Maxpac - B7

maxPAC Hardware
Reference Guide
278596 Rev. B7
Refer to this publication for complete and accurate information that helps you better operate and service Metso
Automation equipment. Your comments and suggestions are welcome.
Metso
1180 Church Road
Lansdale, PA 19446
Attention: Manager, Technical Publications
Copyright © 2013 by Metso Automation USA Inc.

Printed in the United States of America
All Rights Reserved
Metso Automation  278596 

Contents
PREFACE ............................................................................................................................III
CHAPTER 1 ...................................................................................................................... 1-1
maxPAC Input/Output Subsystem ............................................................................................................................. 1-1

Overview.................................................................................................................................................................... 1-1
Model IOP I/O Subsystem ..................................................................................................................................... 1-1
Cabinet ............................................................................................................................................................... 1-1
Chassis Assembly .............................................................................................................................................. 1-2
DPU Mounting................................................................................................................................................... 1-4
I/O Modules ....................................................................................................................................................... 1-4
I/O Module Types .............................................................................................................................................. 1-5
Power Supply ......................................................................................................................................................... 1-6
Field Termination Options ..................................................................................................................................... 1-7
Local Terminations (standard) ........................................................................................................................... 1-7
Remote Terminations (option) ........................................................................................................................... 1-7
Termination Assemblies .................................................................................................................................... 1-8
Installing Model IOP I/O Equipment ..................................................................................................................... 1-8
Sequence of Mounting Operations ......................................................................................................................... 1-8
Mounting I/O Chassis Assemblies ......................................................................................................................... 1-9
Cabling, Power, and Ground Wiring ................................................................................................................... 1-10
Supplying 24V Power to the I/O Modules ....................................................................................................... 1-10
Interconnecting I/O Racks ............................................................................................................................... 1-10
Summary of Cabling Rules for maxPAC I/O ................................................................................................... 1-14
maxPAC I/O Bus Cables.................................................................................................................................. 1-14
Module Mounting Considerations ....................................................................................................................... 1-16
I/O Modules ..................................................................................................................................................... 1-16
DPU Modules .................................................................................................................................................. 1-16
Module Addressing .............................................................................................................................................. 1-17
Backup Configuration Options ............................................................................................................................ 1-18
Shared Configuration ....................................................................................................................................... 1-18
Redundant Configuration ................................................................................................................................. 1-18
Mixed Configuration ........................................................................................................................................ 1-19
Remote I/O........................................................................................................................................................... 1-20
Specifications ....................................................................................................................................................... 1-22
Environment..................................................................................................................................................... 1-22
I/O Bus ............................................................................................................................................................. 1-22
Inputs/Outputs .................................................................................................................................................. 1-22
CHAPTER 2 ...................................................................................................................... 2-1
Analog Input Modules Isolated Input Module IOP301 ............................................................................................ 2-1

maxPAC Hardware Reference Guide
Overview....................................................................................................................................................................2-1
LED Indication ......................................................................................................................................................2-1
Bus Address ...........................................................................................................................................................2-2
Jumper Configuration ............................................................................................................................................2-2
Program Resistors ..................................................................................................................................................2-2
Module Operation ..................................................................................................................................................2-4
Diagnostics.............................................................................................................................................................2-5
Module specifications ............................................................................................................................................2-6
Field Wiring ...........................................................................................................................................................2-7
Field Wiring for Redundant Modules with Common Transmitter .........................................................................2-8
CHAPTER 3 ...................................................................................................................... 3-1
Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305.................................... 3-1
Overview....................................................................................................................................................................3-1
LED Indication ......................................................................................................................................................3-1
Bus Address ...........................................................................................................................................................3-2
Diagnostics.............................................................................................................................................................3-4
Module Specifications ...........................................................................................................................................3-4
Field Wiring for IOP302 ........................................................................................................................................3-5
Field Wiring – IOP 305 Analog Input Module ......................................................................................................3-6
Field Wiring For Redundant Modules with Common Transmitter ........................................................................3-7
CHAPTER 4 ...................................................................................................................... 4-1
Analog Input Modules 3 Wire RTD Module IOP303 .............................................................................................. 4-1

Overview....................................................................................................................................................................4-1
LED Indication ......................................................................................................................................................4-1
Bus Address ...........................................................................................................................................................4-2
Diagnostics.............................................................................................................................................................4-4
Field Wiring ...........................................................................................................................................................4-6
Field Wiring For Redundant Modules with Common RTD ...................................................................................4-7
CHAPTER 5 ...................................................................................................................... 5-1
Analog Input Modules TC Module IOP304 ............................................................................................................. 5-1

Overview....................................................................................................................................................................5-1
LED Indication ......................................................................................................................................................5-1
Bus Address ...........................................................................................................................................................5-2
Cold Junction Compensation .................................................................................................................................5-2
Diagnostics.............................................................................................................................................................5-3
Field Wiring ...........................................................................................................................................................5-5
Field Wiring For Redundant Modules with Common TC ......................................................................................5-6

Contents
CHAPTER 6 ...................................................................................................................... 6-1
Analog Output Modules 4-20 mA Output Module IOP320 .....................................................................................6-1
4-20 mA Isolated Output Module IOP321 .................................................................................................................6-1

LED Indication ...................................................................................................................................................... 6-1
Bus Address ........................................................................................................................................................... 6-2
Jumper Configuration ............................................................................................................................................ 6-2
Module Operation .................................................................................................................................................. 6-3
Diagnostics ............................................................................................................................................................ 6-5
Module Specifications ........................................................................................................................................... 6-5
Field Wiring ........................................................................................................................................................... 6-6
Field wiring for redundant modules with common end element ............................................................................ 6-7
CHAPTER 7 ...................................................................................................................... 7-1
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331 ...................7-1
Overview.................................................................................................................................................................... 7-1
LED Indication ...................................................................................................................................................... 7-1
Bus Address ........................................................................................................................................................... 7-2
Module specifications ............................................................................................................................................ 7-3
Field Wiring ........................................................................................................................................................... 7-4
Field Wiring For Redundant Modules with Common DI ....................................................................................... 7-5
CHAPTER 8 ...................................................................................................................... 8-1
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332
240V AC/DC Isolated Input Module IOP333 ............................................................................................................8-1
Overview.................................................................................................................................................................... 8-1
LED Indication ...................................................................................................................................................... 8-1
Bus Address ........................................................................................................................................................... 8-2
Module Specifications ........................................................................................................................................... 8-3
Field Wiring ........................................................................................................................................................... 8-4
Field Wiring For Redundant Modules with Isolated DI ......................................................................................... 8-5
CHAPTER 9 ...................................................................................................................... 9-1
Digital Input Modules Counter Timer Module IOP335 ........................................................................................... 9-1

LED Indication ...................................................................................................................................................... 9-1
Bus Address ........................................................................................................................................................... 9-2
Diagnostics ............................................................................................................................................................ 9-4
Module specifications ............................................................................................................................................ 9-4
Field Wiring ........................................................................................................................................................... 9-5
CHAPTER 10 .................................................................................................................. 10-1
v
Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350 Relay Driver Module
IOP353 ....................................................................................................................................................................... 10-1
Overview..................................................................................................................................................................10-1
LED Indication ....................................................................................................................................................10-2
Bus Address .........................................................................................................................................................10-2
Jumper Configuration ..........................................................................................................................................10-2
Module Operation ................................................................................................................................................10-3
Module Specifications .........................................................................................................................................10-5
Field Wiring – IOP 351 (Form A/B Relay Module) ............................................................................................10-6
Wiring – IOP350 (Form C Relay Module) ..........................................................................................................10-7
Field Wiring – IOP 353 (Relay Driver Module) ..................................................................................................10-8
Field Wiring For Redundant Modules with Common End Element ....................................................................10-9
CHAPTER 11 .................................................................................................................. 11-1
Bus Extender Module Module IOP371 .................................................................................................................. 11-1

Overview..................................................................................................................................................................11-1
BEM Front Panel .............................................................................................................................................11-2
Link Fail Relay.................................................................................................................................................11-2
LED Indications ...............................................................................................................................................11-2
Link Test ..........................................................................................................................................................11-2
Bus Address .....................................................................................................................................................11-2
Jumper Configuration.......................................................................................................................................11-2
DPU Compatibility ..........................................................................................................................................11-3
I/O Bus Loading ...............................................................................................................................................11-3
Optical Cabling ................................................................................................................................................11-3
Model 564 and maxPAC I/O Compatibility.....................................................................................................11-4
Termination Requirements ...............................................................................................................................11-4
Non Redundant BEM Configuration Approaches ................................................................................................11-5
Redundant BEM Configuration Approaches – Three types .................................................................................11-6
Configuring Local Redundant I/O and Remote Common I/O ..........................................................................11-7
Configuring Local Redundant I/O and Remote Redundant I/O .......................................................................11-7
Configuring Local and Remote Common I/O ..................................................................................................11-7
BEM Configuration Considerations ...................................................................................................................11-11
Calculating Link Capacities ...........................................................................................................................11-11
Ensuring Link Availability .................................................................................................................................11-11
Detecting Failover Conditions .......................................................................................................................11-12
Cabling Recommendations ............................................................................................................................11-12
BEM Operation ..................................................................................................................................................11-13
Specifications .....................................................................................................................................................11-15
CHAPTER 12 .................................................................................................................. 12-1
QuadPAT Module IOP336 ..................................................................................................................................... 12-1
QuadPAT Termination Module IOP337 ............................................................................................................... 12-1

Overview..................................................................................................................................................................12-1
Front Panel .......................................................................................................................................................12-2
LED Indication ....................................................................................................................................................12-2
Bus Address .........................................................................................................................................................12-4
DPU Compatibility ..............................................................................................................................................12-4

Contents
QuadPAT Termination .................................................................................................................................... 12-5

Feedback Options ................................................................................................................................................ 12-6
Output Options..................................................................................................................................................... 12-6
Limit Switch Detection ........................................................................................................................................ 12-6
Redundant Configuration ..................................................................................................................................... 12-7
Diagnostics .......................................................................................................................................................... 12-8
Module Field Connections ................................................................................................................................... 12-9
Termination Field Connections Channels 1-2 .................................................................................................... 12-10
Termination Field Connections Channels 3-4 .................................................................................................... 12-11
Group1 Analog I/O Configuration ..................................................................................................................... 12-12
Digital I/O Configuration Channels 1-2 ............................................................................................................. 12-14
Digital I/O Configuration Channels 3-4 ............................................................................................................. 12-15
Digital I/O Configuration - DC Power Switches ................................................................................................ 12-16
Specifications ..................................................................................................................................................... 12-17
CHAPTER 13 .................................................................................................................. 13-1
Turbine Valve Positioner Module IOP341 .............................................................................................................13-1
Turbine Valve Termination Module IOP342 .........................................................................................................13-1

Overview.................................................................................................................................................................. 13-1
Positioner Front Panel.......................................................................................................................................... 13-2
LED Indication .................................................................................................................................................... 13-3
Jumper Configuration .......................................................................................................................................... 13-4
Bus Address ......................................................................................................................................................... 13-6
DPU Compatibility .............................................................................................................................................. 13-6
Module Operation ................................................................................................................................................ 13-6
Turbine Valve Termination.............................................................................................................................. 13-8
Configuration ....................................................................................................................................................... 13-8
Calibration ........................................................................................................................................................... 13-8
Diagnostics .......................................................................................................................................................... 13-9
Module Field Connections ................................................................................................................................. 13-11
Termination Field Connections .......................................................................................................................... 13-12
Digital I/O Configuration ................................................................................................................................... 13-15
Specifications ..................................................................................................................................................... 13-16
CHAPTER 14 .................................................................................................................. 14-1
Overspeed Trip Module IOP345 ............................................................................................................................. 14-1
Overspeed Termination Module IOP346 ................................................................................................................14-1

Overview.................................................................................................................................................................. 14-1
Overspeed Front Panel ..................................................................................................................................... 14-2
LED Indication .................................................................................................................................................... 14-2
Bus Address ......................................................................................................................................................... 14-5
DPU Compatibility .............................................................................................................................................. 14-5
Overspeed Trip Termination ............................................................................................................................ 14-6
Diagnostics .......................................................................................................................................................... 14-7
vii
Module Field Connections ...................................................................................................................................14-8

Termination Field Connections ............................................................................................................................14-9
Group1 Analog I/O Configuration .....................................................................................................................14-12
Group2 Analog I/O Configuration .....................................................................................................................14-13
Digital I/O Configuration ...................................................................................................................................14-14
Specifications .....................................................................................................................................................14-15
CHAPTER 15 .................................................................................................................. 15-1
HART 8 Channel Input Module IOP307 ................................................................................................................ 15-1
HART 16 Channel Input Module IOP308 .............................................................................................................. 15-1
HART Output Module IOP322 ............................................................................................................................... 15-1
HART Transceiver Module IOP364 ....................................................................................................................... 15-1

Overview..................................................................................................................................................................15-1
LED Indication ....................................................................................................................................................15-2
Bus Address .........................................................................................................................................................15-3
Diagnostics...........................................................................................................................................................15-4
HART 8-Channel Input Field Connections ..........................................................................................................15-5
HART 16-Channel Input Field Connections ........................................................................................................15-6
HART Analog Output ..........................................................................................................................................15-7
HART Transceiver Field Connections .................................................................................................................15-8
Transceiver to Analog Input Wiring ....................................................................................................................15-9
Transceiver to Analog Input Wiring ..................................................................................................................15-10
Transceiver to Output Driver Wiring .................................................................................................................15-13
Transceiver to Analog Output Wiring ................................................................................................................15-14
HART 8-channel Analog Input Wiring ..............................................................................................................15-15
HART 16-channel Analog Input Wiring ............................................................................................................15-19
HART Analog Output Wiring ............................................................................................................................15-22
Specifications .....................................................................................................................................................15-24
CHAPTER 16 .................................................................................................................. 16-1
Serial Communications Module IOP365................................................................................................................. 16-1
Serial Termination Assembly ITP201 ..................................................................................................................... 16-1

Overview..................................................................................................................................................................16-1
LED Indication ....................................................................................................................................................16-1
Bus Address .........................................................................................................................................................16-2

Contents

Termination Assembly Operation ........................................................................................................................ 16-3
Diagnostics .......................................................................................................................................................... 16-4
Serial Communications Module Field Connections ............................................................................................. 16-5
Termination Assembly Input Connections ........................................................................................................... 16-6
Termination Assembly Output Connections ........................................................................................................ 16-7
Redundant Modules ............................................................................................................................................. 16-7
Specifications ....................................................................................................................................................... 16-8
CHAPTER 17 .................................................................................................................. 17-1
I-module CPO403 ......................................................................................................................................................17-1

Overview.................................................................................................................................................................. 17-1
LED Indications ................................................................................................................................................... 17-3
Bus Address ......................................................................................................................................................... 17-4
Compatibility ....................................................................................................................................................... 17-4
Mounting.............................................................................................................................................................. 17-6
Cabling................................................................................................................................................................. 17-6
Specifications ....................................................................................................................................................... 17-8
ix
Preface
This publication, which describes the installation and operation of maxPAC,

assumes familiarity with the DPU and its configuration. For additional
information on related topics, refer to the following publications:
Book No. Book Title

278590 Model PDP Series 200 maxDPU4E Hardware Guide
278705 Model PDP Series 400 maxDPU4F Hardware Guide
278561 System Power and Grounding
278589 Function Blocks Programmer’s Reference and User’s
Guide

Chapter 1
maxPAC
Input/Output Subsystem
Overview
The maxPAC Input/Output System links the maxDNA Distributed Control
System to real world process control inputs and outputs. The Input/Output
system uses a compact design to provide the system with greatly enhanced
I/O capacity in relatively little space. A close relationship exists, in turn,
between this I/O system and the maxDNA Distributed Processing Unit
(DPU) which it serves.
The DPU and the I/O modules mount in an I/O chassis assembly. The
backplane in the chassis assembly provides the I/O bus connection between
the DPU and the I/O modules. It also provides the system power and field
power connections to the modules. Multiple I/O chassis that share the I/O
bus can be installed in a cabinet.
Model IOP I/O Subsystem

Cabinet
Two standard cabinet types are available for the mounting of I/O system
hardware. The cabinet is available as either a NEMA (National Electrical
Manufacturers Association) type 1 or 12 and consists of the following:
 Welded steel construction

 Front and Rear access
 I/O mounted in front and rear of cabinet (standard)
 I/O mounted in front and terminations in rear of cabinet (option)
 Other mounting arrangement options are also available
 Removable doors
 19” rack mount rails with standard E.I.A. hole spacing
 Top or bottom Cable access
 Size 85 7/8” h x 24 ¾”w x 38 7/8”d
Optional Cabinet styles and sizes are also available.

The following figure shows a typical cabinet arrangement with I/O in both
the front and rear of the cabinet.
Figure 1-1. Typical Cabinet Arrangement, Front and Rear Views
Chassis Assembly
Three chassis assembly types are available for the installation of the I/O
module as follows:
 IOP382 Eight-pack assembly to accommodate up to eight maxPAC I/O

modules. The DPU4F can also reside in this chassis.
 IOP383 Six-pack assembly to accommodate a DPU4E or a Model 564 I/O

module in the right most position along with six maxPAC I/O modules; the
DPU4E takes up the equivalent of two maxPAC I/O module positions.
 IOP381 Four-pack assembly to accommodate four maxPAC or Model 564

I/O modules.
1-2 Metso Automation  278596 

maxPAC Input/Output Subsystem
The rack assemblies contain an I/O backplane featuring edge connectors for
I/O modules and connectors for 24V system supply and 24V and 48V loop
power supplies. Input/Output modules connect to the I/O bus through four to
eight connectors on the backplane, depending on chassis style.
The backplane also contains ribbon cable connectors to interconnect chassis

assemblies and extend the I/O bus to the maximum number of modules
supported by the DPU.
S y s te m 2 4 V
I /O B u s
I /O B u s
C o n n e c to r
C o n n e c to r s
F ie ld 4 8 V
F ie ld 2 4 V
Figure 1-2. Eight-Pack Rack
Figure 1-3. Six Wide Rack with DPU4E
Metso Automation  278596  1-3

Model Number Description

IOP381 4-wide frame assembly
IOP382 8-wide rack assembly
IOP383 6-wide rack assembly
IOP015 maxPAC Chassis used with IOP381
IOP011,012 Model 564 Chassis used with IOP381
DPU Mounting
DPU4E mounts in the right most position of the six-pack chassis assembly. It
occupies the equivalent of two I/O modules. Refer to Publication 278590 for
DPU4E information. DPU4F mounts in the left most position of the eight-
pack chassis assembly. It occupies the equivalent of one I/O module. Refer to
Publication 278705 for DPU4F information.
I/O Modules
The I/O modules are rugged enclosed printed circuit board assemblies. The
edge connection at the rear of each module provides the interface to the
backplane and the I/O bus. System power and field power, when applicable, is
also available through this connection.
While I/O modules vary by type, they may include one or more of the
following:
 A color bar on the module faceplate identifies the module type. Each
module type has a unique color.
 Euro-style terminal connector blocks for field wiring; each block contains
16 connectors;
 Rotary address switch;
 Light Emitting Diodes (LED) for module status indication;
 All the modules that require field power include a front mounted fuse
disconnect and a LED fuse status indication;
 All discrete modules include front mounted LEDs for input/output logic
state;
 The TC module includes front-end connectors with thermistors to measure

the junction temperature for cold junction compensation.
The I/O modules may be inserted and withdrawn safely with 24 Vdc and field
power applied.

