Rockwell Automation 57C332 User Manual

AutoMaxrPower Supply
Modules and Racks

M/N 57C493 Power Supply Module
M/N 57C494 Power Supply Module
M/N 57C331 16ĆSlot Rack
M/N 57C332 10ĆSlot Rack
M/N 57C334 6ĆSlot Rack

Instruction Manual J2Ć3008Ć4

DANGER

ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS
INVOLVED SHOULD INSTALL, ADJUST, OPERATE, OR SERVICE THIS
EQUIPMENT. READ AND UNDERSTAND THIS MANUAL AND OTHER
APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING. FAILURE
TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY
OR LOSS OF LIFE.

DANGER

THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE
LOCAL, NATIONAL, AND INTERNATIONAL CODES. WIRING PRACTICES,
GROUNDING, DISCONNECTS, AND OVERĆCURRENT PROTECTION ARE OF
PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS PRECAUTION
COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.

WARNING

INSERTING OR REMOVING THE POWER SUPPLY MODULE OR ITS
CONNECTING CABLES MAY RESULT IN UNEXPECTED MACHINE MOTION.
POWER TO THE MODULE SHOULD BE TURNED OFF BEFORE INSERTING OR
REMOVING THE MODULE OR ITS CONNECTING CABLES. FAILURE TO
OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY.

WARNING

THE USER MUST PROVIDE AN EXTERNAL, HARDWIRED EMERGENCY STOP
CIRCUIT OUTSIDE THE PROGRAMMABLE CONTROLLER CIRCUITRY. THIS
CIRCUIT MUST DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION.
UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS
NOT FOLLOWED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN
BODILY INJURY.

CAUTION: The power supply module and racks contain staticĆsensitive components.

Careless handling cancause severe damage. Do nottouch the connectors ontheback
of the power supply module or the racks. When not in use, the power supply module
should be stored in an antiĆstaticbag. The plasticcover should not be removed. Failure
to observe this precaution could result in damage to or destruction of equipment.

Allen-Bradley and Rockwell Automation are trademarks of Rockwell Automation, Inc,.
Trademarks not belonging to Rockwell Automation are property of their respective companies.

Table of Contents

1.0 Introduction 1Ć1...............................................

1.1 Additional Information 1Ć1....................................

1.2 Related Hardware and Software 1Ć2...........................

2.0 Mechanical/Electrical Description 2Ć1...........................

2.1 Power Supply Module Mechanical Description 2Ć1.........

2.1.1 Power Supply Module LED Indicators 2Ć4.................

2.1.2 Power Supply Module Terminal Block 2Ć4.................

2.1.3 Power Supply Module Battery Connection

(M/N 57C493 only) 2Ć4.................................

2.1.4 Power Supply Module Keyswitch 2Ć4.....................

2.2 Power Supply Module Electrical Description 2Ć5.................

2.3 Rack Mechanical Description 2Ć5..............................

2.4 Rack Electrical Description 2Ć6................................

3.0 Installation 3Ć1................................................

3.1 Wiring 3Ć1..................................................

3.2 Initial Installation 3Ć1.........................................

3.3 Power Supply Module Replacement 3Ć5........................

3.4 Rack Replacement 3Ć6.......................................

4.0 Diagnostics and Troubleshooting 4Ć1............................

4.1 The POWER LED Is Off 4Ć1...................................

4.2 The FAULT LED is On 4Ć2....................................

I

Appendices

Appendix A

Technical Specifications AĆ1......................................

Appendix B

External Connections BĆ1........................................

Appendix C

Rack Backplane CĆ1............................................

Appendix D

Rack Mounting Pattern DĆ1.......................................

Appendix E

Power Requirements of AutoMax Modules EĆ1.....................

II

List of Figures

Figure 2.1 Ć 376W Power Supply Module (M/N 57C493) 2Ć2................

Figure 2.2 Ć 147W Power Supply Module (M/N 57C494) 2Ć3................

Figure 2.3 Ć 6ĆSlot Rack 2Ć6............................................

