Spectrum Controls 140 MPM 204 00sc User Manual

Meter Proving ModuleMeter Proving Module
Meter Proving Module
Meter Proving ModuleMeter Proving Module
Cat. No. Quantum Automation Series 140 MPM 204 00sc - 4 Channel
Installation Instructions
Owners Guide 0300190-01 Rev. A
Meter Proving Module
Preface
Read this preface to familiarize yourself with the rest of the manual. This preface covers the following topics:
What this guide covers
Who should use this guide
Contents of the guide
Related publications
Conventions used in this guide
What this Guide CoversWhat this Guide Covers
What this Guide Covers
What this Guide CoversWhat this Guide Covers
This guide describes the hardware and firmware included in the 4- and 8-channel Quantum™ Counter/Flow Meter modules for the Schneider Automation Series Quantum PLC. The document contains the information required to install and wire, configure, use, and troubleshoot the modules.
Who Should Use This GuideWho Should Use This Guide
Who Should Use This Guide
Who Should Use This GuideWho Should Use This Guide
Use this guide if you install, configure, or maintain a control system that uses the module with a PLC. You should have a basic understanding of Quantum products. Additionally, you should understand electronic process control and the ladder program instructions required to generate the electronic control signals for the PLC. If you do not have these prerequisites, contact your local Schneider Alliance representative for the proper training before using this product.
Manual ContentsManual Contents
Manual Contents
Manual ContentsManual Contents
The table below lists the contents of this guide.
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ChapterChapter
Chapter
ChapterChapter
Chapter 1 An overview of the module Chapter 2 Installation and wiring guidelines Chapter 3 Instructions for configuring the module Chapter 4 Programming instructions Chapter 5 Information on module diagnostics and troubleshooting Appendix A Specifications for the module
DescriptionDescription
Description
DescriptionDescription
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Quantum Series 140 MPM 204 00sc
Related DocumentationRelated Documentation
Related Documentation
Related DocumentationRelated Documentation
The table below lists a number of reference documents that provide information to assist you when working with one of the Quantum counter modules.
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Document Document
Document
Document Document
Modicon Modsoft Programmer User Manual Schneider Electronics, 890 USE 115 00 Modicon TSX Quantum Automation Series Hardware Reference Guide Schneider Electronics, 840 USE 100 00 Guide for the Installation of Electrical Noise Inputs to Controllers from External Sources IEEE Std. 518- 1977 Recommended Practice for Grounding of Industrial and Commercial Power Systems IEEE Std. 142- 1982 Noise Reduction Techniques in Electronic Systems Henry W. Ott; published by Wiley-Interscience of New York, 1976
Conventions Used in This ManualConventions Used in This Manual
Conventions Used in This Manual
Conventions Used in This ManualConventions Used in This Manual
The following conventions are used throughout this manual:
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Numbered lists provide sequential steps or hierarchical information.
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OverviewOverview
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OverviewOverview General DescriptionGeneral Description
General Description
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Installation and Installation and
Installation and
Installation and Installation and Compliance with Safety StandardsCompliance with Safety Standards
Compliance with Safety Standards
Compliance with Safety StandardsCompliance with Safety Standards PowerPower
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Installation ConsiderationsInstallation Considerations
Installation Considerations
Installation ConsiderationsInstallation Considerations Module InstallationModule Installation
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Module ConfigurationModule Configuration
Module Configuration
Module ConfigurationModule Configuration Module Module
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Module Module Setting Up the Configuration SoftwarSetting Up the Configuration Softwar
Setting Up the Configuration Softwar
Setting Up the Configuration SoftwarSetting Up the Configuration Softwar Making Bit Settings for Zoom RegistersMaking Bit Settings for Zoom Registers
Making Bit Settings for Zoom Registers
Making Bit Settings for Zoom RegistersMaking Bit Settings for Zoom Registers Bit Settings for 3X RegistersBit Settings for 3X Registers
Bit Settings for 3X Registers
Bit Settings for 3X RegistersBit Settings for 3X Registers
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Maintenance and DiagnosticsMaintenance and Diagnostics
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Maintenance and DiagnosticsMaintenance and Diagnostics Safety ConsiderationsSafety Considerations
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eventive Maintenanceeventive Maintenance
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SpecificationsSpecifications
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SpecificationsSpecifications EnvirEnvir
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Electrical SpecificationsElectrical Specifications
Electrical Specifications
Electrical SpecificationsElectrical Specifications
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Meter Proving Module
1 1
ChapterChapter
1
Chapter
ChapterChapter
1 1
OverviewOverview
Overview
OverviewOverview
This chapter describes the 4-channel Quantum Meter Proving Module (called “MPM ” in this document). It also explains how the Schneider Automation Series Quantum PLC reads input data from a Quantum module.