Figure 1-4. Typical I/O Module Front Panel
I/O Module Types

Because of the variety of input and output ranges needed in distributed control
applications, the Model IOP I/O offers many types of easily configurable
discrete and analog I/O modules. For a list of modules, along with their
ranges and number of points per module, refer to the following tables.
Digital Input (AC/DC)*

Part Number Description
IOP330 24 Vdc common input; 16 channels
IOP334 24 Vdc isolated input; 16 channels
IOP331 48 Vdc common input; 16 channels
IOP332 120 Vac/dc isolated input; 16 channels
IOP333 240 Vac/Vdc isolated input; 16 channels
IOP350 Form C relay; 10 channels
IOP351 Form A/B relay; 16 channels
IOP335 Pulse I/O , 8 channels
*ac Voltages/currents are RMS

Analog Input
IOP301 Isolated analog input; 16 channels
IOP302 4-20mA common input; 16 channels
IOP303 3-wire RTD input; 8 channels
IOP304 Thermocouple/emf input; 16 channels
IOP305 Voltage common input; 16 channels
IOP306 Kit with sixteen 100 Ohm resistors
IOP307 4-20mA HART input, 8 channels
IOP308 4-20mA, HART input, 16 channels
Analog Output
IOP320 4-2mA common output, 8 channels
IOP321 4-20mA isolated output, 8 channels
IOP322 4-20mA HART output, 8 channels
Other
IOP371 Bus Extender Module
IOP336 QuadPAT, 4 channels
IOP341 Turbine Valve Positioner
IOP345 Turbine Overspeed
IOP364 HART Transceiver
IOP365 Serial Communications
Power Supply
The maxDNA Input/Output System uses the Model APS Power Supply
Assembly, which provides 24V dc power for Distributed Processing Units
and I/O. This Power Supply Assembly consists of a 19-inch rack mount or
flush mount chassis accommodating up to six independent 10 amp power
supply modules. Metso Automation typically installs the power supply
modules in an N + 1 redundancy configuration. Because each module is
individually isolated, the chassis can be split to provide both system power
and loop power.
Power supply features consists of the following:

 Redundant AC power inputs

 250 Watt power supply modules

 Hot replaceable
 Current Sharing
 Power factor correction
 Front panel indicators on each module
 AC input
 Output voltage status
 Output current level
 External status signals
Field Termination Options

A maxPAC system uses three field cable termination approaches:
Local Terminations Field cables terminate directly on the I/O

module.
Remote Terminations Field cables terminate on terminal blocks
remotely to the I/O module with an
interconnecting cable back to the I/O module.
Termination Assemblies The QuadPAT, Turbine Valve and Overspeed
modules require a DIN rail mounted termination
assembly. Field cables terminate on this
assembly with an interconnecting cable back to
the I/O module.
Local Terminations (standard)

Each I/O module is supplied with two 16 point, “Euro-Style” screw clamp
plugs that mate to the Printed Circuit Board Header on the module. Field
cables would be routed directly to these Euro-Style plugs, which can accept
up to a #12awg conductor.
Remote Terminations (option)

Many remote field cable termination options are possible. Listed below are a
few examples:
 I/O in front of cabinet, terminations in the rear of cabinet.

 Termination cabinet mounted adjacent to I/O cabinet.
 Termination cabinet located remotely from I/O cabinet.
The types of terminal blocks installed in the termination facility are too
numerous to list; typically these terminations are DIN rail style. The cabling
back to the I/O module is typically made using two multi-conductor cables,
one to each of the Euro-Style plugs supplied with the individual I/O module.

Termination Assemblies
IOP337 QuadPAT Termination Assembly
IOP342 Turbine Valve Termination Assembly
IOP346 Turbine Overspeed
CTO301 QuadPAT Module to Termination Assembly Cable
CTO302 Turbine Valve Module to Termination Assembly Cable
CTO303 Turbine Overspeed Module to Termination Assembly Cable
IOP201 Serial Communications Termination Assembly
CPO403 I-module Assembly
Installing Model IOP I/O Equipment

This section covers the physical mounting and installation of the Model IOP
I/O equipment. See "Module Mounting Considerations," before mounting
any equipment.
The following tools and hardware are required:
 Screwdriver
 Hex Key Wrench, Metso Part No. 064598
 Mounting Screws, Metso Part No. 030162 (8 per unit supplied)
 Nut Retainers, Metso Part No. 003530 (8 per unit supplied)
 Crimp Tool for field connectors, Weidmuller Part No. 906480
 Crimp Contact Removal Tool, Weidmuller Part No. 906481
Before mounting any hardware, see "Cabling, Power, and Ground Wiring."
Sequence of Mounting Operations

Mounting the parts of the Model IOP I/O in proper order can save time and
duplication of effort.
Follow this sequence as closely as possible for best results:
1. Refer to field wiring instructions that can influence mounting locations

for chassis assemblies and chassis assembly/module replacement.
2. Mount the chassis assemblies; see "Mounting I/O Chassis Assemblies."
3. Perform all steps as outlined in "Cabling, Power, and Ground Wiring."
5. Complete field wiring.

6. Refer to "Module Addressing" for switch settings and jumper selections.
7. Install I/O modules.
If your field wiring enters through the bottom of the cabinet, mount the
Model IOP I/O units from top to bottom. This will make wiring of future
units easier, since you will not have to pull wires from the bottom of the
cabinet past existing Model IOP I/O units. This same reasoning applies to
field wiring entering the top of the cabinet. Here you mount the Model IOP
units from bottom to top.
Mounting I/O Chassis Assemblies

The Model IOP I/O chassis assembly attaches to the rear mounting rails in
standard 19-inch maxDNA I/O cabinets. Three chassis styles are available.
See “Chassis Assembly.” Up to seven chassis assemblies may be installed in
a standard cabinet.
Usually, the Model IOP I/O units are supplied already mounted in cabinets,
but if you are mounting them yourself, follow this procedure.
Note: before you mount an I/O chassis, it should contain the I/O backplane.
To attach the chassis assembly:
1. At the desired chassis assembly mounting location in the cabinet, place

eight 10-32 nut retainers (Metso Part No. 003530) in the rear mounting
rail holes that correspond to the eight screw slots on the Model IOP
chassis assembly.
2. The holes in the maxDNA cabinet rear mounting rails are arranged in a
repeating pattern of two holes close together separated by a single hole.
To make sure all chassis assembly mounting screw cutouts line up to
corresponding mounting rail holes, you must align the top mounting
screw cutouts (left and right) of the chassis assembly with the top holes
(left and right) of two hole pair.
3. Position the chassis assembly (two ribbon connectors to the right) so that
the screw slots align with the nut retainers. Insert eight 10-32 mounting
screws (Metso Part No. 030162) and tighten securely.
Cabling, power wiring, and chassis assembly to cabinet frame grounding

should be completed before mounting the I/O modules. See next section.

Cabling, Power, and Ground Wiring

This section describes power wiring, Model IOP I/O connection, and
connection to other Model IOP I/O units. The connections covered in this
section should be done after the chassis assemblies are in place and before
the I/O modules are mounted. Some cabling can be done when the I/O
modules are mounted, but the job is easier when they are removed. (See also
Interconnecting I/O Racks).
Cables used in the maxDNA Distributed Control Systems are labeled at both
ends with the device and connector number. Interconnecting ribbon cables
are designed for specific orientation, however, the connectors still prohibit
wrong electrical connection.
Refer to Publication 278561, System Power and Grounding, for a discussion

of cabinet grounding.
Supplying 24V Power to the I/O Modules

The I/O system requires a 24 Vdc ±4.0 Vdc power supply. Normally, this is a
maxDNA power supply mounted in the cabinet holding the DPU; to ensure
reliability, Metso Automation recommends using a maxDNA power supply
exclusively. If another 24 Vdc power supply is used, it must meet the same
specification requirements as the maxDNA supply. All modules are
individually fused. The CMOS technology in the Model IOP I/O design
results in low module power consumption.
Whether the power source is the standard maxDNA supply or another

supply, the +24 Volts connector plugs into the 24V connector on the right
side of the I/O backplane.
Caution: The +24 Vdc power supply used to power any maxDNA hardware
should never be used for external relay contact wetting or to power any other
field equipment. Use a separate supply for contact wetting to provide noise
and interference protection for the maxDNA hardware.
Interconnecting I/O Racks

Use a ribbon cable to interconnect, in a daisy chain manner, two or more
adjacent I/O chassis assemblies in the same maxDNA I/O cabinet group.
The cables should be installed in a manner that minimizes the total I/O bus
length. This is done by utilizing the I/O bus connectors on both ends of the
racks so that the bus “flows through” the racks.
For example, consider the two-cabinet system shown in Figure 1-5a. A

maxDPU4F pair is installed in the leftmost slots of the top two racks in
cabinet 1. The bus begins at the DPU and flows through the rack to the
connectors on the right side of the rack (P9 & P10). A ribbon cable connects
the right side of rack 1 to the right side of rack 2. The bus flows through
rack 2 to connector P11. Another ribbon cable connects the left side of rack

2 to the left side of rack 3. The bus flows through rack 3 to connectors P9
and P10. This same pattern is repeated until the last rack has been reached.
Notice that the bottom rack of cabinet #1 is connected to the bottom rack of
cabinet #2 by a cable that runs from P11 to P9. This is because that results
in a shorter cable length than it would be had it run from P11 to P11. It is
also a much shorter cable length than if it had been run from the bottom of
cabinet 1 to the top rack in cabinet 2.
To reiterate, when cabling the I/O racks together, the goal is to keep the I/O
bus length as short as possible. Connecting the cables on alternate sides of
the racks so that the I/O bus “flows through” from one rack to the next does
this.
Note that the ribbon cable connectors are keyed. The color stripe on the
ribbon cable should match pin 1 on the backpanel connector. Connector pin
1 is indicated by a white triangle symbol on the backpanel adjacent to the
connector.
A bus terminator (CPO402) must be installed at the end of the I/O bus
farthest from the DPU. The bus terminator is a small PC card assembly that
is designed to plug in to the I/O bus connector. When installing a
terminator, be sure to match its pin 1 indication to the pin 1 indication on the
backpanel. In Figure 1-5a, the terminator is shown inserted into connector
P9 of the top rack in cabinet 2. That is the point on the bus that is farthest
from the DPU.
If you add I/O racks to your system at a later date, remember to move the
terminator from its old location to the new end of the bus.
The placement of terminators on the bus is highly dependent upon the

system configuration (numbers of racks, numbers of modules, lengths of
cables, etc.). For that reason, in some instances, an additional terminator at
the DPU end might be required. Monitor the I/O Bus Errors and, if your
system seems to have an excessive amount, try adding the additional
terminator.
Refer to the Bus Extender Module chapter in this manual for information on
how to install terminators when BEMs are present in the system.
Terminating systems with Redundant or Mixed (Shared + Redundant) I/O is

a little more complicated than a system with only Shared I/O. Refer to the
Figures 1-5b and 1-5c for examples. Additional information on Shared,
Redundant and Mixed I/O is contained in the Backup Configuration Options
section of this manual.

Cabinet #2 Cabinet #1
Terminator
D
P9 P P9
P11 P11
P10 U P10
D
P9 P9
P11 P
P11
P10 U P10
P9 P9
P11 P11
P10 P10
P9 P9
P11 P11
P10 P10
Figure 1-5a. Interconnecting maxPAC I/O Racks (Shared I/O)
I/ O B a c k u p C a b le
T e rm i n a to r
(C P O 3 0 9 )
R e d u n d a n t I /O P9
P11 DPU
P r im a r y
P10
T e r m in a t o r
P11 DPU
S e c o n d a ry
P10
I/ O B u s C a b le
T e r m in a t o r
P11
P r im a r y
P10
T e r m in a t o r
P11
S e c o n d a ry
P10
Figure 1-5b. Terminating & Cabling Redundant I/O

T e r m in a t o r
DPU
R edundant P9
P11
I/O
P r im a r y
P10
T e r m in a t o r
DPU
R edundant P9
P11
I/O
S e c o n d a ry
P10
I/O B u s C a b le
T e r m in a t o r
R edundant P9
P11
I/O
P r im a r y
P10 P ri
Com
T e r m in a t o r
R edundant P9
P11 Sec
I/O
Y - m o d u le
S e c o n d a ry
P10 (C P O 4 0 1 )
T e r m in a t o r
P11 Com m on P9
I/O
P10
N o te s :
1 . K e e p th e r e d u n d a n t I/O r a c k s c lo s e to th e D P U s th a t d r iv e th e m .
2 . P la c e th e Y - m o d u le c lo s e to th e I/O b u s c o n n e c to r s ( P 1 0 ) o n th e re d u n d a n t r a c k s .
Figure 1-5c. Terminating & Cabling Mixed I/O with a Y-module

Summary of Cabling Rules for maxPAC I/O

 Keep the total I/O bus length (cables + backpanels) as short as possible.
The following techniques will do this.
 Use “flow through” cabling.
 When connecting columns of racks together, connect the bottom

rack of column 1 to the bottom rack in column 2 or the top rack
of column 1 to the top rack of column 2. In other words, do not
cable a top rack to a bottom rack.
 Put the DPU at one end of the I/O bus. Never put the DPU in the
middle.
 Terminate the far end of the I/O bus (the end farthest from the DPU).
 In a system with Common (shared) I/O, the terminator should be

placed at the far end of the common I/O bus. In a system with
Redundant I/O, install a terminator at the far end of both redundant
I/O bus segments. In a system with mixed (common + redundant)
I/O, terminate all segments (refer to the CPO403 chapter for more
information).
 The maximum number of maxPAC modules supported by the

maxDPU4E or maxDPU4F within a cabinet or adjacent cabinet pair is
60. This number of modules is reduced when the electrical I/O bus is
extended to other cabinets.
 The limit of 60 modules per bus segment is based upon the electrical
characteristics of the bus drivers. Other considerations such as the
types of modules used, the use of BEMs and the availability of DPU
resources may change the number and types of modules permitted.
Thus, it is very important that the user verify the correctness of the
proposed configuration by running the I/O Configuration Tool. Refer
to Publication 278609 for more information on the tool.
maxPAC I/O Bus Cables

A variety of different maxPAC I/O bus cables are available. Use the cables
that are appropriate for your application based upon the positions of your I/O
racks. Due to the orientation and location of the connectors, different cables
are used for connections to P9/P10 vs. P11 when the racks are spaced
relatively close together. For longer runs, the same types of cables may be
used for all connectors.

Cables for maxPAC Connections to P9 & P10
CPO301 10 inches - 0 rack units between racks
CPO303 12 inches - 1 rack unit between racks
Cables for maxPAC Connections to P11
CPO323 12 inches – 0 or 1 rack units between racks
CPO324 14 inches – 2 rack units between racks
CPO325 28 inches – 10 rack units between racks
Long Cables for maxPAC Connections to P9, P10 or P11
For I/O bus connections to a cabinet outside the cabinet group, use the
following cables:
CPO307 7-foot cable
CPO315 15-foot cable
CPO400-LL Custom length cable (about 20 feet maximum)
Cables for Connections between maxPAC and 564 Racks
For applications that require I/O bus connections between maxPAC racks
and Model 564 I/O racks, the following cables are available. Note that
Model 564 I/O racks do not support “flow through” cabling so they will
connect to the I/O bus as stubs.
CPO504 13 inches - 2 rack units between racks (use P9 or P10)
CPO507 7-foot cable
CPO515 15-foot cable
CPO500-LL Custom length cable (about 20 feet maximum)

Module Mounting Considerations

I/O Modules
As you determine how modules are positioned in a cabinet, give some thought
to the signal levels that are to be wired to the modules. High and low signal
levels and AC and DC wiring should be kept separate. In general, wherever
possible, modules receiving the same type and level of signals should be
grouped together, with similar signal types arranged in vertical columns.
DPU Modules
The DPU4E requires the use of the six-wide chassis and is mounted in the
right most position. DPU4F is mounted in the left most position of the 8-
wide chassis to take advantage of the airflow. Likewise, when using a
second DPU for backup, it is mounted on a second chassis beneath the
primary DPU.
Before mounting I/O modules, you should complete power and grounding
and field wiring and any I/O module preparation and adjustment. See
appropriate chapters in this publication to check correct addressing and
jumper selection on the modules.
Before installing an I/O module in the right-most position of a chassis

assembly, make sure the +24Vdc is connected to the chassis assembly as
well as the I/O bus cable. Additionally, connect the cabinet frame ground to
the Model IOP I/O chassis assembly before installing an I/O module in the
extreme left position of a chassis assembly. Refer to "Cabling, Power, and
Ground Wiring."
Before installing any modules, complete all field wiring.
Model IOP I/O is designed to allow module installation and removal with the
+24Vdc power supply ON.
To mount modules:
1. With chassis assembly in place and all wiring completed, position

module into top and bottom card guides of the chassis. Gently slide
module forward, verifying that the connector pins on the side of the
module board engage the corresponding contact guides on the chassis
assembly.
2. When the contacts are engaged and resistance is felt, firmly press on the
front panel of the module front plate to make the simultaneous
connections at the front and rear. Apply pressure to the left of the LEDs
to place the force directly in line with the printed circuit card of the
module.

3. Secure module to chassis assembly with the top and bottom lock-down
screws on the front of the module.
Module Addressing
You must set addresses for each I/O module using rotary switches mounted
in the lower or upper right corner of the printed circuit board of the module,
depending on module type. These hexadecimal switches permit 255 logical
addresses (hexadecimal FF is not available). The lower switch is the low
order address and the upper switch is the high order address. (The
PROFIBUS modules – IOP401 through IOP404 are the only exception to
this rule. On those modules the top rotary switch is the least significant
portion of the address)
M o s t S ig n i f ic a n t
L e s s S i g n if ic a n t
Address switch position for all modules except the PROFIBUS interface.
maxPAC modules use one, two, four or eight addresses. The address set on
the module is its base address. For the eight-address module the base address
is the address of channel 1. The module will automatically occupy an
address for each of its channels, starting with its base address.
To convert the hexadecimal address to the equivalent logical (decimal)

address:
1. Multiply the low order switch setting by 1 to get the decimal equivalent,
where switch positions A to F correspond to 10 to 15, respectively.
2. Multiply the high order switch setting by 16 to get the decimal

equivalent, where switch positions A to F correspond to 10 to 15,
respectively.
3. Add the two decimal equivalents for logical (decimal) module address.
For example, a 2 setting of the high order switch (2 x 16 = 32) and a setting
of low order switch (10) gives a module a logical (decimal) address of 42,
the decimal equivalent of the hexadecimal word 2A formed by the switch
setting.
Module addressing is completely independent of module physical locations.