Figure 2.4 Ć 10ĆSlot Rack 2Ć6...........................................

Figure 2.5 Ć 16ĆSlot Rack 2Ć7...........................................

Figure 2.6 Ć Rack Slot Limitations 2Ć7....................................

Figure 2.7 Ć Typical Input Power Connections 2Ć8.........................

III

1.0 INTRODUCTION

The products described in this instruction manual are manufactured
by Reliance Electric Industrial Company.

The Power Supply module (M/N 57C493 or M/NĂ57C494) converts
115 VAC input power into the DC voltages necessary to operate the
other modules contained in the Rack. The Rack provides the
mechanical means of mounting 6 (M/N 57C334), 10 (M/NĂ57C332),
or 16 (M/NĂ57C331) DCS 5000 or AutoMax modules, as well as the
Power Supply module. The Multibust backplane in the Rack
provides two sets of bus lines for local communication among the
DCS 5000 and AutoMax modules.

The M/N 57C393 Power Supply module can provide a maximum
continuous output of 376 watts to power modules in the AutoMax
rack. The M/N 57C394 Power Supply module can provide a
maximum continuous output of 147 watts to power modules in the
AutoMax rack. When using the M/N 57C494 Power Supply module in
a 10 or 16Ćslot rack, make certain that the power requirements of the
modules in the rack do not exceed the capacity of the Power Supply
module. See Appendix E for a list of AutoMaxĆcompatible modules
and their power requirements.

This instruction manual describes the functions and specifications of
the Power Supply modules and the Rack. It also includes a detailed
overview of installation and servicing procedures.

1.1 Additional Information

You should be familiar with the instruction manuals which describe
your system configuration. This may include, but is not limited to, the
following:

D JĆ3636 COMMON MEMORY MODULE INSTRUCTION MANUAL

D JĆ3649 AutoMax CONFIGURATION TASK MANUAL

D JĆ3630 ReSource AutoMax PROGRAMMING EXECUTIVE

D JĆ3650 AutoMax PROCESSOR MODULE INSTRUCTION

D JĆ3668 DCS 5000 POCKET REFERENCE

D JĆ3669 AutoMax POCKET REFERENCE

D JĆ3675 AutoMax ENHANCED BASIC LANGUAGE

D JĆ3676 AutoMax CONTROL BLOCK LANGUAGE INSTRUCTION

D JĆ3677 AutoMax LADDER LOGIC LANGUAGE INSTRUCTION

D IEEE 518GUIDE FOR THE INSTALLATION OF ELECTRICAL

D IEEE 796STANDARD MICROCOMPUTER SYSTEM BUS

D Your ReSource AutoMax PROGRAMMING EXECUTIVE

INSTRUCTION MANUAL

INSTRUCTION MANUAL VERSION 1.0

MANUAL

INSTRUCTION MANUAL

MANUAL

MANUAL

EQUIPMENT TO MINIMIZE ELECTRICAL NOISE
INPUTS TO CONTROLLERS

1Ć1

D Other instruction manuals applicable to your hardware

configuration

D Your personal computer and DOS operating system manual(s).

1.2 Related Hardware and Software

The Power Supply modules and Racks are sold individually.
M/NĂ57C493 contains one 376 watt Power Supply module and two
keyswitch keys. M/N 57C494 contains one 147 watt Power Supply
module and two keyswitch keys. M/N 57C331 contains one 16Ćslot
Rack. M/N 57C332 contains one 10Ćslot Rack. M/N 57C334 contains
one 6Ćslot Rack. One Power Supply module and one Rack are used
with various input, output, and special purpose modules, as well as
the following hardware and software, which can be purchased
separately:

1. AutoMax or DCS 5000 Processor modules. The following
Processor modules can be used only with the M/N 57C493
Power Supply module:M/NĂ57C430 AutoMax Processor(s) or
M/NĂ57C407 DCS 5000 Processor(s). Note that all Processors in
a single Rack must be of the same type, i.e., AutoMax and DCS
5000 Processors cannot be mixed in one Rack.