Shipped with your module is an MS-DOS formatted floppy disk titled “Quantum Runtime Files,” Spectrum Controls, Inc. The disk contains runtime files that are required to use all versions of this module. Files include an ID file, parameter screen software, help file, and multiplexing software examples for 4X and 3X register use.
NOTENOTE
NOTE The module is used with a field wiring terminal block, Modicon 140 XTS 002 00 or 140
NOTENOTE
CFA040 00 40-pin cablefast. Either of these must be ordered separately.
Included in this chapter is information about:
General description
Hardware features
Overview of module
System operation
General DescriptionGeneral Description
General Description
General DescriptionGeneral Description
The Quantum MPM module is designed for flow meter applications that require specialty features such as pulse fidelity checking and pulse interpolation for short run prover testing. It supports both AC and DC input signals from flow meters. The module conditions the inputs to standard digital levels. It stores the converted data in its image table for retrieval by any Quantum PLC.
The module communicates with the PLC and receives its power through the PLC backplane from the +5VDC rack power supplies. No external power supply is required.
Your MPM supports connections from any combination of flow meter devices, with different input voltage ranges. Each channel is individually configurable via software for a specific input device and provides rate and limit detection. Flow mode and input range are configured in two channel groups.
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Quantum Series 140 MPM 204 00sc
Meter Input ModesMeter Input Modes
Meter Input Modes
Meter Input ModesMeter Input Modes
The flow meter mode is compatible with a variable reluctance AC input, which counts AC zero crossing signals from 50 mV to 75V AC peak.
The module accepts +5 to +45 V gating (enable) pulses for standard meter proving applications. This module does perform pulse interpolation for meter proving allowing short run prover verification.
The module also has external inhibit/trigger lines using a 5V discrete pulse to regulate activity.
Module FeaturesModule Features
Module Features
Module FeaturesModule Features
The Quantum counter module features:
Four input channels
Four redundant input channels for pulse fidelity checking
(API Level B, phase, sequence, count, frequency monitoring)
Four external enable inputs
Double Chronometry Pulse Interpolation which allows 4 decimal places of resolution.
Four gating (enable) pulses for meter proving
Input filter frequency 50 kHz max., AC or DC
Maximum count value 65 K or 16 M
Programmable scaling, K, M, and R factors
Channel update time 1 ms/channel
Rate output with programmable timeout allowing low frequency measurement
Meter logic level state
Programmable counter alarm flags and rate operating modes
Two software-selectable filters: 30 or 50 kHz digital, 15 kHz analog
Channel-to-backplane isolation 1000VDC
Channel-to-channel isolation 0 V
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Meter Proving Module
Hardware FeaturesHardware Features
Hardware Features
Hardware FeaturesHardware Features
The Quantum counter module contains a removable Modicon 40-pin terminal block providing connections for up to eight input devices. The illustration below shows the hardware features of the module.
The module supports these input types:
AC (50 mV to 75V peak)
5VDC
12VDC
24VDC
Both rate and count data are simultaneously available to the user. User selectable instantaneous or average rate modes are supported.
For improved noise reduction, the module has a digital filter that is selectable between 50 kHz and 30 kHz. A selectable analog 15 kHz single-pole filter is also available for low speed applications.
Module configuration is stored in the PLC memory. Normally configuration uses ModSoft, Concept, Fast-Track, and ProWorks programming software. Details are provided in chapter 3, “Module Configuration.”
Counter ModeCounter Mode
Counter Mode
Counter ModeCounter Mode
The counter functions of the module include programmable control of the counter, including start, stop, reset, and user-defined flags. The module makes the state of input counter levels available to the PLC, allowing any channel to be used as a discrete input.
The module has an onboard timer that converts counter inputs into a rate output. Both counter total and calculated input rate are made available to the PLC at the same time. The maximum filter frequency for an input signal is 50 kHz.