Each module address must be different from all other module addresses in
the system. Digital input modules must have an address less than 32 decimal
if they are scanned every millisecond to support Sequence of Events (SOE)

time tagging. Addresses are determined by the system designer during

system planning.
Backup Configuration Options

Three input/output configuration options are available: shared, redundant, and
mixed.
Shared Configuration
A shared I/O configuration uses a primary DPU, a secondary DPU, and one set
of Model IOP parallel modules. See Figure 1-6. Both DPUs share the I/O bus
but only the active DPU (primary or secondary) receives data from, and sends
data to, the set of common I/O modules.
R e d u n d a n t n e tw o r k
D D
P P
U U
I /O B u s
I I I I I I I I I I
O O O O O O O O O O
Figure 1-6. Shared Configuration
Redundant Configuration
A redundant I/O configuration uses a primary DPU, a secondary DPU, and
two identical sets of Model IOP parallel modules. See Figure 1-7. The
primary and secondary DPUs receive data from, and send data to, their set of
I/O modules. Outputs from the inactive string of modules are inhibited until
they become active. It is necessary to install a Part No. CPO309 cable
between the two I/O strings as shown; this cable inverts the output-enable
signal so that outputs of the inactive I/O string are disabled.

R e d u n d a n t n e tw o rk
D D
P P
U U
I/O B u s
I I I I I I I I I I
O O O O O O O O O O
CPO 309
Figure 1-7. Redundant Configuration
Mixed Configuration
A mixed configuration uses primary DPU, a secondary DPU, an I/O backup
adapter, two identical sets of redundant Model IOP parallel modules, and
various other common (shared) Model IOP modules. See Figure 1-8. The
primary and secondary DPUs talk to the redundant modules. The active DPU
(primary or secondary) also talks to the common set of I/O modules.
In redundant or mixed configurations, the inactive DPU polls its redundant

modules for hardware failures when it is not performing control actions. No
transfer of control will occur if a failure is detected by the inactive DPU. The
inactive DPU also continuously updates its analog output modules with current
values so that bumpless transfer occurs when the inactive DPU becomes
active.
Two different I/O backup adapters are available. The original style is the
CPO401 (also known as the Y-module). The CPO401 is essentially a switch
that connects the common I/O to the active DPU.
The newer style I/O backup adapter is the CPO403 (also known as the I-
module). Like the CPO401, the CPO403 also connects the common I/O to the
active DPU. But, in addition, it also performs continuous tests on the common
bus to determine the health of that bus. Only if the common I/O bus is healthy
(e.g., no signals are shorted to ground) will the CPO403 connect the common

I/O to the DPU. That is done to protect the system from common bus faults.
Refer to the CPO403 chapter of this manual for more information.
R e d u n d a n t n e tw o rk
D D
P P
U U
R e d u n d a n t I /O B u s R e d u n d a n t I /O B u s
I I I I I I I I I I
O O O O O O O O O O
Y-
m o d u le
C o m m o n I /O B u s
I I I I I
O O O O O
Figure 1-8. Mixed Configuration using the CPO401 Y-module
Remote I/O
A Bus Extender Module (BEM) permits the I/O bus to be extended up to
2,000 meters using highly reliable and noise immune fiber optic cables.
BEMs, configured in pairs, support both locally and remotely mounted I/O
cards. In a typical configuration using redundant Distributed Processing
Units (DPUs), an I/O cabinet installed locally in a control room contains I/O
modules, a DPU pair, and a BEM pair. This is connected via I/O optical
cable to a ruggedized remote cabinet containing I/O modules, and a second
BEM pair. The optical link is established between the local and remote

expander modules. Any DPU or redundant pair of DPUs can communicate

with I/O that are locally and/or remotely mounted. Figure 1-9 shows a
typical configuration with both redundant and common local I/O and
common remote I/O. The Y adapter would also be required at the remote
end to support both common and redundant remote I/O.
re d u n d a n t n e tw o rk
D D
Y
P ADAPTER
P
U U
B B
E E
M M C o n tr o l
b a c k p la n e b a c k p la n e
Room
I I I I I I I I
O O O O O O O O
O p t ic a l
C a b le
R e m o te
B B lo c a tio n
E E
M M
I I I I I I
O O O O O O
I I I I I I I I
O O O O O O O O
Figure 1-9. Typical Bus Extender Module Configuration

Specifications
Environment
The Model IOP I/O operates in the temperature range of 0C to 60C at a
relative humidity range of 0 to 90%, noncondensing.
I/O Bus
The Model IOP I/O uses an 8-bit parallel asynchronous I/O bus, capable of
10 microsecond transfers. The I/O bus interface uses LSI circuitry for better
reliability. Parity checks are performed on all inputs and outputs, with
additional security provided for outputs using a check-before-execute control
strategy.
To further enhance reliability, I/O incorporates module address verification

and multiple module detection checks. Bus fault detection is also performed
by automatic confirmation of input data on every module.
Inputs/Outputs
All modules, both analog and digital types, withstand the normal or common
mode connection (IEEE-472, ANSI c37.90) and still maintain correct
operation. Common mode transients are bypassed to chassis metal work. All
points are optically isolated from the maxDNA I/O bus. Channel to channel
isolation allows series or parallel connection between channels or external
relay systems. All digital modules have logic state indication on the front
panel, one indication per point.
In addition to logic state indication, digital output modules contain fused

outputs and a front-panel blown fuse indicator. Each output also has a
deadman timer (approximately 1 second) that can be optionally used to
freeze or drop out all outputs if the module is not updated by the DPU.

Chapter 2
Analog Input Modules

Isolated Input Module IOP301
Overview
This module, featuring 16 isolated input channels, can be configured for any
mix of voltage or current inputs. The current loop can be powered from a
field supply or from a system loop supply provided via the backplane edge
connector. For current inputs, this module is pin and function compatible
with the IOP302 input module.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on
when system power is present and the module is communicating with the

DPU. This LED blinks on and off when the module is not being scanned by
the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting.
For use as a replacement for a Model 564 module this module requires 16
bus addresses and provides 15 channels. The addressing rules specified in
the Model 564 manuals still apply.
When used as a maxPAC module, the module only requires two bus
addresses and provides 16 channels. Each module address must be on an
even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to
31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers, located near the address switches. Refer
to the following table for jumper setting information.
Jumper Installed Not Installed

W1 50 Hz 60Hz
W6 Model 564 maxPAC
In addition, five jumpers per channel determine the type of input connected
to the channel.
Input Type A B C D E
4-20 mA powered by Metso IN IN IN IN OUT
Automation
4-20 mA powered by user IN IN OUT OUT IN
Voltage input OUT OUT OUT OUT IN
Program Resistors
Jacks are provides at the front of the module for the installation of a pair of
resistors per channel. These resistors can be used to scale a voltage input to
the 2.4V span of the A/D measurement. These resistors are identified as
follows:
Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Series R 1 7 26 32 51 57 78 85 113 120 142 148 175 193 211 233
Shunt R 3 10 29 35 53 60 80 88 115 123 144 151 177 196 215 234

The input circuit configuration for each type of input is shown in the
following sketch. An electronic fuse protects the 24-volt loop power to the
transmitter. A 200-Ohm thermistor in series with the 4-20 mA input provides
current limiting for voltages up to 100 Volts. The 24-volt loop supply is
available to the module from the backplane. For current inputs with external
shunt the channel is configured for voltage input and Rs = 0.
2 4 V (+ )
F r o m b a c k p la n e
2 4 V (-)
1A 1B
200
Rs
+
100 A /D
X m itte r Rp
1D -
1
24V 1E
1C
4 -2 0 m a p o w e re d b y sy ste m
200 1B
1A
+
+
Rs
100 A /D
V o lta g e Rp
1D -
1
-
1E
1C
V o lta g e in p u t
200 1A 1B
+ Rs
+
A /D
100
X m itte r Rp
1 1D -
-
1E
1C
4 -2 0 m a p o w e re d e x te rn a lly ,
in te rn a l sh u n t

Module Operation
This microprocessor-based module supports up to 16 isolated high level
inputs. A sigma delta A/D and precision reference is provided for each pair
of inputs. The A/D reads the voltage generated by the selected input and
converts the differential measurement to a 15-bit plus sign binary value
representing the voltage input, which is read by the microcontroller. The
microcontroller initiates the conversion and waits for the conversion to
complete.
The digital filter in the oversampling A/D provides excellent 50/60 Hz

normal mode rejection. Prior to starting each conversion, the microcontroller
selects one of the two input channels by means of two solid-state, optically
coupled relays. The two inputs are multiplexed with optical relays to provide
channel to channel isolation. Immediately following each measurement,
open input and over range conditions are checked.
A separate DC/DC converter provides isolated power to each A/D converter

measuring circuit. Communication between the microcontroller and each
A/D is serial at 100KHz. A separate group of optical isolators provide the
isolation between each A/D and the serial logic circuits. The microprocessor
provides the input data to the DPU on demand via the bus FPGA. The FPGA
provides the I/O bus interface logic; its program is loaded from the FLASH
on power up.
Module calibration is done automatically at power up following startup

diagnostics. Calibration is repeated periodically online to compensate for
temperature effects.

5 V - lo g ic
R e g u la to r 24V
D C /D C
REF FLA SH
C hannel 1
M u ltip le x e r
O PTO
A /D 1
C hannel 2
uC
FPG A
O p tic a l is o la tio n
I /O B u s
b e tw e e n e a c h p a ir
o f c h a n n e ls
D C /D C
REF
C hannel 15
M u ltip le x e r
O PTO
A /D 8
C hannel 16
o p tic a l iso la tio n

fie ld to lo g ic
Diagnostics
The module executes diagnostics on power up. When an error is detected on
power-up or during online operation, the front-panel green LED, labeled
Active, blinks the first digit at a slower rate and the second digit at a faster
rate. During normal operation the active LED is on continuously or flashes at
a steady one-second rate when the module is not being scanned. The
diagnostic codes are as follows:
Error Condition Code

A/D send fault 0x12
A/D receive fault 0x13
A/D self calibration failure 0x14
Bad A/D communication 0x15
A/D does not complete conversion 0x16
RAM Test Failure (power-on) 0x22

CPU Stack Error (power-on) 0x23

CPU Error (power-on) 0x24
Checksum Error (power-on) 0x25
Interrupt Error (power-on) 0x26
FPGA Download Error (power-on) 0x32
Module specifications
Resolution 15 bits plus sign
Scan Rate 100 msec.
Temperature Sensitivity ±0.004% of reading/oC ±1.5uv/oC RTI
Accuracy ±0.1% of full scale at 25oC
Source Impedance Effect 10 Mohm operational, 20K Ohms on loss of power
Conversion method Sigma Delta oversampling. Single A/D per channel
Span 4 to 20 mA, 0-2.4V
Calibration Self-calibration on power up. Periodically on line
to compensate for temperature effects
Input Impedance - 4-20 mA input 300 Ohms
- voltage input 1 Mohm
Normal Mode Voltage 50 Volts
Normal Mode Rejection 60db @ 50/60 Hz
Common Mode Voltage 250VAC RMS or 320 VDC
Common Mode Rejection 120db @ 50/60 Hz, 100 Ohm imbalance
Isolation 1500 Vac (field to logic)
500 Vac (channel to channel)
Input Power 400 mA
(from 24V system supply)

Field Wiring
P2 P3
1 1
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
C hannel 1 C hannel 9
2 2
In (+ ) In (+ )
3 3
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
4 4
In (+ ) In (+ )
5 5
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
6 C hannel 3 6 C hannel 11
In (+ ) In (+ )
7 7
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
In (+ ) In (+ )
9 9
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
10
10
In (+ ) In (+ )
11 11
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
In (+ ) In (+ )
13 13
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
In (+ ) In (+ )
15 15
2 4 V ,I n ( - ) 2 4 V ,I n ( - )
16 C hannel 8 C hannel 16
16
In (+ ) In (+ )

Field Wiring for Redundant Modules with Common Transmitter

The following figure shows the recommended wiring for two redundant
IOP301 analog input modules that share a common two-wire or four-wire
transmitter.
Redundant inputs must be configured as voltage inputs with an external 100-

Ohm shunt resistor. The recommended maximum distance between the shunt
and the I/O module is 10 meters. The +24V connection should be
independently fused to each transmitter.
The connection to the (-) terminal of the 24v supply must be made at the (-)
side of the shunt resistor. The voltage that is developed across each 100-
Ohm shunt by the 4-20 mA signal from the transmitter is wired to the AI
module using twisted pair cables. A PTC thermistor is recommended
between the transmitter output and the 100-Ohm shunt. This protects the
100-Ohm shunt against over voltage and provides additional resistance to
increase the transmitter load to 250 Ohms. Kit IOP306 supplies 16 pairs of
100-Ohm shunts and thermistors to support two IOP301 analog input
modules.
T w is te d p a ir
(-)
4 w ir e
100
T r a n s m itte r
(+ )
th e r m is to r P r im a r y
IO P 3 0 1
A I M o d u le
(-)
(+ )
S e c o n d a ry
IO P 3 0 1
A I M o d u le
Four Wire Transmitter

(-)
T w is te d p a ir
(-)
24V 100
(+ )
S u p p ly
(+ )
th e r m is to r
P r im a r y
IO P 3 0 1
A I M o d u le
2 w ir e
T r a n s m itte r
(-)
(+ )
S e c o n d a ry
IO P 3 0 1
A I M o d u le
Two Wire Transmitter

Chapter 3
4-20 mA Input Module IOP302
Voltage Input Module IOP305
Overview
The IOP302 module features sixteen 4-20 mA common input channels. The
IOP305 module features 16 voltage input (not current input) channels.
Transmitter loop power is available to the module via the backplane,
providing individually fused 24V transmitter power for each channel.
LED Indication

DPU. This LED blinks on and off at a constant rate when the module is not
being scanned by the DPU.
Bus Address
The module contains two jumpers. Refer to the following table for jumper
setting information.

W1 50 Hz 60Hz
W6 Model 564 maxPAC
Module Operation
This microprocessor-based module supports up to 16 4-20 mA inputs, all
powered from a local 24V loop supply. A sigma delta A/D and reference are
provided for each input. Each A/D constantly reads the voltage generated by
the input and converts the differential measurement to a 15-bit plus sign
binary value, which is read by the microcontroller.

normal mode rejection. Immediately following each measurement, open
input and over range conditions are checked. A DC/DC converter provides
isolated power to the A/D measuring circuit. Communication between the
microcontroller and the A/D is serial at 100KHz. Optical isolators provide
the isolation between the A/D and the serial logic circuits.
The microprocessor provides the input data to the DPU on demand via the
bus FPGA. The FPGA provides the I/O bus interface logic; its program is
loaded from the FLASH on power up. Module calibration is done
automatically at power up following startup diagnostics. Calibration is
repeated periodically online to compensate for temperature effects.
3-2
4-20 mA Input Module IOP 302
Voltage Input Module IOP 305
5 V - f ie ld 5 V - lo g ic
D C /D C R e g u la to r 24V
REF FLA SH
S ig n a l
C hannel 1 C o n d itio n in g A /D
O PTO uC
FPG A
I /O B u s
REF o p tic a l iso la tio n

fie ld to lo g ic
S ig n a l
C hannel 16 C o n d itio n in g A /D
The input circuit for each channel of the 4-20 mA input module is shown in
the following sketch. An electronic fuse protects the 24V loop power to the
transmitter. A 200-Ohm thermistor in series with the input provides current
limiting for overvoltage conditions up to 100 Volts. The 24-volt supply is
available to the module from the backplane.
C u r r e n t L im it
200
100 A /D
2 4 V (-)
F r o m b a c k p la n e
2 4 V (+ )
F u se
The following sketch shows the input circuit for the voltage-input module.

A /D
Voltage Input Module
Diagnostics

A/D send fault 0x12
FPGA Download Error (power –on) 0x32
Module Specifications
Scan Rate 20 msec.
Accuracy ±0.1% of full scale at 25oC
Source Impedance Effect 10 Mohm operational, 20K Ohms on loss of power
Conversion method Sigma Delta oversampling. Single A/D per channel
Span 4 to 20 mA, 0-2.4V.
Calibration Self-calibration on power up. Periodically on line to
compensate for temperature effects
Input Impedance IOP302, 300 Ohms; IOP305, 1mOhm
Normal Mode Voltage IOP302, 50 Volts; IOP305, 24 Volts
Common Mode Voltage 100 volts dc or peak ac for the group
Isolation 1,500 Vac field to logic
Input Power 125 mA
3-4
Field Wiring for IOP302

P2 P3
1 1
24V 24V
T r a n s m i tt e r T r a n s m i tt e r 2
2
I in I in
3 3
24V 24V
4
I in I in
5 5
24V 24V
T r a n s m i tt e r 6 C hannel 3 T r a n s m i tt e r 6 C hannel 11
I in I in
7 7
24V 24V
8
I in I in
9 9
24V 24V
10
I in I in
11 11
24V 24V
12
I in I in
13 13
24V 24V
T r a n s m i tt e r C h an n el 7 T r a n s m i tt e r 14 C h an n el 15
14
I in I in
15 15
24V 24V
C h an n el 8 C h an n el 16
T r a n s m i tt e r 16 T r a n s m i tt e r 16
I in I in

Field Wiring – IOP 305 Analog Input Module
P2 P3
1 1
(-) (-)
0 - 2 .4 V 0 - 2 .4 V
2 2
(+ ) (+ )
3 3
(-) (-)
0 - 2 .4 V 0 - 2 .4 V
4 4
(+ ) (+ )
5 5
(-) (-)
0 - 2 .4 V C h an n el 11
0 - 2 .4 V 6 C h an n el 3 6
(+ ) (+ )
7 7
(-) (-)
0 - 2 .4 V 0 - 2 .4 V
8
8
(+ ) (+ )
9 9
(-) (-)
C h an n el 5 0 - 2 .4 V C hannel 13
0 - 2 .4 V
10 10
(+ ) (+ )
11 11
(-) (-)
C h an n el 6 0 - 2 .4 V
C hannel 14
0 - 2 .4 V 12
12
(+ ) (+ )
13 13
(-) (-)
0 - 2 .4 V C h an n el 7 0 - 2 .4 V
14 C hannel 15
14
(+ ) (+ )
15 15
(-) (-)
0 - 2 .4 V C h an n el 8 0 - 2 .4 V C h an n el 16
16 16
(+ ) (+ )
3-6
Field Wiring For Redundant Modules with Common Transmitter
The following figure shows the recommended wiring for two redundant
IOP305 analog input channels that share a common transmitter.
The recommended maximum distance between the shunt resistor and the I/O
module is 10 meters. The +24V connection is independently fused to each
transmitter. The voltage that is developed across each 100-Ohm shunt by the
4-20 mA signal from the transmitter is wired to the AI module using twisted
pair cables.
The (-) terminal of the loop supply is connected to the (-) side of the shunt
resistors so that the 4-20 mA current does not flow through the twisted pairs
wires. A PTC thermistor is recommended between the transmitter output and
the 100-Ohm shunt. This protects the 100-Ohm shunt against over voltage
and provides additional resistance to increase the transmitter load to 250
Ohms. Kit IOP306 supplies 16 pairs of 100-Ohm shunts and thermistors to
support two IOP305 analog input modules.
(+ )
DCS 24V
L o o p S u p p ly
(-)
T w i s te d p a ir
(-)
100
T r a n s m i tt e r
(+ )
2 - w i re
t h e r m i s to r
P rim a ry
IO P 3 0 5
A I M o d u le
(-)
(+ )
S e co n d a ry
IO P 3 0 5
A I M o d u le

Chapter 4

3 Wire RTD Module IOP303
Overview
This module features 8 isolated 3-wire RTD input channels.
LED Indication
the DPU. It is also used to display errors detected by diagnostics.

