be to use a shielded Ethernet cable, but to connect the shield at
one end only.

3. One option is to break the shield.

4. A more elegant method is to expand the shielded Ethernet cabling with a piece
of unshielded Ethernet cable.

5. You can ground the shield via an external 0.1 uF/250 V plastic capacitor. This
will connect the HF transients to the ground.

1

2

3

4

5

1-1
2-2
3-3

8-8

Industrial Ethernet

RJ45

RJ45

RJ45

RJ45

RJ45

RJ45

RJ45

RJ45

Operator panel

Operator panel

Operator panel

Operator panel

Shielded

Short and
unshielded

0.1 uF

250 V

Additional Installation Tips

Mitsubishi Electric, MA00780C 21

6.3 To Achieve Better EMC Protection

– Initially, use the original cabling from the supplier primarily.
– Use shielded cables for RS232 communication.
– Use twisted pair and shielded cabling for RS422 and RS485.
– Use the cabling intended for the bus type; Ethernet, Profibus, CC-Link, CAN,

Device Net etc.

– Install and connect according to applicable specifications for the relevant bus stan-

dard.
– Use shielded cabling for Ethernet, preferably with foil + braided shield.
– D-sub covers should be shielded, and the shield should be connected to the cover

360 ° where the cable comes in.
– Connect the shield at both ends.

With longer distances, there is a risk that the ground potential may be different. In
that case, the shield should only be connected at one end. A good alternative is to
connect the other end of the shield to the ground via a 0.1 uF/250 V plastic capacitor.
Both ends are then connected to the ground in terms of HF, but only connected to
the ground at one end in terms of LF, thus avoiding the 50 Hz grounding loops.

– Use an EMC cable gland or regular plastic cable gland, remove the outer jacket

and connect the shield to the installation plate with a 360 ° metal cable clamp.
– Place the 24 V DC and communications cabling in one cable trunk/cable duct and

230/380 V AC in another. If the cables need to be crossed, cross them at 90 ° only.

Avoid combining the cabling for stronger 24 V DC outputs with the communi-

cation cabling.
– Ferrite cores that are snapped onto the shielded cabling may remove minor distur-

bances. Large ferrite pieces that are snapped onto unshielded cabling and where

the wires go 2-4 times around the cores are approximately 5-25 times more effi-

cient.

Shielded cable

Ground plane 1 Ground plane 2

Ground plate

Ground plate
in another building

0.1 uF/250 V

Not same potential

Metal cabinet Metal cabinet

Terminal o r

connector

Terminal or

connector

EMC cable gland

Plastic cable gland

Shielded cable Shielded cable

Cable clamp
in steel

Short distance

Additional Installation Tips

22 Mitsubishi Electric, MA00780C

6.4 Ambient Temperature

The maximum ambient temperature for the operator panel is provided in the
specifications. The ambient temperature refers to the temperature in the device
cabinet which cools the panel’s electronics.

In most cases, the ambient temperature for the operator panel is significantly higher
than the device cabinet’s ambient temperature.

If the cabinet is tall and there are a number of heat-generating devices, the
temperature at the top of the cabinet will be considerably higher than the theoretical
temperature increase that would be expected. All electronics are sensitive to heat. The
lifespan of an electrolytic capacitor is cut in half with an 8-10 ° increase in
temperature. A 15-20 ° temperature increase results in a quarter of the lifespan etc.

Rittal has a good program for estimating the anticipated average temperature in the
cabinet as well as a large program for controlling the temperature in the device
cabinet.

An enamel-coated steel cabinet has a radiant heat value of 5.5 W/m

2

and degrees C.

Installing a fan inside the cabinet will even out the temperature, while moving air
provides considerably better cooling than still air. A suitable fan is a 120 x 120 mm
axial fan, available in 24 V DC, 115 and 230 V AC.

Install the fan so that it sits in the cooler area and will blow cold air against the
operator panel. If the fan is mounted at the top and sucks air upwards, the fan’s
ambient temperature will be higher = shorter lifespan.

A good fan with a ball-bearing mounting has an expected lifespan of at least 40,000
hours (not a guaranteed lifespan) at 40 °C. This corresponds to at least 4 years of
continuous use. If a thermostat is installed, the fan only needs to come on when
needed.

Large graphic terminals draw only one fifth of the current when the background
lighting is off. The loss effect drops from e.g. 25 W to only 5 W.

The operator panel’s loss effect = supply voltage x current. Virtually no power goes
to external users and no loss effects due to inputs.

5354

Top
50

° inside

Middle
45

° inside

Bottom
40

° inside

Operator
panel

30

°C outside

Power

Power

Power

Airflow

Axial fan
120x120 mm

Additional Installation Tips

Mitsubishi Electric, MA00780C 23

6.5 Safety

Most of the operator panels are fed with 24 V DC.

1. If you use a power supply that meets safety standards and only feeds the operator

panel, there is no problem.

2. However, if you have a 24 V unit that also feeds other units, there is reason to be

cautious.
The operator panel does not have insulation that meets safety requirements in
the event of a potential short circuit between 230 V AC and 24 V DC. It is
assumed that the 24 V feed is secure, for example, SELV according to
EN 60950 (protection against electric shock) and UL 950.