The counter supports the following input K, M, R scale factors:
“K” used for range scaling; programmable for each channel. ( Count = Raw count / K )
“M” used for meter calibration. ( Count = raw count * M / 10,000, Rate = raw rate * M/10,000 )
“R” used to scale the rate output. ( Rate = Raw Rate / R * M/10,000 )
In counter mode, the module updates normal at 1 ms/channel. The counter accumulator output is available in two ranges. The maximum count total for the normal range is 65 K. The extended range uses two data words per channel and counts up to 16 M.
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Quantum Series 140 MPM 204 00sc
HardwarHardwar
Hardwar
HardwarHardwar
Door (removable) Covers the terminal block and includes an identification label for terminals. Door label Permits easy terminal identification. LED indicators Display operating and fault status of module.
Side label (nameplate) Provides module identification. Self-locking tabs Secure module in rack slot. Terminal block Used for field wiring the module.
Diagnostic LEDsDiagnostic LEDs
Diagnostic LEDs
Diagnostic LEDsDiagnostic LEDs
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DescriptionDescription
Description
DescriptionDescription
Details are provided in “
Diagnostic LEDsDiagnostic LEDs
Diagnostic LEDs”.
Diagnostic LEDsDiagnostic LEDs
The module supports the LEDs listed in table 1-1 . These LEDs help you identify the source of problems that can occur during power-up or during normal operation. Power-up and operation diagnostics are explained in chapter 5, “Maintenance and Diagnostics.”
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LED NameLED Name
LED Name
LED NameLED Name
Ready (Module Status) Green On Module powered up and functioning normally.
Active Green On Bus communication is established between module and PLC.
Fault Red On Module self-test error or fatal hardware error. LED blinks to
Channel Status (8 LEDs) Green On Channel is enabled and a valid input signal is present. The
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ColorColor
Color
ColorColor
StateState
State
StateState
Off Module is not powered up.
Off No bus communication.
Blinking Type of self-test error. Count the number of blinks before a
State DescriptionState Description
State Description
State DescriptionState Description
indicate type of self-test error.
pause to determine the error code. Possible codes are listed in the table below.
LED indicates the state of the counter enable bit. It does not indicate the state of an external hardware gate. See description of the counter enable bit in chapter 3, “Module Configuration.”
Code (Number Code (Number
Code (Number
Code (Number Code (Number
On Solid No Faults 1 Frequency Limit Out of Range. 2 Not applicable 3 Not applicable 4 Channel Pair Gate Enable Configuration Mismatch. 5 Quadrature Pair Configuration Mismatch. 6 Not applicable 7 Not applicable 8 Unrecognized parameter type.
of Blinks)of Blinks)
of Blinks)
of Blinks)of Blinks)
ErrErr
Err
ErrErr
oror
or
oror
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ype
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ypeype
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able 1-3 Blink Codes forable 1-3 Blink Codes for
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Fault LED Fault LED
Fault LED
Fault LED Fault LED
Meter Proving Module
Code (Number Code (Number
Code (Number
Code (Number Code (Number
Off No Faults 1 Dual Port RAM fault. 2 FPGA init fault. 3 FPGA1 program fault. 4 FPGA2 program fault. 5 FPGA1 fault. 6 FPGA2 Fault. 7 Watchdog Fault. 8 ROM CRC fault. 9 EEPROM fault. 10 Both Speed mode and Autosequence mode selected
Recommended CablesRecommended Cables
Recommended Cables
Recommended CablesRecommended Cables
of Blinks)of Blinks)
of Blinks)
of Blinks)of Blinks)
ErrErr
oror
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or
oror
ypeype
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ype
TT
ypeype
Err
ErrErr
(Mutually exclusive)
To minimize interference from radiated electrical noise, we recommend twisted-pair and shielded cables.