Bus Address
For use as a replacement for a Model 564 module this module requires 8 bus
addresses and provides 7 channels. The addressing rules specified in the
Model 564 manuals still apply.
The module contains three jumpers. Refer to the following table for jumper
setting information.

W2 Common I/O Redundant I/O
W3 50 Hz 60 Hz
W4 Not used
W6 Model 564** maxPAC
** For version B or earlier, W7 must be installed for model 564 operation
Module Operation
This microprocessor-based module supports up to 8 RTD inputs, which can
be independently configured. A reference excitation current is provided for
each input. A sigma delta A/D reads the voltage generated by one of the
eight inputs and converts the differential measurement to a 15-bit plus sign
binary value representing the millivolt input, which is read by the
microcontroller.
Multiple readings are done for each channel to compensate for the error
introduced by the field wiring in 3-wire RTDs. The microcontroller initiates
the conversion and waits for the conversion to complete. The digital filter in
the oversampling A/D provides excellent 50/60 Hz normal mode rejection.
The A/D also provides a variable gain amplifier function. Prior to starting
each conversion, the microcontroller sets the gain required in the A/D and
selects the RTD excitation current based on the configuration for that input.
It also selects the input channel by means of four solid-state optically
coupled relays.
The inputs are multiplexed with optical relays to provide channel to channel
isolation. Immediately following each measurement, open RTD and over
range conditions are checked. A DC/DC converter provides isolated power
to the field side of the measuring circuit. Communication between the
microcontroller and the A/D is serial at 100KHz.
4-2
3 Wire RTD Module IOP 303
Optical isolators provide the isolation between the A/D and the serial logic
circuits. The microprocessor provides the input data to the DPU on demand
via the bus FPGA. The FPGA provides the I/O bus interface logic; its
program is loaded from the FLASH on power up.

5 V - lo g ic
5 V - f ie ld D C /D C R e g u la to r 24V
E x c ita tio n
FLA SH
C u rre n t
C hannel 1 REF
F ie ld O PTO uC F ie ld
A /D
I n te r f a c e I n te r f a c e
C ir c u its C ir c u its I /O B u s
C hannel 8
fie ld to lo g ic

Diagnostics

A/D send fault 0x12
Scan Rate 8 points converted in 1.6 seconds
Input Type 10 ohm Cu, 10 ohm Pt, 25 ohm Pt, 100 ohm Cu,
100 ohm Pt, 100 ohm Ni, 1000 ohm Pt
Input Range 0 – 1000 ohms
Accuracy ±0.15% of reading ±0.5oC
Input Multiplexer Solid-state FET, optical isolation
Conversion method Sigma Delta oversampling
Linearization Digital in DPU. RTD ranges may be randomly
mixed.
Calibration Self-calibration on power up. Periodically on
line to compensate for temperature effects.
Maximum Lead Resistance 5 Ohms each lead
Compensation
Backup Conversions disabled if common RTD is
connected to redundant modules.
Conformity Error ±0.3oC, ±0.5oF
Common Mode Rejection 120db @ 50/60Hz, 100 Ohm imbalance
Common Mode Voltage 240VAC RMS, 350VDC peak
Input Power 125 mA
4-4
The following tables show the supported RTD types and the temperature range over which the accuracy is
maintained. The quality indication for the values will go “Doubtful” if the range is exceeded.
Degrees F
RTD Type Low Range High Range
101 100 Ohm Platinum a 385 -292 1,562
102 10 Ohm Copper -103 302
103 10 Ohm Platinum -94 1,832
104 25 Ohm Platinum -330 1,000
105 100 Ohm Nickel IPTS 68 -40 284
106 100 Ohm Copper 25C -310 302
107 1000 Ohm Platinum -328 932
108 100 Ohm Platinum a 3902 0 212
109 100 Ohm Platinum a 392 -328 1,166
110 98 13 Ohm Platinum -328 1,112
111 100 Ohm Platinum a 3916 -328 1,148
112 25 5 Ohm Platinum -328 1,166
113 100 Ohm Copper a 427 -148 500
114 50 Ohm Copper -148 500
115 9 035 Ohm Copper -148 500
116 100 Ohm Nickel a 618 -76 356
117 120 Ohm Nickel -112 500
118 604 Ohm Nickel Iron -148 399
119 1000 Ohm Nickel Iron -148 399
Degrees C
RTD Type Low Range High Range
201 100 Ohm Platinum a 385 -180 850
202 10 Ohm Copper -75 150
203 10 Ohm Platinum -70 1,000
204 25 Ohm Platinum -201 538
205 100 Ohm Nickel IPTS 68 -40 140
206 100 Ohm Copper 25C -190 150
207 1000 Ohm Platinum -200 500
208 100 Ohm Platinum a 3902 -18 100
209 100 Ohm Platinum a 392 -200 630
210 98 13 Ohm Platinum -200 600
211 100 Ohm Platinum a 3916 -200 620
212 25 5 Ohm Platinum -200 630
213 100 Ohm Copper a 427 -100 260
214 50 Ohm Copper -100 260
215 9 035 Ohm Copper -100 260
216 100 Ohm Nickel a 618 -60 180
217 120 Ohm Nickel -80 260
218 604 Ohm Nickel Iron -100 204
219 1000 Ohm Nickel Iron -100 204

Field Wiring
P2 P3
1 1
D o N o t U se D o N o t U se
2 2
3 C hannel 1 3 C h a n n e l5
4 4
5 5
6 6
7 7
8 8
9 9
10 10
0 0
12 12
13 13
14 14
15 15
11 16 1161
Note: Field wires must be of equal length
4-6
Field Wiring For Redundant Modules with Common RTD
T w i s te d p a ir , s a m e le n g th
(+ )
(-)
P r i m a ry
IO P 3 0 3
R T D M o d u le
R et
W 2 – n o t in s t a l le d
(+ )
(-) S e c o n d a ry
IO P 3 0 3
R T D M o d u le
R et
W 2 - n o t i n s t a l le d

Chapter 5

TC Module IOP304
Overview
This module features 16 isolated thermocouple or emf input channels
LED Indication
DPU. This LED blinks on and off at a constant rate when the module is not
being scanned by the DPU.

Bus Address
even boundary (i.e. 32, 34, 50 etc.) in the range of 32 to 252. Addresses 0
to 31 are reserved for digital input modules.
The module contains three jumpers. These jumpers are located at the rear of
the module above the edge connector. Refer to the following table for
jumper setting information.

W3 50 Hz 60Hz
W6 Model 564 maxPAC
Cold Junction Compensation

If this module is configured by the DPU to perform cold junction
compensation, a thermistor (Metso Part No. 074566) must be installed in
connectors P4 and P5 at the front of the module, above and below the input
connectors.
Module Operation
This microprocessor-based module supports up to 16 TC or emf inputs,
which may be independently configured. A sigma delta A/D reads the
voltage generated by one of the 16 TC or emf inputs and converts the
differential measurement into a 15 bit plus sign binary value representing the
millivolt input, which is read by the microcontroller. The microcontroller
initiates the conversion and waits for the conversion to complete.

normal mode rejection. The A/D also provides a variable gain amplifier
function. Prior to starting each conversion, the microcontroller sets the gain
required in the A/D for each configured input measurement, and selects the
input channel by means of two solid state, optically coupled relays.
5-2
TC Module IOP304
The inputs are multiplexed with optical relays to provide channel to channel
isolation. Immediately following each measurement, open TC and over range
conditions are checked. A DC/DC converter circuit provides isolated power
to the field side of the measuring circuit. Communication between the
microcontroller and the A/D is serial at 100KHz. Optical isolators provide
the isolation between the field side and the serial logic circuits. The
microprocessor provides the input data to the DPU on demand via the bus
FPGA. The FPGA provides the I/O bus interface logic; its program is loaded
from the FLASH on power up.

When thermocouples are measured, the module monitors the TC cold

junction temperature and the input value read is compensated for the cold
junction temperature. Thermistors, installed at the terminal blocks provided
above and below the field connectors, are used to measure the TC cold
junction temperature. When remote terminations are used, these thermistors
must be removed from the module and moved to the wiring connections at
the remote terminations. The microcontroller schedules periodic
measurements of the thermistors and uses these measurements to calculate a
cold junction temperature for each channel.
5 V - lo g ic
5 V - f ie ld D C /D C R e g u la to r 24V
FLA SH
C hannel 1 REF
A /D O PTO uC
F ie ld I n te r f a c e
FPG A
C ir c u its
I /O B u s
O PEN
TC
C hannel 16

fie ld to lo g ic
Diagnostics



A/D send fault 0x12
Scan Rate 16 points converted in 1 seconds
Input Type Types B, D, E, G, J, K, N, R, S, T, Platinell II
Type B: 250oC to 1800oC
Type E: -200oC to 1000oC
Type J: -210oC to 1200oC
Type K: -200oC to 1370oC
Type N: -200oC to 1300oC
Type R: -50oC to 1768oC
Type S: -50oC to 1768oC
Type T: -200oC to 400oC
Input Range +/-10mv, +/-25mv, +/-60mv, +/-100mv,
+/-250mv, +600/-250mv
Accuracy ±0.15% of reading ±0.5oC
Input Multiplexer Solid-state FET, optical isolation
Conversion method Sigma Delta oversampling
Linearization Digital in DPU. RTD ranges may be randomly
mixed.
Calibration Self-calibration on power up. Periodically on
line to compensate for temperature effects
RJ Compensation Digital in module
Open TC Detection Performed each reading (1,000 0hm threshold)
Backup Conversions disabled if common TC is
connected to redundant modules
Conformity Error ±0.3oC, ±0.5oF
Reference Junction Error ±0.25oC
5-4
TC Module IOP304
Input Power 125 mA
Field Wiring
P2 P3
1 1
+ +
2 2
- -
3 3
+ +
4 C h an n el 2 C h an n el 10
4
- -
5 5
+ +
6 C h an n el 3 6 C h an n el 11
- -
7 7
+ +
- -
9 - -
9
+ +
10 10
0 - -
0
11 11
+ +
12
- -
13 13
+ +
14
- -
15 15
+ +
11 16 C h an n el 8 11 16 C h an n el 16
- -

Field Wiring For Redundant Modules with Common TC
(+ )
(-)
P r im a r y
IO P 3 0 4
T C M o d u le
T C e x te n s io n w ir e W 2 – n o t in s ta lle d
(+ )
(-)
S e c o n d a ry
IO P 3 0 4
T C M o d u le
W 2 - n o t in s ta lle d
Note: Thermistors must be installed in both modules.
5-6
Chapter 6
Analog Output Modules

4-20 mA Output Module IOP320
4-20 mA Isolated Output Module IOP321
These modules, featuring eight 4-20 mA output channels, receive power

from the 24V-system supply via the backplane edge connector. Loop power
is also available to the IOP320 module via the backplane and is individually
fused 24V for each channel. The IOP321 module provides fused isolated
field power for each channel.
LED Indication
the DPU.

The IOP320 has a second green LED that provides the status of the loop
power fuse disconnect. If the fuse blows or is removed, the LED will go off
indicating that none of the eight AO channels have loop power (i.e., none of
the AO channels will work).
Since the IOP321 has 8 isolated outputs, there is no need for a common fuse
or LED. Instead, each output has an electronic fuse that automatically resets
when the output fault is removed. An output fault on one channel will not
affect the other channels.
Bus Address
The IOP320 module requires eight bus addresses, one address for each
channel. Each module address must start on a 0 or eight boundary (i.e. 32,
40, 48, etc.) in the range of 32 to 240 decimal. A valid AO address must be
evenly divisible by 8. Remember that the addresses in maxDPUTOOLS are
shown in decimal but the address switches on the modules are in
hexadecimal. That means that the low order switch must be set to either a 0
or to an 8. Here are a few examples:
32 decimal = 20 hex. Set the address switches to 2 – 0.
40 decimal = 28 hex. Set the address switches to 2 – 8.
232 decimal = E8 hex. Set the address switches to E – 8.
The IOP321 module only requires two consecutive bus addresses when the
jumper is set for the two address burst mode. The address must start on an
even boundary (i.e. 32, 34, 36, etc.) in the range of 32 – 252 decimal.
If you configure the IOP321 for 8 address mode, follow the address rules for
the IOP320.
Addresses 0 to 31 are reserved for digital input modules.
The IOP320 module contains four jumpers. Refer to the following table for
jumper setting information. Note: this is for the newer modules that have
two rotary address switches.

W1 Run Mode Calibrate Mode
W2 Hold Output Reset Output
W3 Secondary Primary
6-2
4-20mA Output Module IOP320
4-20mA Isolated Output Module IOP321
The IOP321 module contains the following jumpers.

W1 maxPAC-8 address 2 address – burst mode
W4 Not used Not used
Definitions:
Run Mode or Calibrate Mode – Set to Run Mode for normal operation.
Calibration mode is used for factory calibration and must be run after a
program update. (IOP320 only, the IOP321 uses auto calibration)
Hold Output or Reset Output – Hold output will retain the last value if
communication is lost to the DPU. The Reset Output will reset the output to
0ma if communications is lost to the DPU for more than 700ms. When
communications has been lost due to a reset of the DPU, the initialization
logic of the user configuration will determine the initial value of the Analog
Output.
Secondary or Primary – for Redundant I/O set the card associated with the
Primary DPU to Primary and the card associated with the Secondary DPU to
Secondary.
Common I/O or Redundant I/O – set to Common I/O if using a single card or
to Redundant I/O if using two cards configured as redundant I/O.
maxPAC-8 address or 2 address – burst mode (IOP321 only) – maxPAC-8

address is used for compatibility when the DPU is using the 8 address mode.
When this mode is set, the IOP321 can be used as a direct replacement for an
IOP320. The two address-burst mode is the best option, and should be used
when supported by the DPU.
Module Operation
This microprocessor-based modules support up to eight 4-20 mA output
channels. Communication between the microcontroller and each output is
serial. The output request received from the I/O bus is translated by the
microcontroller and transmitted to each output circuit via a high-speed
optical isolator. This optical isolator provides the isolation between the logic
and the field.
For the IOP320, the interface to the output circuit is a pulse width modulated
signal. The duty cycle of the serialized output is proportional to the output
level. The output circuit converts this signal into 4-20 mA. Open load is

detected and reported to the DPU. The IOP321 uses a synchronous serial
interface to set the outputs. Channel to channel isolation is also provided in
this module.
The FPGA provides the I/O bus interface logic; its program is loaded from
the FLASH on power up.
A watchdog timer function is included to monitor communications on the

I/O bus. The watchdog timers will timeout if there is no communications on
the I/O bus for longer than 0.7 seconds. When this occurs, the outputs will
either reset or remain in their last state depending on the position of the
onboard program jumper.

diagnostics.
The 24-Volt loop supply is available to the IOP320 module from the
backplane. All the outputs are connected to the loop supply. The IOP321
module provides isolated field power for each channel.
A O M o d u le
5 V - lo g ic
R e g u la to r 24V
FLA SH
4 -2 0 m a
C hannel 1 out D /A 1 O PTO
uC
P o w e r e d f r o m f ie ld FPG A
I /O B u s
2 4 V s u p p ly
4 -2 0 m a
C hannel 8 out D /A 8 O PTO
o p tic a l is o la tio n
f ie ld to lo g ic
6-4
Diagnostics

Calibration Error (channel 1 to 8) 0x41 – 0x48
IOP320 IOP321
Resolution 12 bits 16bits
Rise Time 750 msec. 10 msec
Temperature Sensitivity ±0.004% of reading/oC +/-50 ppm of FS/oC
±1.5uv/oC RTI
Accuracy at 25oC ±0.1% of reading ± .05% 0.25% of full scale
of full scale
Span 4 to 20 mA. 4 to 20 mA.
Calibration Self-calibration on power No Calibration Required
up with calibration
jumper set
Load Impedance 0 – 800 Ohms 0 – 600 Ohms
Input Power 175 mA 400 mA
(from 24V system
supply)
Isolation Field to System Field to System
Channel to Channel

Field Wiring
P2
1
Iout
C hannel 1
Load 2
R e tu r n
3
Iout
C hannel 2
Load 4
R e tu r n
5
Iout
Load 6 C hannel 3
R e tu r n
7
Iout
C hannel 4
Load 8
R e tu r n
9
Iout
C hannel 5
Load 10
R e tu r n
11
Iout
C hannel 6
Load 12
R e tu r n
13
Iout
Load 14 C hannel 7
R e tu r n
15
Iout
Load C hannel 8
16
R e tu r n
6-6
Field wiring for redundant modules with common end element
Current (+)
Loop
Controlled (-)
Device Primary
IOP320
AO Module
W2 – as needed
W3 – not installed
W4 - not installed
(+)
(-)
Secondary
IOP 320
AO Module
W2 – as needed
W3 – installed
Current (+)
Loop
Controlled (-)
Device Primary
IOP321
AO Module
W2 – as needed
W5 - not installed
(+)
(-)
Secondary
IOP 321
AO Module
W2 – as needed
W3 – installed

