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5403
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Schneider 5403, 5404 User Manual

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5403 and 5404 Digital Input Modules
Installation, Operation and Maintenance Setup Manual
2/24/2017
5403 and 5404 Digital Input Modules
Copyright © 2014 - 2017 Schneider Electric Canada Inc. All rights reserved. The information provided in this documentation contains general descriptions
and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.
No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric.
All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components.
Trademarks
Schneider Electric, ClearSCADA, SCADAPack, Solarpack, Realflo, Telepace, Telebus, SCADAServer, and Modbus are trademarks and the property of Schneider Electric SE, its subsidiaries and affiliated companies. All other trademarks are the property of their respective owners.
Microsoft and Windows are registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.
Address
Schneider Electric Telemetry & Remote SCADA Solutions 415 Legget Drive, Suite 101, Kanata, Ontario K2K 3R1 Canada Direct Worldwide: +1 (613) 591-1943 Fax: +1 (613) 591-1022 Toll Free within North America: 1 (888) 267-2232 www.schneider-electric.com
5403 and 5404 Digital Input Modules
Table of Contents
Technical Support..........................................................................5
Technical Support: Americas, Europe, Middle East, Asia ..................................... 5
Technical Support: Australia .................................................................................. 5
Safety Information .........................................................................6
Important Information ............................................................................................. 6
Please Note ............................................................................................................ 7
Before You Begin ................................................................................................... 7
Operation and Adjustments ................................................................................... 7
Acceptable Use ...................................................................................................... 8
About The Book .............................................................................9
At a Glance ............................................................................................................ 9
Overview ....................................................................................... 10
Installation .................................................................................... 12
Field Wiring .......................................................................................................... 12
Address Selection ................................................................................................ 13
Operation and Maintenance ........................................................ 16
LED Indicators ...................................................................................................... 16
Troubleshooting ................................................................................................... 16
Specifications .............................................................................. 17
Voltage Ranges .................................................................................................... 18
Approvals and Certifications ...................................................... 19
5403 and 5404 Digital Input Modules
Index of Figures
Figure 1: 5403 Digital Input Module ................................................................... 10
Figure 2: 5404 Digital Input Module ................................................................... 11
Figure 3: Field Wiring Examples ........................................................................ 13
Figure 4: Model 5403 Module Address Switches ............................................... 14
Figure 5: Model 5404 Module Address Switches ............................................... 15
5403 and 5404 Digital Input Modules

Technical Support

Questions and requests related to any part of this documentation can be directed to one of the following support centers:

Technical Support: Americas, Europe, Middle East, Asia

Available Monday to Friday 8:00am – 6:30pm Eastern Time Toll free within North America 1-888-226-6876 Direct Worldwide +1-613-591-1943 Email supportTRSS@schneider-electric.com

Technical Support: Australia

Inside Australia 1300 369 233
Email au.help@schneider-electric.com
5403 and 5404 Digital Input Modules
The addition of this symbol to a Danger or Warning safety message indicates that an electrical hazard exists, which will result in personal injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, can result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.

Safety Information

Important Information

Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.
5403 and 5404 Digital Input Modules
WARNING
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.  Before operational tests are performed, remove all blocks or other
temporary holding means used for shipment from all component devices.
Remove tools, meters, and debris from equipment.
Failure to follow these instructions can result in death or serious injury.

Please Note

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.
A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and the installation, and has received safety training to recognize and avoid the hazards involved.

Before You Begin

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective point-of-operation guarding on a machine can result in serious injury to the operator of that machine.
Follow all start-up tests recommended in the equipment documentation. Store all equipment documentation for future references.
Software testing must be done in both simulated and real environments. Verify that the completed system is free from all short circuits and grounds,
except those grounds installed according to local regulations (according to the National Electrical Code in the U.S.A, for instance). If high-potential voltage testing is necessary, follow recommendations in equipment documentation to prevent accidental equipment damage.