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Quantum Series 140 MPM 204 00sc
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Meter Proving Module
2 2
ChapterChapter
2
Chapter
ChapterChapter
2 2
Installation and WInstallation and W
Installation and W
Installation and WInstallation and W
This chapter includes information about:
Module compliance with safety standards
Power requirements
Installation considerations, such as prevention of electrostatic discharge
Installing the module
Field wiring of the module and analog input devices
Compliance with Safety StandardsCompliance with Safety Standards
Compliance with Safety Standards
Compliance with Safety StandardsCompliance with Safety Standards
The module is compliant with the safety standards described in this section. It is intended for use in an industrial environment. The product has been approved for installation within the European Union and EEA regions.
iringiring
iring
iringiring
UL and CUL Safety StandardsUL and CUL Safety Standards
UL and CUL Safety Standards
UL and CUL Safety StandardsUL and CUL Safety Standards
The module complies with UL and CSA safety requirements and is certified to the applicable standards, as described in appendix A.
EMC DirectiveEMC Directive
EMC Directive
EMC DirectiveEMC Directive
The module has been tested to meet Council Directive 89/336/EEC Electromagnetic Compatibility (EMC) and the following standards, in whole or in part, documented in a technical construction file:
EN 50081-2
EMC - Generic Emission Standard, Part 2 - Industrial Environment
EN 50082-2
EMC - Generic Immunity Standard, Part 2 - Industrial Environment
EN 61000-3-2
Quasi-Stationary Current Harmonics
EN 61000-3-3
Voltage Fluctuation and Flicker
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Quantum Series 140 MPM 204 00sc
Low VLow V
Low V
Low VLow V
This product is tested to meet Council Directive 73/23/EEC Low Voltage, since it operates with inputs under 75 VDC and 50VAC rms. It applies the safety requirements of EN 61131-2 Programmable Controllers, Part 2 – Equipment Requirements and Tests. For specific information required by EN 61131-2, see the appropriate sections in this publication.
Power RequirementsPower Requirements
Power Requirements
Power RequirementsPower Requirements
The module receives power through the PLC backplane from the +5VDC power supply. The maximum current drawn for the module is 670mA.
Installation ConsiderationsInstallation Considerations
Installation Considerations
Installation ConsiderationsInstallation Considerations
This section describes several considerations to keep in mind when installing the module in a PLC system. The following documents contain information that might help you as you install and wire the module:
oltage Directiveoltage Directive
oltage Directive
oltage Directiveoltage Directive
National Electrical Code
, published by the National Fire Protection Association, Boston, MA
IEEE Standard 518-1977,
Noise Inputs to Controllers from External Sources
IEEE Standard 142-1982,
Systems
Noise Reduction Techniques in Electronic Systems
New York, 1976
Preventing Electrostatic DischargePreventing Electrostatic Discharge
Preventing Electrostatic Discharge
Preventing Electrostatic DischargePreventing Electrostatic Discharge
CAUTION: CAUTION:
CAUTION: Electrostatic discharge can damage integrated circuits or semiconductors if you
CAUTION: CAUTION:
touch module bus connector pins. Substitution of components may impair suitability for Class 1, Division 2.
To prevent electrostatic discharge, follow these guidelines when you handle the module:
Touch a grounded object to discharge static potential.
Wear an approved wrist strap grounding device.
Do not touch the backplane connector or connector pins.
Do not touch circuit components inside the module.
Guide for the Installation of Electrical Equipment to Minimize Electrical
Recommended Practices for Grounding of Industrial and Commercial Power
, by Henry W. Ott; published by Wiley-Interscience,
If available, use a static-safe work station.
When it is not in use, keep the module in its static-shield box.
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Meter Proving Module
Reducing NoiseReducing Noise
Reducing Noise
Reducing NoiseReducing Noise
Most applications require installation in an industrial enclosure to reduce the effects of electrical interference. Electrical noise, to which analog inputs and outputs are highly susceptible, will reduce the performance (accuracy) of the module.
Selecting a LocationSelecting a Location
Selecting a Location
Selecting a LocationSelecting a Location
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ARNING
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2, Groups A, B, C, D or nonhazardous locations only. Substitution of components may impair suitability for Class I, Division 2. Do not replace, connect, or disconnect components unless power has been switched off or the area is known to be nonhazardous. This product must be installed in an enclosure. All wiring must comply with N.E.C. article 501-4(b).
Two factors determine where to install the module in the PLC rack: ambient temperature and electrical noise. Place the module:
EXPLOSION HAZARDEXPLOSION HAZARD
EXPLOSION HAZARD This equipment is suitable for use in Class I, Division
EXPLOSION HAZARDEXPLOSION HAZARD
Close to the bottom of the enclosure to take advantage of cooler air.