Chapter 7
Digital Input Modules

24V Common Input Module IOP330
Overview
These modules feature 16 digital common inputs.
LED Indication
Individual red front-panel LEDs provide the input status indication for each
channel. A green LED, labeled Active at the bottom of the module front
panel, is on when system power is present and the module is communicating
with the DPU. This LED blinks on and off when the module is not being

scanned by the DPU. A second green LED provides the status of the loop
power fuse disconnect.
Bus Address
This module requires one bus address. The address range for digital input
modules is 0 to 31 (0 – 1F). The address range for digital input modules
configured as “slow DIs” is 32 to 254.
Module Operation
The following is a simplified sketch of the circuit for one channel. The
signal-conditioning block provides filtering, current limiting circuit, and an
input threshold. It also includes the input status LED. The optical isolator
provides isolation between the field circuits and the logic circuits. The input
status is buffered and latched in the I/O bus interface circuit. The data is
presented to the I/O bus as a 16-bit word when the module is scanned by the
DPU. A watchdog timer in the I/O bus interface circuit controls the
operation of the active LED, causing it to blink when the module is not
scanned for 0.7 seconds.
The 24V/48V(+) and 24V/48V(-) loop power signals are connected to all the
channels. They are routed to the module from the backplane via a fuse
disconnect which is accessible from the front of the module.
2 4 V /4 8 V ( - ) 2 4 V /4 8 V ( + )
F u s e d is c o n n e c t
S ig n a l I /O B U S
C o n d itio n in g I n te r f a c e
C ir c u it C ir c u it
T o o t h e r c h a n n e ls
7-2
IOP 330 – 24V IOP331 – 48V
Rated Input Voltage 24Vdc nominal, 40 Vdc 48Vdc nominal, 60V dc
maximum maximum
Input current per point 5 mA @ 24 Volts 5 mA @ 48 Volts
On-State Voltage 8.5 Volts 22 Volts
Isolation 250 VAC continuous, 1,500 VAC for 1 minute
User input to logic
Indicators 1 LED per point provides status indication.
LED provides power and communication indication.
LED provides loop power disconnect status
I/O Bus Address One address
Input Power 50 mA

Field Wiring
P2 P3
1 1
2 2
3 3
4 4
5 5
6 C h an n el 3 6 C h an n el 11
7 7
8 8
9 9
10 10
0 0
11 11
12
13 13
14
15 15
11 16 C h an n el 8 11 16 C h an n el 16
7-4
Field Wiring For Redundant Modules with Common DI
(+ )
(-)
P r im a r y
I O P 3 0 ,3 3 1
D I M o d u le
(+ )
(-)
S e co n d a ry
I O P 3 3 0 ,3 3 1
D I M o d u le

Chapter 8

24V DC Isolated Input Module IOP334
120V AC/DC Isolated Input Module IOP332
Overview
These modules provide16 isolated digital inputs
LED Indication
Individual red front-panel LEDs provide the input status indication for each


scanned by the DPU.
Bus Address
This module requires one bus address. The address range for digital input
modules is 0 to 31 (0 – 1F). The address range for digital input modules
configured as “slow DIs” is 32 to 254.
For IOP332 and IOP333, jumpers (W1—W16) must be installed for AC
inputs.
Note: IOP334 does not include jumpers.
Module Operation
The following is a simplified sketch of the circuit for one channel. The
signal-conditioning block provides filtering, current limiting circuit, and an
input threshold. It also includes the LED. The optical isolator provides
isolation between the field circuits and the logic circuits. The input status is
buffered and latched in the I/O bus interface circuit. The data is presented to
the I/O bus as a 16-bit word when the module is scanned by the DPU. A
watchdog timer in the interface circuit controls the operation of the active
LED, causing it to blink when the module is not scanned for 0.7 seconds.
S ig n a l I /O B U S
I n p u t V o lta g e C o n d itio n in g I n te r f a c e
C ir c u it C ir c u it
8-2
IOP 332 – 120V IOP333 – 240V IOP334 – 24V
Rated Input 120 Volts ac/dc nom. 240 Volts ac/dc nom. 24V dc nominal,
Voltage 180 Volts max 280 Volts max 40V dc max
Input current per 5 mA @ 120 Volts 5 mA @ 240 Volts 5 mA @ 24Volts
point
On-State Voltage 48 Volts dc 70 Volts dc 8.5 Volts dc
100 Volts ac
Isolation 60 VAC; 250 VAC continuous, 125 VAC; 1500 VAC for 1 minute
User input to
logic
Isolation 350 VAC continuous
Channel to
channel
Indicators 1 LED per point provides status indication
LED provides power and communication indication

Input Power 50 mA
(from 24V
system supply)

Field Wiring
P2 P3
1 1
A C /D C C hannel 1 C hannel 9
2 A C /D C 2
3 3
A C /D C 4 C hannel 2 A C /D C 4 C hannel 10
5 5
7 7
A C /D C 8 A C /D C 8
9 9
0 0
11 11
13 13
15 15
A C /D C 11 16 A C /D C 11 16
8-4
Field Wiring For Redundant Modules with Isolated DI
(+ )
(-)
A C /D C
P r im a r y
D I M o d u le
(+ )
(-)
S e co n d a ry
D I M o d u le

Chapter 9

Counter Timer Module IOP335
This module provides eight isolated digital input channels. Each channel
provides a pair of digital inputs, which can be individually programmed to
support 24, or 48 Volt inputs.
F e a tu re s
S o ftw a re s to re d in F L A S H
L o w P o w e r D is s ip a tio in
C o n fig u ra tio n p e r c h a n n e l
LED Indication
A red status LED is provided for each input. A green LED, labeled Active on
the module front panel, is on when system power is present and the module
is communicating with the DPU. This LED blinks on and off when the
module is not being scanned by the DPU.

Bus Address
This module only requires two bus addresses and provides 8 channels.
Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in
the range of 32 to 252. Addresses 0 to 31 are reserved for digital input
modules. This module is compatible with DPU4E and DPU4F only.
A two-position jumper is used to select the input voltage for each channel.
The input number identifies the jumpers. The two positions are A and B as
follows:

W1A - 16A 24 V 48V
W4 Factory test Normal Operation
This microprocessor-based module supports up to eight pulse input channels.

Each channel can be independently configured for both function type and
debounce time. The functions supported are:
Mode 1 – Frequency Input
Frequency in counts per second in input1. Input 2 is not used. The

Pulse I/O Buffer in DPU4E supports the following timebase mode
selections for frequency measurement: 20 msecs, 50 msecs, 100
msecs, 250 msecs, 500 msecs, and 1 second. For the selected
timebase, the Pulse I/O module measures frequency for the
specified duration and normalizes each measurement to cycles per
second. The measurement is updated at the end of each interval
and the counts read by the DPU when the module is scanned
represent the average of the last four measurements in
cycles/second. The scan rate of the DPU is asynchronous from
the scan rate by the module. The accuracy of the frequency
measurement is +/-1 count for the one-second timebase. The
accuracy for the other timebases is approximately the normalizing
multiplier divided by 4. Thus for the shortest timebase (20 msecs),
the accuracy is reduced to approximately +/-12 counts.
In applications requiring fast frequecy measurements, a period

measurement (mode 7) can also be used to measure frequency.
Since each count in the period measurement corresponds to 0.5
microseconds, the inverse of the period will yield a fast frequency
9-2
measurement with an accuracy of 0.1% for a 2000Hz input and

0.25% for a 5000Hz.
Mode 2– Simple Event Counter (default configuration)
32 bit accumulation of OFF-to-ON transitions in input1. Input2

provides an external accumulator reset.
Mode 3 – Up/Down Event Counter
Net counts of OFF to ON transitions in input1 and input2. Input1

counts up and input2 counts down.
Mode 4 – On-Time Timer
The timebase frequency (0.5 usec/count) is counted while input1 =

ON. Input 2 provides an external reset.
Mode 5 – Up/Down Pulse Timer
Counts corresponding to the on-time difference in input1 and input2.

The timebase frequency (0.5 usec/count) is counted up while
input1 = ON and counted down while input2 is ON.
Mode 6 – Pulse Width
ON time of last detected pulse in input1, based on the timebase

frequency (0.5 usec/count). Input2 is not used. The measurement
is updated at the end of each detected pulse (ON to OFF
transition). Counts read by DPU represent the average of the last
four measurements.
Mode 7 – Period
Time duration between the last onset of input1and the previous onset
of input1. The timebase frequency (0.5 usec/count) is counted
during this time. Input2 is not used. The measurement is updated
at the end of each detected period. Counts read by DPU represent
the average of the last four measurements.
Module Operation
This microprocessor based module supports up to 16 digital inputs. As
shown in the functional block diagram, the field circuits are used to detect
and optically isolate the digital inputs. High-speed optical isolators support
higher frequency inputs. The processor circuits implement the configured

timing functions and provide the interface to the I/O bus FPGA. The Time
Processor Unit (TPU) included in the 68332 processor is used to process the
timing functions. The TPU operates from microcode masked in 68332 ROM.
The 16 DI inputs are debounced in an FPGA and are available individually
to the processor TPU inputs.
Diagnostics
The module executes diagnostics on power up. To indicate any errors
detected during power-up or on-line operation the LED labeled active blinks
the first digit at a slower rate and the second digit at a faster rate.
During normal operation this LED stays on or flashes at a steady one-second

rate when the module is not being scanned. The diagnostic codes are as
follows:

Input voltage 24V, 48V jumper selectable
Input thresholds 24V – 10 Volts
48V – 20 Volts
Debounce 0-255 msec dynamically configured per
channel
Accuracy 1 cycle or ±0.15%, whichever is greater
Maximum frequency 32KHz
Minimum Pulse Width 10 usecs
Input Power 150 mA
9-4
Field Wiring
P2 P3
1 1
+ +
v
2 4 V /4 8 V In p u t 1 In p u t 9
2 2 4 V /4 8 V 2
- -
C hannel 1 3 C hannel 5 3
+ +
2 4 V /4 8 V In p u t 2 2 4 V /4 8 V In p u t 1 0
4 4
- -
5 5
+ +
2 4 V /4 8 V 6 In p u t 3 2 4 V /4 8 V 6 In p u t 1 1
- -
+ +
In p u t 4 In p u t 1 2
2 4 V /4 8 V 8 2 4 V /4 8 V 8
- -
9 9
+ +
2 4 V /4 8 V In p u t 5 2 4 V /4 8 V In p u t 1 3
10 10
- 0 - 0
+ +
2 4 V /4 8 V 12 In p u t 6 2 4 V /4 8 V In p u t 1 4
12
- -
13 13
+ +
2 4 V /4 8 V 14 In p u t 7 2 4 V /4 8 V In p u t 1 5
14
- -
+ +
2 4 V /4 8 V 11 16 I n p u t8 11 16
2 4 V /4 8 V In p u t 1 6
- -

Chapter 10
Digital Output Modules

Form A/B Relay Module IOP351
Form C Relay Module IOP350
Relay Driver Module IOP353
Overview
These modules provide 16 Form A relays, 10 form C relays, or 16 Relay
Driver outputs. The form A outputs can be converted to form B via on-board
jumpers.

LED Indication
Individual red front-panel LEDs provide the output status indication for each
scanned by the DPU.
Bus Address
This module requires one I/O one bus address.
This module requires one bus address. The address range for digital output
modules is 32 to 254. Addresses 0 to 31 are reserved for digital input
modules.
Jumper W1 configures all the outputs to either reset or fail in place when
there is no communications in the I/O Bus for more than 0.7 seconds.
Configuration is as follows:
Jumper Position 2-3 Position 1-2

W1 Reset Output Hold Output
(Drop)
For the IOP351 module, each channel can be strapped in the printed circuit
assembly for form A or form B operation per the following table. The default
configuration is form A for all channels.
Channel Number Form A Form B

1 R100 R101
2 R103 R104
3 R106 R107
4 R108 R109
5 R111 R112
6 R114 R115
7 R116 R117
8 R119 R120
9 R122 R123
10 R124 R125
11 R127 R128
12 R130 R131
13 R132 R133
14 R135 R136
15 R138 R139
16 R140 R141
10-2
Module Operation
The following is a simplified sketch of the circuit for one channel. The relay
drivers energize the relay coils and control the operation of the output LEDs
to correspond to the data in the I/O bus interface circuit. A watchdog timer in
the interface circuit controls the operation of the active LED, causing it to
blink when the module is not scanned for 0.7 seconds. It also controls the
state of the outputs on loss of communications.
5V R eg 24V
C hannel 1
BUFFER
I /O B u s
I /O B u s
I n te r f a c e
C ir c u it
C hannel 16
PRO M

fie ld to lo g ic
Relay Outputs IOP350 and IOP351

5V Reg +24V
Channel 1
+24V
BUFFER
I/O Bus
Interface I/O Bus
Circuit
Channel 16
+24V
PROM
Relay Driver Outputs IOP353
CAUTION: This Module does not support operation using an external power supply.
The +24V output on this module must be used to prevent false operation under
various cable or power failure conditions.
10-4
IOP 350 – Form C IOP351 – Form A/B IOP353 – Relay Driver
Maximum Switching 5 amps @ 250 VAC 100 mA @24 VDC
Capacity 3 amps @ 30 VDC
0.3 amps @ 110 VDC
Number of Channels 10 16 16
Expected Relay Life Mechanical @ 180cpm - 5X10^6 Unlimited
Electrical @ 20cpm (resistive load) – 10^5
Maximum Operating Speed 20cpm
Operating Time 15 msec. Maximum (excluding bounce) 1 msec. Maximum (excluding
external relay)
Release Time 5 msec. Maximum (excluding bounce) 1 msec. Maximum (excluding
external relay)
LED Indication 1 LED per point provides output status indication
active LED provides power and communication indication
Input Power 400 mA 2.0 Amps maximum with all
(from 24V system supply) outputs driving full load.

Field Wiring – IOP 351 (Form A/B Relay Module)

P2 P3
1 1
2 2
3 3
4 4
5 5
7 7
8 8
9 9
10 10
0 0
11 11
13 13
15 15
C hannel 8 11 16 C hannel 16 11 16
10-6
Wiring – IOP350 (Form C Relay Module)
P2 P3
1 1
2 2
C hannel 1
C hannel 6
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
0 0
11 11
12 12
13 13
14 14
15 15
11 16 11 16

Field Wiring – IOP 353 (Relay Driver Module)

P2 P3
1 1
Return Return
Channel 1 Channel 9
2 2
+24V +24V
3 3
Return Return
Channel 2 4 Channel 10 4
+24V +24V
5 5
Return Return
+24V +24V
7 7
Return Return
Channel 4 Channel 12
8 8
+24V +24V
9 9
Return Return
0 +24V 0 +24V
11 11
Return Return
+24V +24V
13 13
Return Return
+24V +24V
15 15
Return Return
Channel 8 11
16 Channel 16 16
+24V +24V
CAUTION: This Module does not support operation using an external

power supply. The +24V output on this module must be used to
prevent false operation under various cable or power failure
conditions.
10-8
Field Wiring For Redundant Modules with Common End Element
Power (+)
Source
(-)
Primary
Switched Relay Module
Device
W1 – Drop
Position 2-3
(+)
(-)
Secondary
Relay Module
W1 – Drop
Position 2-3
Relay Outputs IOP350 and IOP351
(- Return)
(-)
Interposer
(+24V)
Relay Primary
Relay Module
(+)
W1 – Drop
Position 2-3
(- Return)
(+24V)
Secondary
Relay Module
W1 – Drop
Position 2-3
Relay Driver IOP353

Chapter 11
Bus Extender Module

Module IOP371
Overview
The Bus Extender Module (BEM) provides a flexible way to distribute the
system throughout the plant, resulting in reduced cabling costs and
installation time. Placing I/O in remote cabinets closer to a given process
typically reduces tray loading and the number of required junction boxes
since remote I/O cabinets are substituted. It also shortens wiring distances to
field devices, such as thermocouples and RTDs.
Features
 Geographic distribution of I/O
 Distance up to 2000 meters
 Real time I/O bus expansion
 Redundant high speed optical links
 Digital output indication of optical link
failover

BEM Front Panel

The BEM front panel contains a pair of optical connectors (optical
transceivers), LEDs to report the status of the two optical links, a push
button for link testing, and screw connections to a Form-C relay, used to
detect and report the failure of either optical cable when redundant cables
are provided (optional).
Link Fail Relay

The relay wiring is shown below.
P2 -1 (top screw) = N.O. contact
P2 -2 = Common
P3 – 3 = N.C. contact
The BEM supports two optical communications links, only one of which is
active at a time. The relay is energized upon loss of communications on the
active optical link. Assume that optical cables are connected to both Link1
and Link 2. Further, assume that Link 1 is active. If the Link1 cable is
removed, communications will be briefly interrupted as the BEM switches
over to Link 2. During the short time when there is no communications, the
relay will activate. If Link 2 is also broken, there will be no communications
and the relay will stay active until a cable is restored and the link is
reestablished. The relay is not energized upon loss of power to the module.
LED Indications
Individual green front-panel LEDs provide status indication for each
channel. The lower LED, labeled Active at the bottom of the module front
panel, is on when the BEM and its associated DPU are active. The LEDs
labeled “link1” and “link2” indicate which optical link is operational.
Link Test
A link test pushbutton is provided to switch operation between the two
optical links. This can be used to verify that the two links are operational.
The link failure relay will activate momentarily when the button is pushed to
switch to the other cable.
Bus Address
This module does not require a bus address.
The module contains two jumpers located in the bottom right corner of the
board. Refer to the following table for jumper setting information.
11-2
Bus Extender Module IOP371

W1 Remote Local
*W3 Redundant Common
* Refer to Figures 11-3, 11-4, 11-5 and 11-6 for jumper settings for local and remote,
common and redundant combinations
Bus Extender Modules, configured in pairs, support both locally and

remotely mounted I/O cards. The local BEM installed with the DPU plugs
into the I/O backplane to access the DPU's parallel I/O bus. Locally mounted
I/O can share the I/O bus with the BEM. The remote BEM receives the bus
data over the optical link and establishes the I/O bus at the remote location.
A single DPU, or redundant pair of DPUs, can communicate with I/O

modules that are locally and/or remotely mounted. In a typical configuration
using redundant Distributed Processing Units (DPUs), an I/O cabinet
installed locally in a control room contains I/O modules, a DPU pair, and a
BEM pair. This is connected via I/O optical cables to a ruggedized remote
cabinet containing I/O modules and a second BEM pair. The optical link is
established between the local and remote Extender modules as shown in
figure 11-4.
DPU Compatibility
The Extender is compatible with 4A, 4B and 4E DPUs, but is not compatible
with the earlier DPU3, DPU4 or controller file models. To use a bus
Extender with DPU 4A and 4B, firmware EPLD may need to be updated.
Contact Metso Automation Customer Care for assistance.
I/O Bus Loading