Operation and Adjustments

The following precautions are from the NEMA Standards Publication ICS 7.1­1995 (English version prevails):
Regardless of the care exercised in the design and manufacture of
equipment or in the selection and ratings of components, there are hazards that can be encountered if such equipment is improperly operated.
It is sometimes possible to misadjust the equipment and thus produce
unsatisfactory or unsafe operation. Always use the manufacturer’s
instructions as a guide for functional adjustments. Personnel who have access to these adjustments should be familiar with the equipment
manufacturer’s instructions and the machinery used with the electrical
equipment.
5403 and 5404 Digital Input Modules
WARNING
UNACCEPTABLE USE
Do not use SCADAPack controllers and expansion modules as an integral part of a safety system. These devices are not safety products.
Failure to follow these instructions can result in death or serious injury.
CAUTION
EQUIPMENT OPERATION HAZARD
When devices are used for applications with technical safety requirements, the relevant instructions must be followed.
Use only Schneider Electric software or approved software with Schneider Electric hardware products.
Failure to follow these instructions can result in minor or moderate injury.
Only those operational adjustments actually required by the operator should
be accessible to the operator. Access to other controls should be restricted to prevent unauthorized changes in operating characteristics.

Acceptable Use

SCADAPack controllers and expansion modules are intended for use in monitoring and controlling non-critical equipment only. They are not intended for safety-critical applications.
5403 and 5404 Digital Input Modules
WARNING
UNINTENDED EQUIPMENT OPERATION
The application of this product requires expertise in the design and programming of control systems. Only persons with such expertise should be allowed to program, install, alter and apply this product.
Follow all local and national safety codes and standards.
Failure to follow these instructions can result in death or serious injury.

About The Book

At a Glance

Document Scope

This manual describes the operation and maintenance of the 5403 and 5404 Digital Input modules.

Validity Notes

This document is valid for all versions of the 5403 and 5404 Digital Input modules.

Product Related Information

User Comments

We welcome your comments about this document. You can reach us by e-mail at
supportTRSS@schneider-electric.com.
5403 and 5404 Digital Input Modules

Overview

The Model 5403 Digital Input module adds eight discrete inputs to a 5000 I/O system. Up to eight Model 5403 modules may be installed on a I/O bus to provide a total of 64 digital inputs.
The Model 5404 Digital Input module adds sixteen discrete inputs to a 5000 I/O system. Up to sixteen Model 5404 modules may be installed on an I/O bus to provide a total of 256 digital inputs.
The digital inputs are optically isolated from the logic power. To simplify field wiring, the inputs are grouped with four inputs sharing a single common return. These groups of four inputs are isolated from each other.
The Model 5403 and 5404 digital input module is available in five standard voltage ranges, for both AC and DC applications. A current limiting resistor on each input determines the voltage range. These resistors can be easily changed to accommodate non-standard signal ranges.
Light emitting diodes on the Model 5403 and 5404 show the status of each of the inputs. The SCADAPack controller module enables or disables the LEDs to control power consumption in solar powered or unattended applications.
Figure 1: 5403 Digital Input Module
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5403 and 5404 Digital Input Modules
Figure 2: 5404 Digital Input Module
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5403 and 5404 Digital Input Modules

Installation

The installation of the 5403 and 5404 modules require mounting the modules on the 7.5mm by 35mm DIN rail and connecting the modules to the system I/O Bus. Refer to the System Configuration Guide for complete information on system layout, I/O Bus cable routing and module installation.