D M/N 57C430 AutoMax Processor
D M/N 57C407 DCS 5000 Processor

Note that all Processors in a single rack must be of the same
type, i.e., AutoMax and DCS 5000 Processors cannot be mixed in
the same rack.

The following AutoMax Processors can be used with the M/N
57C493 or M/N 57C494 Power Supply module. These processor
modules can be mixed in the same rack:

D M/N 57C430A
D M/N 57C431
D M/N 57C435

2. ReSource AutoMax Programming Executive software or
ReSource DCS 5000 Programming Executive software.

3. M/NĂ57C127 RSĆ232C ReSource Interface Cable. This cable is
used to connect the personal computer to the Processor module.

4. M/NĂ57C413 (or later) or M/N 57C423 (or later) Common Memory
module. This module is used when there is more than one
Processor in the Rack. Note that only M/N 57C413B (and later) or
M/N 57C423 (and later) Common Memory module can be used
with the M/N 57C494 Power Supply.

5. M/N 57C492 Battery BackĆUp. This unit is used when there is a
Common Memory module (M/N 57C413 or M/N 57C413A only),
a M/N 57C407 or M/N 57C430 Processor, or both in the Rack.
The Battery BackĆUp unit can be used only with the M/N 57C493
Power Supply.

6. M/N 57C384 Battery BackĆUp cable. This cable is used with the
Battery BackĆUp unit.

1Ć2

2.0 MECHANICAL/ELECTRICAL
DESCRIPTION

The following is a description of the mechanical and electrical
components, as well as the characteristics of the input connections,
for the Power Supply module and Racks. Unless noted otherwise, the
descriptions that follow describe both M/N 57C493 and M/N 57C494
Power Supply modules.

2.1 Power Supply Module Mechanical Description

The M/N 57C494 Power Supply module is a printed circuit board
assembly that plugs into the leftmost position of the 6Ć, 10Ć, or 16ĆSlot
Rack. When it is installed in a 10Ć or 16ĆSlot Rack, there will be a
oneĆslotĆwide space to the right of the Power Supply. If desired, this
space can be covered with a blank faceplate (M/N 61C599).

The M/N 57C493 Power Supply module is a printed circuit board
assembly that plugs into the leftmost position of either the 10Ć or
16ĆSlot Rack. It cannot be used with the 6ĆSlot Rack. Both modules
are enclosed in protective steel housings with integral heatsink.
Through its connection to the Multibus backplane of the Rack, the
Power Supply module provides the DC voltages necessary to power
the logic circuitry of modules in the Rack. On the faceplate of the M/N
57C493 Power Supply module are two LED indicators, a terminal
block connector, a keyswitch, a fuse, and a battery backĆup
connector. See figure 2.1.

On the faceplate of the M/N 57C494 Power Supply module are two
LED indicators, a terminal block connector, a keyswitch, and a fuse.
See figure 2.2.

2Ć1

376W

57C493

PROGRAM

FUSE TYPE
250 V
MDA 15A

MEMORY
PROTECT

POWER

FAULT

SET
UP

BATTERY
BACK UP

2Ć2

GND

L2
120 VAC
L1

Figure 2.1Ć 376W Power Supply Module (M/N 57C493)

147W

57C494

POWER

FAULT

PROGRAM

MEMORY
PROTECT

FUSE TYPE
250 V
MDA 5A

SET
UP

L2
120 VAC
L1

Figure 2.2Ć 147W Power Supply Module (M/N 57C494)

2Ć3

2.1.1 Power Supply Module LED Indicators

The Power Supply module faceplate contains 2 LEDs. The green LED
labeled POWER" is lit to indicate when incoming AC power is within
the specified ranges. The red LED labeled FAULT" is normally off.
When it is on, it indicates the output voltages are not all above the
low voltage alarm thresholds or the watchdog OK signal is high.

2.1.2 Power Supply Module Terminal Block

The terminal block on the Power Supply faceplate provides the
means to connect the 115 VAC power and a ground wire from the
rack to the module. Note that terminals 1-5 (reading top to bottom)
are not functional.