BEMs may also be used to expand the number of I/O modules that may be
configured locally. The local BEM represents the same bus loading as one
I/O module, regardless of the number of I/O modules attached to the remote
I/O bus. Without the use of BEMs, a single DPU supports up to 60 modules.
When BEMs are used, a DPU could support up to 60 modules locally and up
to 45 modules (including a remote BEM) at each remote location. See Figure
11-2. The DPU supports a maximum of 255 I/O addresses (local + remote
modules).
Important: Remember other factors limit the number of modules you may
configure, such as I/O mix, DPU loading, application requirements, etc. Such
sizing factors need to be considered when planning I/O configurations. See
also "BEM Configuration Considerations."
Optical Cabling
The two front-accessible optical transceivers, designated Link 1 (top link)
and Link 2 (bottom link), each have two ST type connectors, one to transmit

(Tx) and the other to receive (Rx). The fiber optic cable connects the
transmit output of one BEM to the receive input of the other BEM.
Multimode 62.5-micron cable is used to connect the local and remote

Extender modules. Cable is run between the redundant optical transceivers
to support redundant optical cable pairs. If redundant cables are provided,
one cable pair is always active while the second pair serves as a hot standby
link. See "Ensuring Link Availability.
Model 564 and maxPAC I/O Compatibility

Because the Extender module has the same form factor as the Model IOP I/O
modules, it can be used in either Model 564 or maxPAC applications. The
module installs in an IOP015 4-pack I/O Chassis or any of the maxPAC
chassis described in chapter 1.
Termination Requirements
Two terminations are required on each electrical I/O bus segment; one at
each end of the bus. This rule applies to the local I/O bus (the bus segment
that contains the DPU) as well as to all remote I/O busses (bus segments that
contain only the BEM and I/O modules).
The DPU itself acts as a terminator so one Terminator card (CPO402) is

required on the other end of the DPU local bus segment. The Local BEM
does not require any more termination than this.
The Remote BEM I/O bus segment does not contain a DPU. Thus, two
terminator cards (CPO402) are required – one plugged in to each end of the
Remote BEM’s electrical bus. The Remote BEM must be placed in the left
or right end of its rack in slot 1 or slot 8. A Terminator card must be placed
adjacent to the BEM, and the other Terminator card must be placed at the
other end of the remote BEM’s electrical bus. See the figure 11-1 titled
“Termination of Local and Remote BEM Busses”.
11-4
D
P P9 P9
P11 P11 Terminator
U P10 P10
D B
P P9 P9
P11 P11
E
U P10 M P10
B
P9
P11 E
M P10 Fiber Optic Cables
Terminator P9
P11
P10
Figure 11–1. Termination of Local and Remote BEM Busses
Non Redundant BEM Configuration Approaches

This type of a configuration can have single or redundant DPUs on a
common I/O bus in which a non redundant BEM is present. See Figure 11-3.
Multiple BEMs can be connected to the I/O bus to allow multiple remote
locations for I/O. See Figure 11-2. A DPU can support up to 60 BEMs
and/or I/O modules and 45 I/O modules per BEM. When multiple BEM
modules are connected to different parts of the system, all BEMs connected
to a DPU must share the same I/O bus as the DPU.
Local Model IOP I/O Bus - Up to 60 BEMs and/or I/O Modules
I I B B B D
/ / E E E P
O O M M M U
Redundant Optical Links
Remote I/O Bus – Area 1 Remote I/O Bus – Area 2 Remote I/O Bus – Area 3
Up to 45 Modules Up to 45 Modules Up to 45 Modules
Figure 11-2. The DPU Supports up to 60 Modules Locally and Up to 45 per Remote Location.

backplane
D
P
Control
U
Room
W1 Installed
W3 Installed
B
I I
E
O O
M
B
I I I I
E
O O O O
M
Optical Optional
To other
Cable Redundant
Locations Optical Cable
Remote
B Location
I I I
E
W1 not installed O O O
M
W3 installed
I I I I
O O O O
Figure 11-3. Non redundant BEM with local and remote common I/O configuration. The
redundant optical cables shown in this illustration are optional but recommended.
Redundant BEM Configuration Approaches – Three types

In a redundant BEM configuration, I/O may be configured to be redundant or
common at the local and/or remote end. A redundant configuration consists
of a primary and secondary DPU; each with its own associated BEM.
11-6
Redundant BEMs may be employed in any of the following configuration

schemes:
1. Local Redundant I/O and Remote Common I/O (with or without local
common I/O).
2. Local Redundant I/O and Remote Redundant I/O (with or without local
common I/O).
3. Local common I/O and remote common I/O.
Configuring Local Redundant I/O and Remote Common I/O

In a local redundant I/O configuration, the I/O bus from each DPU at the
local end is connected separately to the redundant modules. The I/O busses
must be connected using a maxPAC Redundant I/O cable (CPO309) or a Y-
module or I-module. If required, common I/O modules can be attached to the
configuration at the local position. A Y-module (CPO401) or an I-module
(CPO403) can be used to combine the two separate local busses into a
common I/O bus. (See fig 11-4)At the remote end, the two remote BEM
modules that are connected to the primary and the secondary DPUs, are to be
connected to the same parallel I/O bus or daisy chained I/O busses. Refer to
figure 11-4 to view a representation of this configuration. Refer to section
titled “Termination Requirements” for details on terminating the remote
common I/O bus.
Configuring Local Redundant I/O and Remote Redundant I/O

The local portion of this configuration would be same as above where the
redundant busses with redundant DPUs and redundant I/O modules are
connected using a maxPAC Redundant I/O cable (CPO309) or a Y-module
or I-module.. If required, common I/O modules can be attached to the
configuration at the local position. A Y-module (CPO401) or an I-module
(CPO403) can be used to combine the two separate local busses into a
common I/O bus. (See fig 11-4). However, at the remote side, the I/O bus
connections to the BEMs’ end must be isolated for redundant I/O
applications. Refer to figure 11-5 to view a representation of this
configuration. Refer to section titled “Termination Requirements” for details
on terminating the remote I/O busses.
Configuring Local and Remote Common I/O

In a redundant DPU and redundant BEM configuration using local common
I/O, the I/O bus “active” control signal from each DPU must be connected to
its associated BEM only. A special cable (LD075267 or LD050107) must be
used to connect the local I/O bus between the racks housing each DPU.
When this cable is used, jumpers in the following module types must be set
up for common I/O as follows:
 Analog Output – W4 installed

 Thermocouple – W2 installed

 RTD – W2 installed
Refer to figure 11-6 to view a representation of this configuration. At the
remote end, the two remote BEM modules that are connected to the primary
and the secondary DPUs, are to be connected to the same parallel I/O bus or
daisy chained I/O busses. Refer to section titled “Termination
Requirements” for details on terminating the remote common I/O bus.
M u s t b e r e p la c e d b y R e d u n d a n t IO
W 1 N o t in s ta lle d c a b le ( C P O 3 0 9 ) in th e a b s e n c e o f L o c a l
C o m m o n IO ( R e fe r to fig 1 1 - 5 )
W 3 N o t in s ta lle d
Local
D Y - m o d u le D R edundant
P (C P O 4 0 1 ) P IO
U or U
I- m o d u le
B B
I I (C P O 4 0 3 ) I I
E E
O O O O
M M
b a c k p la n e b a c k p la n e
O p t io n a l
I I I I
Local
O O O O
C o m m o n IO
O p tic a l
C a b le s
O p tio n a l
Redundant R e m o te
O p tic a l
B B lo c a t io n
C a b le s
E E
M M
I I I W 1 In s ta lle d I I I
W 3 N o t in s ta lle d
O O O O O O
I I I I R e m o te I I I I
O O O O C o m m o n IO O O O O
Figure 11-4. Redundant DPUs with local common (optional), local redundant and remote common IO.
11-8
Must be replaced by Y-module (CPO401) or I-module

(CPO403) to add optional local common IO to
configuration (Refer to fig 11-4)
maxPAC to maxPAC
Redundant IO cable
D CP0309 D
P P
U U Local
B B Redundant
I I I I
E E IO
O O O O
M M
backplane backplane
W1 Not installed
W3 Installed
Optical
Cables
Optional
Redundant
Optical
Cables
Remote
Redundant
B IO
E
M
I I I I I I I
W1 Installed
W3 Installed O O O O O O O
B
E
M
I I I I I I I
O O O O O O O
Figure 11-5. Redundant DPUs with only redundant IOs at local and remote location.

Special cable for only Local

Common IO with
Redundant BEMs
LD050107
or
D LD075267 D
P P
U U Local
W1 Not installed Common IO
B W3 Not installed
B
I I I I
E E
O O O O
backplane
M M
backplane
Optical
Cables
Optional
Redundant
Optical
Cables
B B
E E
M M
I I I W1 Installed I I I
O O O W3 Not installed O O O
I I I I Remote I I I I
O O O O Common IO O O O O
Figure 11-6. Redundant DPUs with only common local IOs and common remote IOs.
11-10
BEM Configuration Considerations

Communication between the DPU and the remote I/O occurs in real time
using the existing Model IOP protocol. The remote I/O modules
communicate with the DPU, as if they were local I/O. Extenders are
transparent to the bus.
Although the BEM extends the Model IOP I/O bus up to 2000 meters, a time
delay factor reduces the maximum number of I/O modules that may be
installed beyond 400 meters. The time delay in the Extender circuit is
minimal; however there is a delay in the optical cable, introduced by the
speed of light, which is proportional to distance (approximately 1 x 10 -9
sec/ft).
In configurations using a cable link no more than 400 meters in length, I/O
module reduction is minimal. See "Calculating Link Capacities."
Calculating Link Capacities

While as noted, a DPU supports up to 45 modules per remote location, a link
delay that is proportional to distance is introduced by the speed of light. The
Extender circuits themselves introduce very little delay. The distance factor
primarily limits the number of Digital Input modules set for SOE operation
since they must be scanned every 1 msec.
An IO Bus Configuration Limits utility is provided to calculate the effect of

link distance on the number of modules and scan rate supported by the DPU.
Refer to Publication 278609 (System Resources Guide) for a description of
this program.
Links can be connected in series or in parallel, the preferred configuration

approach. In a parallel link, a star approach, each remote location's BEM is
connected to a BEM located on the electrical bus with the DPU.
In a series link, the links can be configured such that one BEM and DPU
connects to a remote's BEM and its rack. This rack then contains another
BEM, which is then connected to a second remote's rack with its BEM. This
configuration approach introduces time delays, which will limit the number
of supported modules. Consult the factory if more than two links are on one
DPU.
Ensuring Link Availability

To ensure link availability, installations may include multiple levels of
redundancy. In configurations using only a single DPU, redundant cables
ensure availability. The loss of either cable pair will automatically route the
signal to the alternate cable pair. Only a momentary loss of the remote I/O,

(milliseconds), will occur while the Extender switches over to the inactive
cable.
To ensure optimal availability, each cable pair should be routed separately to

minimize the probability of damage to both cables. With separate cables, in
the event a cable should break or fail, a second cable is still available.
In configurations using redundant DPUs, each DPU can have its own bus
Extender to the remote location. Any single failure of the Extender or cable
will not result in loss of operation, and the replacement of the failed
component can occur without loss of service.
A failure in the remote location will only affect the remote I/O modules
associated with the remote Extender.
Refer to the front-panel LEDs and digital output to identify fault conditions
detected by the link, specifically loss of lock and receive error.
Detecting Failover Conditions

A Form C relay is provided to indicate a link failure. When a BEM
experiences a failover between the redundant links, a momentary relay
closure occurs. Attach the DI Contact on module front panel to a Digital
Input Module to monitor this logic output. The module produces a logic
output to indicate and report the occurrence of an optical link failover or link
failure.
Use a front panel pushbutton to test the redundant links. The pushbutton
initiates a failover between the two links.
Cabling Recommendations
To augment cable reliability, Metso Automation recommends the following
cabling practices:
For configurations using either single or redundant pairs of BEMs, use two
separate, four-fiber optical cables (Part No. CON064-LLLL). Attach one
cable to Link 1 and the other cable to Link 2. As noted, route cables
separately to minimize the possibility of damage to both cables.
For each link connect two of the four available connector ends to the optical
transceiver connectors. The two extra, unused fibers in each cable serve as
spares in the event that the active fibers are cut or damaged.
11-12
BEM Operation
Each Extender module is packaged in a Model IOP I/O style printed circuit
board. Each board contains a chipset that includes a transmitter, receiver and
an optical transceiver. The transmitter converts the parallel data into serial
data, appends encoded error checking bits and sends the data serially over a
very fast fiber optic link (160 MBaud). The receiver decodes the serial data,
does error checking and converts the data back to the original parallel form.
The Extender also includes the buffers/darlingtons associated with the

Model IOP bus, bosfet switches to disconnect the backup DPU Extender
from the bus, and a CPLD to provide some small additional logic required to
support the operation of the chip set. The MACK condition (multiple
modules on the bus) is detected by the remote Extender transmitted over the
link and simulated locally for interpretation by the DPU.
Figure 11-7 shows a functional block diagram of the Bus Extender Module.
Operation is as follows:
I/O Bus Interface – Buffers to duplicate both the DPU and I/O module bus
interface. The ACK signal from the module is detected at the remote end
transmitted by the link and simulated at the DPU end.
CPLD –provides all the logic resources required by the link. This includes
latching and synchronizing the bus data to the frame clock, error detection
and link failover.
Transmitter (Serializer) – Converts a snapshot of the parallel bus data into

160Mb TTL level serial stream.
Receiver (Serializer) – Converts the received TTL level serial stream into
parallel data.
Frame Clock – 8 MHz clock initiates the serial conversion of the I/O bus
data. Thus a snapshot of the Model IOP bus is sent every 125 nsecs. This
corresponds to a serial speed of 160Mb of the optical transceivers.

L o c a l A re a R e m o te a re a
P r im a r y
DP U
Local Bus R e m o te B u s
O U T /IN
E x p a n d e rs F ib e r
E x p a n d e rs
L O /H I
AD D R R e c e iv e r
T r a n s m it t e r
D A TA B
u
LA TC H
f
f
IN T
e R ed u n d an t
R ed u n d an t
R e m o te
r F ib e r O p t ic CP LD
CP LD F ib e r O p t ic 564 B us
T r a n s c e iv e r B
s T r a n s c e iv e r
D A T A [ 8 ..0 ] u
M M f
A
F ib e r A
f
O U T /IN
C C
K K e
R e c e iv e r L O /H I
T r a n s m it t e r r
AC K
s AD D R
XAC K
D A TA
A L T _ IN
LA TC H
S ta tu s IN T
S e co n d ary
DP U
D A T A [ 8 ..0 ]
O U T /IN F ib e r
B
L O /H I u
R e c e iv e r f
AC K
AD D R B T r a n s m it t e r f
u e XAC K
D A TA r
f
s A L T _ IN
LA TC H f
e R ed u n d an t
R ed u n d an t
IN T F ib e r O p t ic
r T r a n s c e iv e r
F ib e r O p t ic CPLD
CP LD T r a n s c e iv e r
s
F ib e r
D A T A [ 8 ..0 ] M M
A A
C C
K K
T r a n s m it t er
R e c e iv e r
AC K
XAC K
A L T _ IN
S ta tu s
Figure 11-7. BEM Functional Block Diagram
Optical Transceivers – Convert the TTL level transmit serial data into an
optical signal and the received optical signal into a TTL level serial data. A
second transceiver supports redundant links for single DPU applications.
The transmitter/receiver chip pair detects the operational state of the active
link.
On power-up transceiver 1 is selected. If a failure is detected, the circuit will

switch the link to transceiver 2, a digital output will be set and an LED will
11-14
identify which link is operational. If the link cannot be established using

transceiver 2 the circuit will go back to transceiver 1 and the sequence will
repeat indefinitely until the link is established.
Power on reset – The power on reset circuit includes a watchdog timer to

monitor the operation of the CPLD.
Specifications
Model:
IOP371 Bus Extender Module (Part No. 181500)
Distance:
Up to 2000 meters
Speed:
Maintain Model IOP I/O bus communications
I/O addresses:
Up to 255 unique I/O addresses per DPU
Link bus loading:

One module
Number of I/O Modules Per Location:

On the DPU Local Bus: 60 maximum including local BEM(s)
On Each Remote BEM Bus: 45 maximum including remote BEM
Approval Bodies and Standards

The product meets SAMA PMC33.1 EMI/RFI specs at three different
frequencies, and is designed to meet IEC 801-2 static specification (8,000
Volts).
Power Requirements
24 Volts @0.5 amps
Environment
The module operates in the temperature range of 0oC to 60oC at a relative
humidity range of 0 to 90%, noncondensing.
Optical cable
62.5/125 m multimode fiber optic cable
CON062-LLLL Two- fiber optical cable
CON064-LLLL Four-fiber optical cable
Operating wavelength 
1300 nm.