3. If there is a substantial distance between the relay contacts for 24 V DC and

230 V AC, it is OK to use the same 24 V devices for all feeds.

4. Connect 0 V on the 24 V feed to the ground. This offers three advantages:

–Safety is increased. The 24 V feed will not be live in the event of a faulty connec-

tion or short circuit between 0 V (24 V) and 230 V phase.
–Transients on the 24 V feed are connected to the ground.
–No risk that the 24 V feed is at a high level in relationship to the ground. This is

not unusual since there is high static electricity.

Example:

Here is an example that explains why a secure 24 V DC feed can be ruined by mixing 24
V relay contacts with 230 V AC relay contacts in a smaller controller. Check that the
“clearances and creepage distances between 24 V DC and 230 V AC fulfill EN 60950 or
UL 950”. If not, input a separate 24 V unit into the operator panel.

4

1

2

4

3

4

5355

Power supply
230 V AC to 24 V DC

Power supply
230 V AC to 24 V DC

Power suppl y
230 V AC to 24 V DC

Operator panel

Operator panel

Operator pa n el

+24 V

+24 V

+24 V

0 V

0 V

0 V

230 V AC

COM1

COM100

Small controller with expansion unit

Ch0
Ch1

Ch100
Ch101

Distance?

Additional Installation Tips

24 Mitsubishi Electric, MA00780C

6.6 Galvanic Isolation

The operator panel has galvanic isolation against the 24 V DC feed but no galvanic
isolation between the communication ports for RS232, RS422/485 and USB. Only
the Ethernet connection has galvanic isolation.

When a PC is connected to the panel, the panel’s internal 0 V (GND) will be
connected to the protective ground via the PC.

A number of USB devices can have the shield connected together with the protective
ground. Here, the panel’s 0 V (GND) is connected to the protective ground when,
for example, a USB memory stick, keyboard or similar device is plugged in.

If a number of units are connected that have a 0 V and a ground connection, and
these are connected to various grounding points, there is a substantial risk of
problems. Grounding currents go through communication cables, the rear plate of
the controller, and internally in the operator panel, and can cause errors.

Use external units to improve communication and achieve galvanic isolation.
Westermo has good industry-standard insulators that are also insulated from the 24
V DC feed.

Note:

It is very important to make sure that the 24 V feed in the external insulation unit is
not connected to one of the communication outlets. If it does not have 100% insulation
against the 24 V feed, disturbances and grounding currents from the 0 V on the 24 V
side will disrupt communication.
Using this type of unit solves one problem but creates a larger problem!
A substandard installation may work now, but problems may arise when other devices
are connected.

5356

Internal electronic

Filter

DC/DC
galvanic isolation

1.5 m

VCC

0 V (GND)

Ethernet

DC/AC

CFL

0 V

+24 V DC

RS422/485 RS232 USB USB

* *

*

***

**

*

Operator panel

Modular controller

PC

RS422 RS232 USB

CPU COM COM2Power

Not same ground potential

PC

Printer

* = Internal 0 V (GND) connection

Additional Installation Tips

Mitsubishi Electric, MA00780C 25

6.7 Cable and Bus Termination RS485

– Use shielded and twisted pair cable.

The pair capacitance may not exceed 52.5 pF/m and area at least 0.25 mm

2

(AWG

24), if you want to use the maximum transfer distance and maximum transfer
speed.

– 0 V, the reference voltage for communication should be included in the cabling.

With two-way communication use two pairs; one pair for communication and
one pair for 0 V.

– The shield must be grounded at one end. The other end is usually grounded, but

with longer distances or when there is a difference in the ground potential, the
shield should be connected to the ground via 0.1 uF/250 V plastic capacitor to
prevent ground current in the braided shield.
A number of manufacturers recommend that the shield be grounded at each node.

Various manufacturers have different systems for bus termination. The RS485
standard does not describe how the “Fail Safe” function would be carried out, just
that the system should be able to handle the error.

Depending on the recipients’ design, the bus wires may be on the same level or
require pull-up or pull-down to ensure that no faulty signals are detected when the
bus is in resting mode (all transmitters are disconnected).

1. Some (older) operator panels had pull-up and pull-down resistance except for
the actual bus termination at 120 ohm, similar to Westermo and Profibus.

2. Newer panels have another type of recipient, so-called built-in “Fail Safe”, where
simple bus termination resistance is sufficient.

If other nodes on the RS485 network require pull-up and pull-down and the
operator panel is at one end of the loop, one of the following procedures can be
carried out:

3. Connect two 1k/0.25 W resistors in the 25-pole D-sub contact. Set jumper pins
6-19.

4. Use CAB8. It offers the option of bus termination with pull-up/-down. It is also
easy to connect the bus cable via the screw terminal block.

1 23

4

5358

+5 V

0 V

120 ohm

1K

1K

120 ohm

(120 ohm)

Inside operator panel

+5 V

1K

1K

0 V
0 V

CAB8

CAB8

Operator
panel
RS422

Bus
RS485

0 V
0 V

0 V
0 V

120 ohm

1K

1K

VCC

+5 V

VCC

2.65 V

2.35 V

Bus termination

Shield

Mitsubishi Electric Automation, Inc.

500 Corporate Woods Parkway
Vernon Hills, IL 60061, USA

Mitsubishi Electric Europe B.V.

Gothaer Strasse 8
D-40880 Ratingen, Germany

MITSUBISHI ELECTRIC