The green ground wire from the Rack connects to the GND"
terminal on the faceplate of the Power Supply. Terminal L2" is the
connection for the AC neutral input line from the Rack. Terminal L1"
is the connection for the AC hot input line from the Rack. See section

3.2 for more information.

2.1.3 Power Supply Module Battery Connection
(M/N 57C493 only)

The faceplate connection labeled BATTERY BACK UP" provides the
means to connect the Battery BackĆUp (M/NĂ57C492) to the Power
Supply module. Note that the Battery BackĆUp unit is required only
when there is a DCS 5000 Processor module (M/NĂ57C407) or a
Common Memory module (M/NĂ57C413 or 57C413A only) in the
Rack. The Battery BackĆUp unit can save the contents of the
Common Memory and DCS 5000 Processor RAM in the event of a
power failure.

The keyswitch is used to reset the OK" signal on the Battery
BackĆUp. It is necessary to reset this signal if the battery fails or if the
cable is removed. See 2.1.4 and 2.2 for more information.

Note that the M/N 57C494 Power Supply module does not contain a
Battery BackĆup connection. Therefore, the above mentioned
Processor and Common Memory modules cannot be used with the
M/N 57C494 Power Supply.

2.1.4 Power Supply Module Keyswitch

The keyswitch on the faceplate routes TTL signals through the
Multibus backplane to the Processor module(s) to allow lockout of
programming functions for system security. The three positions of the
keyswitch are PROGRAM, MEMORY PROTECT, and SET UP. The
position of the keyswitch indicates the security level of the rack, i.e.,
the kind of ONĆLINE Menu operations that can be performed through
a personal computer communicating with the processors in the rack.
The MEMORY PROTECT position allows only monitoring of variables
and saving of tasks from the rack. SETUP allows the operator to
monitor all variables, modify tunable variables, and save tasks from
the rack. The PROGRAM position allows the operator to perform all
ONĆLINE Menu functions, providing the password for the rack is also
entered. See the appropriate Programming Executive instruction
manual for more information.

2Ć4

2.2 Power Supply Module Electrical
Description

When the Power Supply module powersĆup, it executes a soft start,"
gradually increasing its output until it reaches the voltage necessary
for logic operations. At this time, the module generates an initialize
signal.

Should the AC input fall below the lower line voltage limit, the module
will generate a power fail interrupt signal at least three milliseconds
before loss of the regulated DC power to allow for orderly system
shutdown. The holdover time on loss of AC input is 20 milliseconds.

In the event of a power fail interrupt signal, 5 Volt output power is
supplied by the Battery BackĆUp (if installed, M/N 57C493 only) for
maintaining the volatile memory of DCS 5000 Processor modules
and the Common Memory module. When the regulated output power
of the Power Supply module is restored to 4.85 Volts or greater,
power will be supplied by the Power Supply module. Note that
AutoMax Processors have onĆboard battery backĆup and do not
require Battery BackĆUp unless there is a Common Memory module
(M/N 57C413 or 57C413A only) in the rack.

If Battery BackĆUp Voltage ever drops below 3.0 Volts, or the cable
between the Battery BackĆUp and M/N 57C493 Power Supply
module is disconnected with the power off, memory will be lost and
the Processor modules will not function until the Power Supply is
manually reset by turning the keyswitch on the front panel from
MEMORY PROTECT to the PROGRAM position.

2.3 Rack Mechanical Description

The 6Ć, 10Ć, and 16ĆSlot Racks provide the mechanical means for
mounting the indicated number of DCS 5000 and AutoMax modules,
as well as the Power Supply module. All Racks are designed for
panel mounting and include builtĆin high capacity cooling fans, an
AC line filter, a surge protector, and a cable management tray. See
figures 2.3, 2.4, and 2.5.

2Ć5

(Nameplate Bracket Removed)

Figure 2.3Ć 6ĆSlot Rack

(Nameplate Bracket Removed)

Figure 2.4Ć 10ĆSlot Rack

2Ć6