Chapter 12
QuadPAT
Module IOP336
QuadPAT Termination
Module IOP337
Overview
The maxPAC Quad Position Adjusting (QuadPAT) module in combination
with the maxPAC Quad PAT termination assembly produces PAT increase
and decrease outputs (120V or open collector) for single phase AC drive
units or three-phase power switches. The module accommodates 1000-ohm
slidewires or two-wire rotary position sensors. In addition, the maxPAC
Quad PAT termination includes the DI circuits for sensing the drive unit
limit switches.
F e a tu r e s
S e lf - c a lib r a tio n o n p o w e r u p
S o f tw a r e s to r e d in F L A S H
F ie ld to lo g ic I s o la tio n
C h a n n e l - to - c h a n n e l I s o la tio n
F a s t s c a n tim e

Front Panel
The QuadPAT front panel contains bicolor LEDs to report the status of the
increase and decrease outputs and limit switch for each channel and also
LEDs for module status indication. It also includes the two I/O connectors.
The top connector includes all the digital I/O and the analog signals are
available at the bottom connector.
LED Indication
A pair of bi-color LEDs provides I/O state indication for each QuadPAT
channel. The DO is the first LED of the pair and the DI is the second LED.
For normally closed limit switches (open at a limit) the LED indication for
each digital input and digital output pair is as follows:
LED Color Description

Output Green Decrease
Output Red Increase
Limit Green Decrease Limit
Limit Red Increase Limit
Limit Amber No limit
Limit OFF No Power
For normally open limit switches the LED indication is as follows:
LED Color Description

Output Green Decrease
Output Red Increase
Limit Green Increase Limit
Limit Red Decrease Limit
Limit OFF No limit
Limit OFF No Power
In addition, the lower green LED, labeled Active at the bottom of the front
panel, is on when power is on and the DPU is communicating with the
module. The upper green LED at the bottom of the front panel indicates that
loop power is turned on.
Refer to the following table for the jumper setting information that is
applicable to this module. Bold indicates the default position of the jumper.
12-2
QuadPAT Module IOP336
QuadPAT Termination IOP337
W1 Not Used
W2 Backup Primary
W3 Not Used
W4 Ignore Limit Stop on Limit
W5 Common I/O Redundant
W6 QuadPAT Other
Channel 1
Jumper Slidewire Rotary sensor
W11 A B
W12 C A,B
W13 A B
W14 Installed Not Installed
W15 A Not Installed
W17 Not Installed Installed
Channel 2
W21 A B
W22 C A,B
W23 A B
W29 A Not Installed
Channel 3
W31 A B
W32 C A,B
W33 A B
W35 A Not Installed
Channel 4
W41 A B
W42 C A,B
W43 A B

Bus Address
This module requires four bus addresses and provides four channels. Each
module address must be a multiple of 4 (i.e. 32, 36, 40, 44, 56, etc.) in the
range of 32 to 248. Addresses 0 to 31 are reserved for digital input modules.
The two address rotary switches can be found at the upper right hand corner
of the module above the edge connector as follows:
DPU Compatibility
This module is only compatible with DPU4E and DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It
includes eight analog inputs, four analog outputs, 8 digital inputs and eight
digital outputs. Successive approximation 14-bit A/D converters digitize the
input signals in microseconds. Sixteen-bit digital to analog output
conversion also provides fast analog outputs. Both the analog inputs and
analog outputs self-calibrate on power up. Optical isolation is provided
between the field circuits and the logic. DC/DC converters provide isolated
power to the A/D converters and analog output circuits. The
microprocessor communicates serially with the field circuits via optical
isolators.
The analog outputs provide the reference for the slidewires. The analog
inputs measure each slidewire feedback and reference. The digital outputs
provide increase and decrease signals to the triac circuits, while the digital
inputs monitor the state of the limit switches.
The microprocessor circuit includes a 25MHz 68332 processor and

associated memory. A FPGA includes the I/O bus control logic and provides
support logic for the other circuits.
12-4
+ /-1 5 V
24V D C /D C 24V
4 -2 0 m a o r
+ /-1 0 V D /A
4 -2 0 m a 2 c h a n n e ls
O p tic a l
0 -2 .5 V I s o la tio n
4 -2 0 m a A /D
0 -2 .5 V 4 c h a n n e ls
4 -2 0 m a
5V
D C /D C
24V
+ /-1 5 V D C /D C
4 -2 0 m a o r
+ /-1 0 V D /A RAM
2 c h a n n e ls FLASH 64K
4 -2 0 m a
O p tic a l 2 M b it P a r ity
I s o la tio n
0 -2 .5 V
A /D
4 -2 0 m a
0 -2 .5 V 4 c h a n n e ls
4 -2 0 m a
68332G C LO C K
P ro c e s s o r
5V
D C /D C 25M H z
D I1 – D I8
FPG A
I/ O B u s
O pen I /O B u s
D O 1 – D O I8 C o lle c to r I n te r fa c e
D r iv e r s
O u tp u t
V ir tu a l
P ow er
QuadPAT Termination
The IOP346 QuadPAT Termination interfaces with the QuadPAT module

via cable CTO301. It is a DIN rail mounted assembly with two 16-point
Euro-style plugs providing the interface for the field connections. The
QUADPAT module provides 24-volt power for the Termination circuits.
The termination assembly provides the following functions:
 It provides four optically isolated TRIAC circuits. Each circuit includes

a pair of TRIACs for the increase and decrease signals as well as the
output suppression circuits

 Each channel also includes digital input circuits to monitor the two limit
switches associated with each channel. The state of the limit switches is
provided to the DPU buffer.
Feedback Options
Slidewire: The bottom of the slidewire is connected to ground through a

100-ohm resistor to allow detection of an open slidewire. A reference
current of 2 ma produces an approximate voltage range of 0.5 to 2 volts for
the slidewire. Open wipers are detected through a pulldown resistor on the
slidewire input. If a high or low signal reading is detected when the module
is scanned by the DPU, outputs to the module from the DPU will be
suspended.
Rotary Sensor: Power to the sensor is supplied from the field 24V. The
sensor 4-20ma signal results in a 0.4 to 2V signal across the internal 100
ohm sensing resistor. Overvoltage protection is provided for the 100 shunt.
If a shorted sensor or an open circuit is detected by the DPU, outputs to the
module are suspended.
Output Options
Single-Phase and Three-Phase Drive Units
TRIAC outputs require the use of the termination assembly.
DC Power Switch
Open collector outputs are wired directly from the module, and the
termination assembly is not required. A commoning strip is required for the
ground connections to the individual power switches. No IEEE surge
suppression is available for the open collector outputs.
Limit Switch Detection
The module detects the state of the drive unit limit switches via the
termination assembly. For Normally Closed switches, the module inhibits
drive unit motion when it detects an open limit switch in the direction of
12-6
travel. The module will ignore the limit switches if jumper SW4 is
installed. If Normally Open contacts are used, jumper SW4 must be
installed and any interlock while the limit is exceeded must be done in the
control logic or external hardware.
Note: The QPAT buffer includes status attributes (Out0xLimitHi or

Out0xLimitLo) that represent the state of the High and Low Limit inputs.
These inputs are normally wired to the limit contacts of the drive unit. The
contacts are most often Normally Closed contacts and open when the limit is
reached. In this case, when the contact is open (the limit exceeded) the
status will be equal to one. If Normally Open contacts are used, the status
attributes will be one and go to zero when the limit is reached (contact
closed). The jumper on the card to ignore the limit does not affect these
status attributes
Redundant Configuration
Standby Mode
Standby mode is activated when a QUAD PAT module is one of a redundant
pair in a backup configuration and its DPU is inactive. All outputs from the
module will be suspended while in the standby mode. The slidewire
reference is also disabled in the standby mode.

Jumper Positions
Jumpers must be re-positioned to remove the 100-ohm slidewire end resistor
and the open slidewire detection resistor from the circuit. See jumper table.
These resistors must be mounted externally.
Jumper W2 is set to designate one module as primary and the other as
backup.
Jumper W5 is removed from both modules to defeat force INT.
Terminal Connections
When using the Quad PAT modules in a redundant configuration all
terminals must be wired in parallel.
Backup transfer Bump

The specified backup transfer bump is 0.2%. On insertion or withdrawal of
an inactive module, up to a 1% temporary bump can occur and the drive unit
will return to its original position within a few seconds depending on the
stroke time of the drive. This bump can be avoided by disabling the ac
power to the inactive module termination, while inserting or withdrawing the
inactive module.
Diagnostics

ADC Serial Transmit Fault 0x12
ADC Sanity Test Failed 0x15
FPGA Error 0x32
FLASH Erase Error 0x35
FLASH Programming Error 0x36
FPGA Error 0x37
Serial I/O Failure 0x38
Parity Error 0x39
12-8
Module Field Connections

P2 P3
1 1
D E C 1 (D O 0 1 ) R e fe re n c e O u t 1
2 2
IN C 1 (D O 0 2 ) F e e d b a c k 1 /F ie ld 2 4 V
3 3
H I L IM 1 (D I0 1 ) R e tu r n / A I I n
4 4
L O L IM 1 (D I0 2 ) F ie ld G r o u n d
5
5
6 6
IN C 2 (D O 0 4 )
F e e d b a c k 2 /F ie ld 2 4 V
7 7
H I L IM 2 (D I0 3 ) R e tu r n /4 - 2 0 m a I n
8 8
L O L IM 2 (D I0 4 )
F ie ld G r o u n d
9 9
10 10
IN C 3 (D O 0 6 ) 0 0
F e e d b a c k 3 /F ie ld 2 4 V
11 11
H I L IM 3 (D I0 5 )
R e tu r n /4 - 2 0 m a I n
12 12
L O L IM 3 (D I0 6 ) F ie ld G r o u n d
13 13
14
14
IN C 4 (D O 0 8 ) F e e d b a c k /F ie ld 2 4 V
15 15
H I L IM 4 (D I0 7 )
R e tu r n /4 - 2 0 m a I n
16
16
L O L IM 4 (D I0 8 )
F ie ld G r o u n d
17
24V
11 18
GND

Termination Field Connections Channels 1-2
F ie ld P2 P1 m o d u le
1 1
C H 1 120V ac C H 1 D ecrease
2 2
C H 1 a c n e u tr a l C H 1 In crease
3 3
C H 1 a c n e u tr a l C H 1 H I L i m it
4 4
C H 1 D ecrease C H 1 L O L IM IT
5 5
C H 1 In crease C H 2 D ecrease
6 6
H i L i m it1 C H 2 In crease
7 7
L i m it C o m C H 2 H i L im it
8 8
L o L i m i t1 C H 2 L o L i m it
9 9
C H 2 120V ac
10 10
0 0
C H 2 a c n e u tr a l
11 11
12 12
C H 2 D ecrease
13 13
C H 2 In crease
14 14
H i L i m it2
15 15
L i m it C o m
16 16
L o L i m i t2
17
24V
18
L o g ic G r o u n d
12-10
Termination Field Connections Channels 3-4
1 1
C H 3 120V ac
2 2
3 3
4 4
C H 3 D ecrease
5 5
C H 3 In crease
6 6
H i L i m it3
7 7
L i m it C o m
8 8
L o L i m i t3
9 9
C H 4 120V ac C H 3 D ecrease
10 10
C H 4 a c n e u tr a l 0 0 C H 3 In crease
11 11
C H 4 a c n e u tr a l C H 3 H i L im it
12 12
C H 4 D ecrease C H 3 L o L i m it
13 13
C H 4 In crease C H 4 D ecrease
14 14
H i L i m it4 C H 4 In crease
15 15
L i m it C o m C H 4 H i L im it
16 16
L o L i m i t4 C H 4 L o L i m it
17
24V
18
L o g ic G r o u n d

Group1 Analog I/O Configuration

S lid e w ir e R o ta ry S en so r
P3 P3
A O 0 1 (4 -2 0 m a ) A O 0 1 (4 -2 0 m a )
1 W 15 A 1 W 15 A
B B
A O 0 1 ( + /- 1 0 V ) A O 0 1 ( + /- 1 0 V )
A A
W 11 A u x A I0 1 W 11 A u x A I0 1
B B
W 16 W 17
W 16 W 17
F1 F1
24V F1 24V F1
2 W 12 2 W 12
A A
A I0 1 A I0 1
C B C B
100K 100K
A W 13 W 13
3 3 A
W 14 W 14
B th e r m B th e r m
F1 F1
4 sh un t sh un t
4
F1 F1
A O 0 2 (4 -2 0 m a ) A O 0 2 (4 -2 0 m a )
W 29 W 29
5 5
W 25 W 26 W 25 W 26
A A
A u x A I0 2 A u x A I0 2
W 21 B W 21 B
24V F1 24V F1
F1 F1
6 A 6 A
A I0 2 A I0 2
C B C
W 22 W 22 B
W 23 100K W 23 100K
7 A 7 A
B th e r m W 24 th e r m
B W 24
F1 F1
sh un t sh un t
8 8
F1 F1
12-12

S lid e w ir e R o ta ry S en so r
P3 P3
A O 0 3 ( 4 -2 0 m a ) A O 0 3 ( 4 -2 0 m a )
9 W 15 A 9 W 35 A
B B
A O 0 3 ( + /-1 0 V ) A O 0 3 ( + /-1 0 V )
A A
W 11 A u x A I0 3 W 31 A u x A I0 3
B B
W 36 W 37
W 36 W 37
F2 F2
24V F2 24V F2
10 W 12 10 W 32
A A
A I0 3 A I0 1
C B C B
100K 100K
A W 13 W 33
11 11 A
W 14 W 34
B th e r m B th e r m
F2 F2
12 sh un t sh un t
12
F2 F2
A O 0 2 ( 4 -2 0 m a ) A O 0 4 ( 4 -2 0 m a )
W 49 W 49
13 13
W 45 W 46 W 45 W 46
A A
A u x A I0 4 A u x A I0 4
W 41 B W 41 B
24V F1 24V F2
F2 F2
14 A 14 A
A I0 4 A I0 4
C B C
W 42 W 22 B
W 43 100K W 43 100K
15 A 15 A
B th e r m W 44 th e r m
B W 44
F2 F2
sh un t sh un t
16 16
F2 F2

Digital I/O Configuration Channels 1-2

Single-Phase and Three-Phase Motors
P2 T e r m in a t io n P1 P2 M o d u le
1
H
120 AC 2
N
3
DEC1 4
M
1 1
5 D O 01
IN C 1
2 2
D O 02
3 3
D I0 1
H I L IM 1
6
7 4 4
D I0 2
8
L O L IM 1
9
H
120 AC
N 10
11
D E C 21 2
M
5 5
13 D O 03
IN C 2
6 6
D O 04
7 7
D I0 3
H I L IM 2 14
15 8 8
D I0 4
16
17 17
24V
L O L IM 2
18 18
GND
12-14
Digital I/O Configuration Channels 3-4

Single-Phase and Three-Phase Motors
P3 T e r m in a t io n P1 P2 M o d u le
1
H
120 AC
2
N
3
DEC3 4
M
9 9
5 D O 05
IN C 3
10 10
D O 06
11 11
D I0 5
6
H I L IM 3
12 12
7
COM D I0 6
8
L O L IM 3
9
H
120 AC
10
N
11
DEC4
12
M
13 13
IN C 4 13 D O 07
14 14
D O 08
15 15
D I0 7
H I L IM 4 14
15 16 16
COM D I0 8
16
L O L IM 4
17 17
24V
18 18
GND

Digital I/O Configuration - DC Power Switches
P2 M o d u le
D ec 1
P ow er D IO 1
c
S w itc h
In c 2 D IO 2
D ec 5
P ow er D IO 3
C o m m o n i n g S tr ip
S w itc h In c
6 D IO 4
7
9
P ow er D IO 5
S w itc h 10
D IO 6
11
12
13
P ow er D IO 3
S w itc h
14
D IO 4
15
16
17
24V
18
GND
12-16
Specifications
TRIAC Outputs – 120VAC:

Maximum Voltage: 200 VAC
Continuous on-state current: 2A
On-state voltage: 1.6 VAC
Off-state current: 3.5 mA
Hold Current: 50 mA
Open Collector Outputs

Maximum Current: 100mA
Maximum Voltage: 28VDC
Maximum on-resistance: 0.2 ohms
Power
24Vdc system supply 400 ma
Temperature 0-60 degrees C

Humidity 0-90% no-condensing
Surge (TRIAC Outputs only) IEEE-472-1974

Chapter 13
Turbine Valve Positioner

Module IOP341
Turbine Valve Termination
Module IOP342
Overview
The Turbine Valve Positioner module implements the logic for real-time
closed loop control of a single turbine valve. The module provides two
independent and electrically isolated channels. Each channel includes a
coil drive output and a position feedback input normally receiving inputs
from position transducers. Each channel also includes auxiliary inputs for
loopback measurement of the output signal.
In addition, a turbine speed input is provided as a service with the intent of
bringing back three speed signals, one on each of three Turbine Valve
Positioner modules for triple redundancy of speed input.
The product consists of a maxPAC Positioning Module and a Turbine Valve

Termination card. The Termination card provides both current and voltage
outputs for characterizing the output for different coil types. It also
provides signal conditioning for the frequency input.
The logic shown in the following sketch is programmed in the maxDPU4F

Atom Compiler language and may be modified by a trained engineer via
tools provided. It is one of up to nine personalities that can be downloaded
to the module and stored in flash memory. A cable is provided for
downloading the configuration. Personality selection, the configuration
Tuning constants for the PI loop, I/O status, and other signals are accessible
via the maxDPU4F.

Pos
V a lv e
Pos > 4 -2 0 m a
Pos
M ode
G o v e rn o r o r
S erv o
T h r o ttle V a lv e
Amp
P o s itio n D e m a n d
+ /- 1 0 v o lt o r
K+ƒ + /- 4 0 m a
S erv o
Pos
Amp
E rr
C o il( s )
S ta tu s
T u r b in e
F req
Speed
Speed
Positioner Front Panel

The Turbine Valve Positioner front panel contains LEDs to report the status
of the digital inputs and outputs, and LEDs for module status indication. It
also includes the two I/O connectors and a connector for the configuration
cable.
13-2
Turbine Valve Positioner IOP341
Turbine Valve Termination IOP342
F e a tu r e s
S e lf - c a lib r a t io n o n p o w e r - u p
S o ft w a r e s t o r e d in F L A S H
F ie ld t o lo g ic is o la t io n
C h a n n e l- to - c h a n n e l is o la t io n
F a s t S c a n T im e
F a s t s le w r a te
F u ll c o m p le m e n t o f I/ O
F r e q u e n c y in p u ts
O n - lin e d ia g n o s t ic s
D o w n lo a d a b le p e r s o n a lity
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip
output and frequency input. Two bicolor LEDS, Stat 1 and Stat 2 provide
diagnostic indication. The TRIP, STAT1 and STAT2 LEDs are driven by
the program running in the module and provide the indication as shown in
the following table. Note that the table shows the LED meanings for the
default module software. The software running in your module may have
been customized for your application thus the meanings of the program
controlled LEDS may be different. The Freq LED is driven by hardware
signal DI01. It will flash at the rate of the input frequency but for all but
very low RPM will appear to be on steady.