Field Wiring

The 5403 module provides 8 digital inputs. The 5404 module provides 16 digital inputs. The input voltage range is set at the factory. On both modules the inputs are grouped with four inputs sharing a single common return. The groups are isolated from each other.
The 5403 module has two groups of four inputs with inputs 0 to 3 in one group and inputs 4 to 7 in the second group. Each group shares a common return.
The 5404 module has four groups of four inputs with inputs 0 to 3 in one group, inputs 4 to 7 in the second group, inputs 8 to 11 in the third group and inputs 12 to 15 in the forth group.
The 5403 and 5404 modules accommodate AC or DC inputs. Observe signal polarity when using DC inputs. Connect the positive signal to the input. Connect the negative signal to the common.
120 VAC digital inputs don't work with some UPSs. The digital input firmware is looking for a minimum input on-time generated by a sine-wave. This time is longer than the on-time generated by some UPSs. The module should not be used with a non-sine wave UPS.
Figure 3: Field Wiring Examples shows typical field wiring. Controller, modem and I/O modules use screw termination style connectors for
termination of field wiring. They accommodate solid or stranded wires from 22 to 12 AWG.
The connectors are removable. This allows module replacement without disturbing the field wiring. Leave enough slack in the wiring for the connector to be removed.
CRemove power before servicing unit. To remove the connector: Pull the connector upward from the board. Apply even pressure to both ends
of the connector. To install the connector: Line up the pins on the module with the holes in the connector.
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5403 and 5404 Digital Input Modules
123456789
10
12345
0
0-3
COM
+
24 Volts
–
24 VAC
6
4-7
COM
7
AC Wiring Examples
DC Wiring Examples
Push the connector onto the pins. Apply even pressure to both ends on the
connector.

Address Selection

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Figure 3: Field Wiring Examples
Figure 3: Field Wiring Examples shows wiring examples for both groups of four inputs on the 5403 and the first two groups of four inputs on the 5404.
The 5000 I/O bus will support a maximum of twenty I/O (input/output) modules. 5000 I/O module types may be combined in any manner to the maximum supported by the controller used. The types of input and output modules available are:
Digital Input modules  Digital Output modules
5403 and 5404 Digital Input Modules
Press this side to add switch value
Press this side to
ignore switch value
1
4
2
Address
0
1
421
421
421
421
421
421
4
2
How to Set Address Switches

Determine the module address.

Press the side of the switches shown in gray above.
Address
1
Address
2
Address
3
Address
4
Address
5
Address
6
Address
7
Analog Input modules  Analog Output modules  Counter Input modules
Each type of I/O module, connected to the I/O bus, has a unique I/O module address. Different types of I/O modules may have the same module address.
The address range supported by the SCADAPack controller module may restrict the I/O module address range. Refer to the controller manual for the maximum address supported.

5403 Address Selection

The three address switches labeled 1, 2, and 4 set the 5403 module address. To set the address:
Open the three switches by pressing down the left side of the switch. Close the switches that total to the desired address. Figure 4: Model 5403 Module Address Switches shows the switch settings for
each of the 8 module addresses.

5404 Address Selection

The four address switches labeled 1, 2, 4 and 8 set the module address. To set the address:
Open the four switches by pressing down the left side of the switch. Close the switches that total to the desired address. Figure 5: Model 5404 Module Address Switches shows the switch settings for
each of the 16 module addresses.
Figure 4: Model 5403 Module Address Switches
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5403 and 5404 Digital Input Modules
Press this side to add switch value
Press this side to
ignore switch value
Address
0
How to Set Address Switches
Determine the module address.
Press the side of the switches
shown in gray above.
Address
1
Address
2
Address
3
Address
4
Address
5
Address
6
Address
7
Address
8
Address
9
Address
10
Address
11
142814281428142
8
1
4
281428142814281
4
2
8
1
4
2
8
1
42814
2
8
Address
12
Address
13
Address
14
Address
15
1
4
2
8
1
4
2
8
1
42814
2
8
Figure 5: Model 5404 Module Address Switches
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5403 and 5404 Digital Input Modules
Conddition
Action
Input LED does not come on when input signal is applied.
Check the LED POWER from the controller module.
Check the input signal at the termination block. If this is a DC input, check the polarity of the
signal.