Away from modules that generate significant heat, such as 32-point I/ O modules.
In a slot away from AC or high-voltage DC modules, hard contact switches, relays, and AC motor
drives.
Away from the rack power supply (if installing a modular controller system).
Protecting Circuit Boards from ContaminationProtecting Circuit Boards from Contamination
Protecting Circuit Boards from Contamination
Protecting Circuit Boards from ContaminationProtecting Circuit Boards from Contamination
The printed circuit boards of the module must be protected from dirt, oil, moisture, and other airborne contaminants. Ensure that the module is kept in an enclosure at all times. The interior of the enclosure should be kept clean and the enclosure door should be kept closed whenever possible.
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iringiring
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iring
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iringiring
For UL and CUL compliance, power and input/output wiring must be in accordance with Class 1,
Division 2 wiring methods (Article 501-4(b) of the National Electrical Code, NFPA 70) and in accordance with the authority having jurisdiction.
Channels are isolated from one another.
Route field wiring away from any other wiring and as far as possible from sources of electrical noise,
such as motors, transformers, contactors, and ac devices. As a general rule, allow at least 15.2 cm (6 in.) of separation for every 120V of power.
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Quantum Series 140 MPM 204 00sc
Routing field wiring in a grounded conduit can reduce electrical noise.
If field wiring must cross AC or power cables, ensure that they cross at right angles.
If multiple power supplies are used with analog inputs, the power supply commons must be connected.
To ensure optimal accuracy, limit overall cable impedance by keeping a cable as short as possible.
Locate the module as close to input devices as the application permits.
Tighten terminal screws with care. Excessive tightening can strip a screw.
The module is generally mounted to a well grounded mounting surface, such as a metal panel.
Additional grounding connections from the module’s mounting tabs or DIN rail (if used) are not required unless the mounting surface cannot be grounded. Keep shield connection to ground as short as possible.
Under normal conditions, the drain wire and shield junction should be connected to earth ground, via a
panel or mounting screw at the module end. Refer to IEEE Std. 518, Section 6.4.2.7 or contact the sensor manufacturer for additional details.
For field wiring, use shielded, twisted-pair cable, and ground each cable’s shield wire at one end only.
At the opposite end of each cable, tape the exposed shield wire to insulate it from electrical contact. A good shield wire ground is a rack assembly mounting bolt or stud.
In the process of wiring the modules, route all signal wires as far as possible from potential sources of
electrical noise, such as motors, transformers, etc. (especially AC devices).
If noise persists for a device, try grounding the opposite end of the cable. (You can only ground one
end at a time.)
Module InstallationModule Installation
Module Installation
Module InstallationModule Installation
This section tells how to insert the module in the PLC rack and remove it as needed. The Quantum counter module is suitable for use in an industrial environment when installed in accordance with these instructions. Specifically, this equipment is intended for use in clean, dry environments (Pollution Degree 2) and for circuits not exceeding Over Voltage Category II (IEC 60664-1).
Installing the TInstalling the T
Installing the T
Installing the TInstalling the T
erminal Blockerminal Block
erminal Block
erminal Blockerminal Block
To install the terminal block:
1.1.
1. Gently insert the terminal block into the module housing.
1.1.
2.2.
2. Install the upper and lower retaining screws, using 0.46 Nm (4.1 in-lb) torque.
2.2.
3.3.
3. Use the write-on label located on the door of the module to identify the module location and type.
3.3.
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Meter Proving Module
Inserting the Module in the PLC RackInserting the Module in the PLC Rack
Inserting the Module in the PLC Rack
Inserting the Module in the PLC RackInserting the Module in the PLC Rack
Do the following to place the module in the PLC rack:
1.1.
1. Ensure that the rack is properly grounded and installed in a NEMA-rated enclosure.
1.1.
2. Disconnect all power to the module, and disconnect it from any connected devices. See “ Removing Power.”
WW
ARNINGARNING
W
ARNING Installation or removal of the module with power applied can cause an electrical
WW
ARNINGARNING
arc. An arc can cause personal injury or property damage by sending an erroneous signal to your system’s field devices. This signal can result in unintended machine motion, an explosion in a hazardous environment, or excessive wear to contacts on both the module and its mating connector (possibly leading to premature failure).
3.3.
3. Align the module with the top of the rack. slot.
3.3.
4.4.
4. Slide the module into the slot until both top and bottom are secure.
4.4.
5.5.
5. Apply firm, even pressure to the module to attach its backplane connector to the PLC bus connector.
5.5.
Never force the module into the slot.
6.6.
6. Tighten the module screws that hold the module to the rack..
6.6.
7.7.
7. Align the terminal block to the module in gently press until it is properly seated.
7.7.
Removing the ModuleRemoving the Module
Removing the Module
Removing the ModuleRemoving the Module
To remove the module from the PLC rack:
1. Disconnect all power to the module, and disconnect it from any connected devices. See “Removing Power.”
2. Gently slide the module out of the rack slot.
WW
ARNINGARNING
W
ARNING Installation or removal of the module with power applied can cause an electrical arc. An arc can
WW
ARNINGARNING
cause personal injury or property damage by sending an erroneous signal to your system’s field devices. This signal can result in unintended machine motion, an explosion in a hazardous environment, or excessive wear to contacts on both the module and its mating connector (possibly leading to premature failure).
Field WField W
Field W
Field WField W
This section provides instructions for field wiring the installed module. You will need:
iringiring
iring
iringiring
A small flat-head screwdriver
Belden 8761 (shielded, twisted pair) cable or equivalent
WW
iringiring
W
See “
iring” for wiring guidelines to keep in mind during field wiring of the module.
WW
iringiring
19
Quantum Series 140 MPM 204 00sc
Removing and Replacing the TRemoving and Replacing the T
Removing and Replacing the T
Removing and Replacing the TRemoving and Replacing the T
When wiring the module, it is not necessary to remove the terminal block. However, if necessary, you can use this procedure for removal and replacement.
1.1.
1. Loosen the upper and lower retaining screws, alternating between screws. The terminal block backs
1.1.
away from the module as you remove the screws.
2.2.
2. Carefully pry the terminal block loose.
2.2.
3.3.
3. When ready to replace the terminal block, insert and tighten the retaining screws. Torque the retaining
3.3.
screws to 0.46 Nm (4.1 in-lb).
erminal Blockerminal Block
erminal Block
erminal Blockerminal Block
20
Meter Proving Module
WW
iring the Tiring the T
W
iring the T
WW
iring the Tiring the T
The module terminal block has eight shield terminals provided as frame ground connections for input wire shielding. There are 8 counter enable lines that are compatible with 5, 12, and 24 VDC inputs. If pulled low with one of these inputs, a channel is disabled. The enable is internally pulled high.
erminal Blockerminal Block
erminal Block
erminal Blockerminal Block
21
Quantum Series 140 MPM 204 00sc
Channel 2 Hi Pin 2
Channel 2 Lo Pin 4
Channel 2 Shield Pin 6
Channel 2 Enable Pin 8
N/C Pin 10
Channel 2 Gate Hi Pin 12
Channel2 Gate Lo Pin 14
Shield Pin 16
N/C Pin 18
N/C Pin 20
Channel 4 Hi Pin 22
Channel 4 Lo Pin 24
Channel 4 Shield Pin 26
Channel 4 Enable Pin 28
N/C Pin 30
Channel 4 Gate Hi Pin 32
Channel 4 Gate Lo Pin 34
Channel 4 Shield Pin 36
N/C Pin 38
N/C Pin 40
Pin 1 Channel 1 Hi
Pin 3 Channel 1 Lo
Pin 5 Channel 1 Shield
Pin 7 Channel 1 Enable
Pin 9 N/C
Pin 11 Channel 1 Gate Hi
Pin 13 Channel 1 Gate Lo
Pin 15 Shield
Pin 17 N/C
Pin 19 N/C
Pin 21 Channel 3 Hi
Pin 23 Channel 3 Lo
Pin 25 Channel 3 Shield
Pin 27 Channel 3 Enable
Pin 29 N/C
Pin 31 Channel 3 Gate Hi
Pin 33 Channel 3 Gate Lo
Pin 35 Channel 3 Shield
Pin 37 N/C
Pin 39 N/C
Each terminal accepts up to two wires, with the restrictions noted in the following table (for shielded, twisted-pair cable).
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