Operation and Maintenance

The 5403 and 5404 modules require no routine maintenance or calibration. If a module is not functioning correctly, contact Schneider Electric Technical Support for more information and instructions for returning the module for repair.

LED Indicators

The model 5403 and 5404 digital input modules have one red status LED per I/O point. This LED is on when the input is monitoring a voltage greater than the minimum rated input voltage.
The SCADAPack controller module, through the I/O bus, powers the LEDs. The LEDs can be disabled to conserve power. Refer to the communication controller or controller manual for more information.

Troubleshooting

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5403 and 5404 Digital Input Modules
Input Points
5403 – 8 5404 – 16
Over-voltage Tolerance
150% sustained over-voltage without damage
Input Current
5mA typical
Input Logic-HI Level
Off to on transition threshold is typically 50% of full scale signal range
Response Time
OFF to ON: 7ms typical ON to OFF: 24ms typical
Isolation
1500 VAC in groups of 4 inputs
Addressing
DIP switch configurable
5403 Power Requirements
5V @ 45mA all LEDs on 5V @ 5mA with LEDs disabled
5404 Power Requirements
5V @ 80mA all LEDs on 5V @ 25mA with LEDs disabled
Visual Indicators
5403 - 8 red LEDs 5404 – 16 red LEDs controlled by the controller for power reduction
Field Terminations
5403 – one 10 pole, removable terminal block 5404 – two 10 pole, removable terminal blocks 12-22 AWG 15 amp contacts
Dimensions
5403 - 4.25 inch (108mm) wide 5404 - 5.65 inch (144mm) wide
4.625 inch (118mm) high
1.75 inch (44mm) deep
Mounting
7.5 x 35 DIN rail
Packaging
Corrosion resistant zinc plated steel with black enamel paint
Environment
5% RH to 95% RH, non-condensing
–40oC to 60oC –40oF to 140oF

Specifications

Disclaimer: Schneider Electric reserves the right to change product
specifications. For more information, visit http://www.schneider-electric.com.
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5403 and 5404 Digital Input Modules
Module Type
Maximum AC/DC Input Voltage
Typical Input On Voltage DC
Typical Input On Voltage AC
5403/5404 - 240
240VACVDC
120VDC
100VAC
5403/5404 - 120
180VAC/DC
60VDC
50VAC
5403/5404 - 48
72 VAC/DC
24VDC
20VAC
5403/5404 - 24
36 VAC/DC
12VDC
10VAC
5403/5404 - 12
18 VAC/DC
6VDC
5VAC

Voltage Ranges

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5403 and 5404 Digital Input Modules
Safety
Non-Incendive Electrical Equipment for Use in Class I, Division 2 Groups A, B, C and D Hazardous Locations.
The 5403 is UL Listed to the following standards:
CSA Std. C22.2 No. 213-M1987 - Hazardous
Locations.
CSA Std. C22.2 No. 142-M1987 - Process Control
Equipment.
UL Std. No. 1604 - Hazardous (Classified) Locations.  UL Std. No. 508 - Industrial Control Equipment.
The 5404 is CSA certified to the requirements of:
CSA Std. C22.2 No. 213-M1987 - Hazardous
Locations.
CSA Std. C22.2 No. 142-M1987 - Process Control
Equipment.
UL Std. No. 1604 - Hazardous (Classified) Locations.  UL Std. No. 916 – Energy Management Equipment.
Digital Emissions
FCC Part 15, Subpart B, Class A Verification EN61000-6-4: Electromagnetic Compatibility Generic Emission
Standard Part2: Industrial Environment C-Tick compliance. Registration number N15744.
Immunity
EN61000-6-2: Electromagnetic Compatibility Generic Standards Immunity for Industrial Environments
Declaration
This product conforms to the above Emissions and Immunity Standards and therefore conforms with the requirements of Council Directive 2004/108/EEC (as amended) relating to electromagnetic compatibility and is eligible to bear the CE mark.
The Low Voltage Directive is not applicable to this product.

Approvals and Certifications

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