LED I/O Color Indication

TRIP DO-02 Red DPU Communication error
or
Dpu Checksum error
or
Bad Quality of Process
Variable input
FREQ DI-01 Green Flashes at input frequency

STAT1 DO-05/DO-06 Green/Red Not Used
STAT2 DO-07/DO-08 Green/Red Not used
The upper green LED at the bottom of the front panel indicates that the
program running in the module has turned on loop power.
The lower green LED, labeled Active at the bottom of the front panel, is on
when power is on and the DPU is communicating with the module. This
LED is also used to display error codes that are the result of the power on
diagnostics. See the Diagnostics section below.
The Turbine Valve Positioner module uses a multi-purpose-positioning
module with multiple jumper options as its base. The base module has four
AI/AO and eight DI/DO. Not all the jumpers are used for this application.
Jumpers W1-W4 at the rear of the module are for factory test only and
must not be installed. Refer to the following table for the jumper setting
information that is applicable to this module. Bold indicates the default
position.
Channel 1 Channel 2
Jumper Position Jumper Position
4-20ma +/-10V 4-20ma +/-10V
W11 B W21 A
W12 A, B W22 C
W13 B W23 B
W14 Not Installed W24 Not Installed
W15 A B W29 Not Installed
W16 OUT IN W25 OUT IN
13-4
Channel 3 Channel 4
4-20ma +/-10V 4-20ma +/-10V
W31 B W41 A
W32 A, B W42 C
W33 B W43 B
W35 A B W49 Not Installed

Refer to the following table for the Turbine Valve Termination jumpers.
W11 and W12 select the resistance in series with the +/-10V or 4-20 ma
output from the Positioner module. W13 and W14 select the +/-40 ma
output or the output selected in the Positioner module (4-20 ma or +/-10V).
When the +/-40 ma output is selected, the +/-10V output must be selected in
the Positioner module. Bold indicates the default position:
Jumper function A B Installed Not Installed

W1 Wetting Local Remote
Voltage
W2 Frequency 0.2 – 10V 24V
Voltage
W11 Channel 1 160 ohms 100 ohms 210 ohms
Series R and +/-10V or 4-20ma
W12 Channel 2 160 ohms 100 ohms 210 ohms
Series R and +/-10V or 4-20ma
W13 V/I Out +/- 40 ma +/-10 volts
or 4-20ma
W14 V/I Out +/- 40 ma +/-10 volts
or 4-20ma
Bus Address
This module consumes two bus addresses. The two address rotary switches
can be found at the upper right hand corner of the module above the edge
connector as follows:
DPU Compatibility
This module is only compatible with maxDPU4F
Module Operation
includes four analog inputs, four analog outputs, 8 digital inputs and eight
digital outputs. Four auxiliary analog inputs are also included for diagnostic
use. Successive approximation 14-bit A/D converters digitize the input
13-6
signals in microseconds. Sixteen-bit digital to analog output conversion

also provides fast analog output current or voltage. Both the analog inputs
and analog outputs self-calibrate on power up.
+ /-1 5 V
24V D C /D C 24V
4 -2 0 m a o r
+ /-1 0 V D /A
4 -2 0 m a 2 c h a n n e ls
O p tic a l
0 -2 .5 V I s o la tio n
4 -2 0 m a A /D
0 -2 .5 V 4 c h a n n e ls
4 -2 0 m a
5V
D C /D C
24V
+ /-1 5 V D C /D C
4 -2 0 m a o r
+ /-1 0 V D /A RAM
4 -2 0 m a
I s o la tio n
0 -2 .5 V
A /D
4 -2 0 m a
0 -2 .5 V 4 c h a n n e ls
4 -2 0 m a
68332G C LO C K
P ro c e s s o r
5V
D C /D C 25M H z
D I1 – D I8
FPG A R S232
I/ O B u s
O pen I /O B u s
D O 1 – D O I8 C o lle c to r I n te r fa c e
D r iv e r s
O u tp u t
V ir tu a l
P ow er
The analog I/O is separated into two electrically isolated groups as shown in
the functional sketch. There is also optical isolation between the field
circuits and the logic. DC/DC converters provide isolated power to the A/D
converters and analog output circuits. The microprocessor communicates
serially with the field circuits via optical isolators.
Each of the four analog output circuits provides 4-20 ma. Two of the
circuits provide –10 to +10 volt outputs. The A/D in each group has four

inputs. Two of the inputs are used as auxiliary inputs for diagnostic
monitoring of the analog outputs.
The microprocessor circuit includes a 25Mhz 68332 processor and

associated memory. The Time Processor Unit (TPU) included in the 68332
processor is used to process the frequency measurements. A FPGA includes
the I/O bus control logic and provides support logic including parity.
Turbine Valve Termination
The IOP342 Turbine Valve Termination interfaces with the Positioner

module via cable CTO302. It is a DIN rail mounted assembly with an 18-
point Euro-style plug providing the interface for the field connections. The
Positioner module provides 24-volt field power for the Termination circuits.
 It converts the +/-10V signals to 0-2 volts plus sign to be fed to the
module for diagnostic loopback.
 A voltage-to-current converter converts the +/-10V signals to –40 to 40

ma. Either voltage or current output is available via jumper selection.
 A current sense circuit measures the output current and provides a 0-2v
signal proportional to the current to the I/O module.
 It conditions and isolates the frequency input and provides a 5-volt TTL
compatible signal to the module.
Configuration
The Turbine Valve Module provides a serial port for downloading the
configuration programs that are generated and compiled with the maxPAC
Positioning Module Compiler Tool. Up to nine programs (personalities) can
reside in the module FLASH. The interpreter code running in the module
executes any one of the nine personalities selected via the DPU. A module
personality typically defines an exchange of variable data between the DPU
POS Buffer and the module I/O and other parameters defined in the module
shell; it also includes the logic sequence that implements the required
application. See the maxPAC Positioning Module Programming Guide.
Calibration
The Turbine Valve Module can be configured via on-board jumper selection
to provide either a current or voltage output. The module is factory
calibrated for 4-20 ma current outputs and the calibration constants are
13-8
stored in FLASH. Calibration is only required when the FLASH program is

upgraded.
The Module Compiler provides functions that allow the user to either
override or restore the factory calibration values. When voltage outputs are
used, the factory calibration values for channels 1 and 3 must be changed to
0 and 65535. This can be accomplished by setting AOLo and AOHi for the
two channels in the first pass of the application program, or by downloading
a calibration program that overrides the values stored in FLASH.
Diagnostics

FPGA Error 0x37
Parity Error 0x39
The turbine valve module can also execute on line diagnostics to verify the
integrity of the loop. This test must be defined in the personality program.
The module shell includes four AOs (AO01-AO04), four AIs (AI01-AI04),
four Auxiliary AIs (AuxAI01- AuxAI04), eight DIs (DI01-DI08) and eight
DOs (DO01 – DO08). These shell variables are associated with I/O signals
at the module I/O connector. The bipolar analog outputs generated by the
module are converted at the termination assembly to a 0-2V plus sign signal.
As shown in the Group1 Analog I/O configuration sketches at the end of the
chapter, the analog output from the module is buffered by the termination
and fed back to AuxAI02. The coil current is fed back to AI02, while the
sign is available as status DI02 (1 is negative).

The personality program must define the input types to be 0-2V. Also the
analog value read at those inputs must be sign adjusted. For example, the
configuration program includes the following code to define the input types
and adjust the sign.
If FirstPass
AIType01 = 1 ;4-20ma AI
AIType02 = 3 ;0-2V AI
AuxAIType02 = 3
EnableOutputs = 1
EndIf
If DI02 = 0
Coil1ACurRaw = AuxAI02
Coil1V = AI02
Else
Coil1ACurRaw = AuxAI02 * -1.0
Coil1V = AI02 * -1.0
EndIf
13-10
P2 P3
1 1
DO1 4 - 2 0 m a o r + /- 1 0 V o u t
2 2
DO2 C h 1 - 2 F ie ld P o w e r
3 3
D I1 4 -2 0 m a in p u t
4 4
D I2
C h 1 - 2 F ie ld G r o u n d
5 5
DO3 V o lta g e F e e d b a c k
6
6
DO4
V o lta g e F e e d b a c k
7 7
D I3
8 8
D I4
9 9
DO5 4 - 2 0 m a o r + /- 1 0 V o u t
10 10
DO6 0
C h 3 - 4 F ie ld P o w e r
11 11
D I6 4 -2 0 m a in p u t
12 12
D I7
C h 3 - 4 f ie ld G r o u n d
13 13
14
14
15 15
D I7
16
16
D I8
17
24V
11 18
GND

Termination Field Connections

1 1
C o il 1 ( + ) F ie ld 2 4 V _ 1
2 2
C o il 2 ( - ) F ie ld R e t_ 1
3 3
C h a ssis G n d 4 - 2 0 m a o r + /- 1 0 V o u t
4 4
F ie ld 2 4 V _ 1 + /- 1 0 V _ 1 lo o p b a c k
5 5
4 - 2 0 m a in p u t C o il_ 1 C u r r e n t lo o p b a c k
6 6
C o il 1 ( + ) C h 1 - 2 F ie ld G r o u n d
7 7
C o il 2 ( - ) F ie ld 2 4 V _ 2
8 8
C h a ssis G n d F ie ld R e t_ 2
9 9
F ie ld 2 4 V _ 2 4 - 2 0 m a o r + /- 1 0 V o u t
10 10
4 - 2 0 m a in p u t 0 0 + /- 1 0 V _ 2 lo o p b a c k
11 11
C o il_ 2 C u r r e n t lo o p b a c k
12 12
24V
13 13
fre q u e n c y
D I 2 ( + /- 1 0 V _ 1 s ig n )
14 14
D I 3 ( + /- 1 0 V _ 2 s ig n )
0 .2 - 1 0 V
15 15
fre q u e n c y
D I1 (fre q u e n c y )
16 16
NO DO1
17
COM 24V
1181
NC L o g ic G r o u n d
13-12
T e r m in a t io n M o d u le
P2 P1 P3
+ /- 4 0 m a
W 13
A O 0 1 (4 -2 0 m a )
50 50 62 50
3 1 W 15 A
1
B
A O 0 1 ( + /- 1 0 V )
C u rren t W 11 A
W 11
A u x A I0 1
S en se B
2
S ig n 1 B u ffe r F1
24V F1
F1
3 W 12
1 2
A
24V F1 C A I0 1
B
4
24V F1 100K
4 -2 0 m a 6 3 A W 13
5
W 14
B th e r m
F1
sh un t
2 4
F1
F1
W 29 A O 0 2 (4 -2 0 m a )
4 5
O u tp u t v o lta g e
A
A u x A I0 2
W 21 B
24V F1
F1
O u tp u t c u r r e n t 5 6 A C
A I0 2
W 22 B
W 23 100K
7 A
B th e r m W 24
F1
sh un t
8
F1

P2 P1 P3
+ /- 4 0 m a
W 14
A O 0 3 (4 -2 0 m a )
50 50 62 50
9 9 W 35 A
6
B
A O 0 3 ( + /- 1 0 V )
C u rren t W 12 A
W 31
A u x A I0 3
S en se B
7
S ig n 2 B u ffe r F1
24V F3
F2
8 7 W 32
10
A
24V F2 C A I0 3
B
9
24V F2 100K
4 -2 0 m a 12 11 A W 33
10
W 34
B th e r m
F2
sh un t
8 12
F2
F2
A O 0 4 (4 -2 0 m a )
W 49
10 13
O u tp u t v o lta g e
A
A u x A I0 4
W 41 B
24V F2
F2
O u tp u t c u r r e n t 11 14 A C
A I0 4
W 42 B
W 43 100K
15 A
B th e r m W 44
F2
sh un t
16
F2
13-14
Digital I/O Configuration
P2 P1 P2
W1
24V F2
12
15 3
D IO 1
13
13 7
W2 S ig n 1 D IO 3
14
C o n d itio n in g
14 8
15 C ir c u it S ig n 2 D IO 4
7
16
17 16 2
D O 02
18
17 17
24V
18 18
GND

Specifications
Turbine valve Outputs
Analog
+/- 10 VDC at 40 ma. or
+/- 40 ma at 200 ohms max
4-20 ma (isolated 24V supplied from the system)
Accuracy:
+/-10V, 4-20 ma: 0.25% of full scale
+/- 40 ma: +/-1% of full scale
Resolution: 16 bits
Slew Time: 5 msecs
Digital
Form C Relay
5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC
Turbine valve Inputs

Analog:
4-20 ma (isolated 24V supplied from the system)
Accuracy: 0.15%
Resolution: 14 bits
Scan Time: 5 msecs
Frequency:
Frequency: 0 -10KHz
Accuracy: 0.1% for frequency up to 5KHz,
0.25% for 5KHz – 50Kz.
Input voltage: 200 mv. to 10V or 24V.
Isolation
Galvanic isolation between two analog I/O groups.
Common mode between groups: 250VAC RMS or 320VDC
Galvanic isolation between field and logic: 500V
RS232 Port: 9600 baud
Power

Humidity 0-90% no-condensing
Surge IEEE-472-1974
13-16
Chapter 14
Overspeed Trip
Module IOP345
Overspeed Termination
Module IOP346
Overview
The Overtrip module measures and processes turbine speed from three
separate tachometers based speed inputs without intervention from the DPU.
If the overspeed logic determines that two out of the three inputs exceed a
defined threshold, Trip contacts are energized to protect the turbine from an
overspeed condition.
R aw Speed3
R aw Speed2 T u r b in e
F
Speed
P u ls e s
R aw Speed1
DPU M e d ia n F ie ld
R u n b a c k S ta tu s
R unback
R unback % > O u tp u t
M e d ia n S p e e d > T r ip
O u tp u t
T r ip %
T r ip S ta tu s
The product consists of a maxPAC Overspeed Positioning Module and an

Overspeed Termination card. The Termination card provides signal

conditioning and isolation for the frequency inputs and also two form C
relays.
The logic shown in the sketch is programmed in the maxDPU4F Atom

Compiler language and may be modified by a trained engineer via tools
provided. It is one of up to nine personalities that can be downloaded to the
module and stored in flash memory. A cable is provided for downloading
the configuration. Personality selection, the configuration, I/O status, and
other signals are accessible via the maxDPUF.
F e a tu r e s
S o ft w a r e s t o r e d in F L A S H
F ie ld t o lo g ic is o la tio n
F a s t s c a n tim e
F a s t fr e q u e n c y m e a s u r e m e n ts
O n - lin e d ia g n o s t ic s
D o w n lo a d a b le p e r s o n a lity
Overspeed Front Panel

The Overspeed module front panel contains LEDs to report the status of the
digital inputs and outputs, and LEDs for module status indication. It also
includes the two I/O connectors and a connector for the configuration cable.
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip
output and frequency input. Two bicolor LEDs, Stat 1 and Stat 2 provide
diagnostic indication. The TRIP1, TRIP2, STAT1 and STAT2 LEDs are
driven by the program running in the module and provide the indication as
14-2
Overspeed Trip Module IOP345
Overspeed Termination IOP 346
shown in the following table. Note that the table shows the LED meanings
for the default module software. The software running in your module may
have been customized for your application thus the meanings of the program
controlled LEDS may be different. The FREQ1, FREQ2, and FREQ3 LEDs
are driven by hardware signals DI01, DI03, and DI05 respectively. They
will flash at the rate of the input frequency but for all but very low RPM will
appear to be on steady.
LED I/O Color Indication

TRIP1 DO-02 Red RPM exceeded the TripRPM
parameter for more than minTrip
seconds.
FREQ1 DI-01 Green Flash at Input frequency
TRIP2 DO-04 Red RPM exceeded the

RunbackRPM parameter for
more than minTrip
seconds.
The upper green LED at the bottom of the front panel indicates that the
program running in the module has turned on loop power.
when power is on and the DPU is communicating with the module. This
LED is also used to display error codes that are the result of the power on
diagnostics. See the Diagnostics section below.
The Overspeed module uses a multi-purpose-positioning module with
multiple jumper options. Not all the jumpers are applicable for this
application because the analog I/O is not used. Refer to the following table
for the jumper setting information that is applicable to this module.
Overspeed Trip Module Jumpers

W11 B W21 B
W12 A W22 Not Installed

W14 Installed W24 Installed

W15 Not Installed W25 Installed
W17 Installed W29 Not Installed
Overspeed Trip Module Jumpers (continued)

W31 B W41 B
Overspeed Termination Module Jumpers
These jumpers configure the three speed sensor inputs. Bold indicates the
default positions. The module supports the use of up to three turbine speed
sensors. Each sensor input may be configured for either an active type or
passive type sensor.
An active sensor has a high level (24VDC) (e.g., an open collector transistor)
ouput. The 24VDC wetting voltage for the output may either come from the
termination module (“Local”) or be supplied by an external source
(“Remote”).
A passive sensor has a low level (0.2Vrms – 10Vrms) frequency output.

Within this range, higher level outputs are preferred for better signal to noise
ratio performance.
The screw terminals used to connect the sensors vary with the type of sensor.
Refer to the “Termination Field Connections” drawings in this chapter for
more information.
Sensor Jumper function Installed Not Installed

1 W1 Wetting 1 Local Remote
Voltage
W2 Frequency 1 0.2 – 10V 24V
Voltage

Voltage
W4 Wetting 2 0.2 – 10V 24V
Voltage
Voltage
14-4
W6 Wetting 3 0.2 – 10V 24V
Voltage
Bus Address
This module consumes two bus addresses.
DPU Compatibility
This module is only compatible with DPU4F
Module Operation
includes four analog inputs, eight analog inputs, 8 digital inputs and eight
digital outputs. The turbine overspeed application utilizes only the digital
I/O portion of the module. The unused analog portion is shown with dashed
lines in the functional sketch.

associated memory. The Time Processor Unit (TPU) included in the 68332
processor is used to process the frequency measurements. A FPGA
provides support logic including parity and the I/O bus control logic.

P o s it io n in g M o d u le
+ /-1 5 V
24V D C /D C 24V
4 -2 0 m a o r
+ /- 1 0 V D /A
4 -2 0 m a 2 c h a n n e ls
O p tic a l
0 - 2 .5 V I s o la tio n
4 -2 0 m a A /D
0 - 2 .5 V 4 c h a n n e ls
4 -2 0 m a
5V
D C /D C
24V
+ /-1 5 V D C /D C
4 -2 0 m a o r
+ /- 1 0 V D /A RAM
4 -2 0 m a
I s o la tio n
0 - 2 .5 V
A /D
4 -2 0 m a
0 - 2 .5 V 4 c h a n n e ls
4 -2 0 m a
68332G C LO C K
P ro c e sso r
5V 25M H z
D C /D C
D I1 – D I8
FPG A R S232
I/ O B u s
O pen I /O B u s
D O 1 – D O I8 C o lle c to r I n te r f a c e
D r iv e r s
O u tp u t
V ir tu a l
P ow er
Overspeed Trip Termination
The IOP346 Turbine Overspeed Termination interfaces with the Positioner

module via cable CTO303. It is a DIN rail mounted assembly with an 18-
point Euro-style plug providing the interface for the field connections. The
Positioner module provides 24-volt field power for the Termination circuits.
 It provides signal conditioning and optical isolation for the three

frequency inputs and provides 5-volt square waves to the module.
 Two form C relay outputs are included.
14-6
Diagnostics

FPGA Error 0x37
Parity Error 0x39

P2 P3
1 1
D O 01
2 2
2 4 V F ie ld P o w e r
D O 02
3 3
D I0 1
4
4
D I0 2 F ie ld G r o u n d
5 5
D O 03
6 6
D O 04
7 7
D I0 3
8 8
D I0 4
9 9
D O 05
10
10
0
D O 06 0
11 11
D I0 6
12 12
D I0 7
13 13
D O 07
14 14
D O 08
15 15
D I0 7
16 16
D I0 8
17
24V
11 18
GND
14-8
Termination Field Connections

0.2-10V
Passive Sensor 1
Passive Speed Sensors
Field P2 P1 Module
1 1
Field 24V
2 2
Field 24V
3 3
0.2 – 10V In 1 Field Ground
Passive 4 4
Sensor Field Ground Field Ground
5 5
Frequency 1
6 6
7 7
0.2 – 10V In 2 Frequency 2
Passive 8
8
Sensor Field Ground
9 9
Frequency 3
10 10
0 0
11 11
0.2 – 10V In 3
Passive 12
12
Sensor Field Ground
13 13
NO DO02 (Trip)
(Trip Relay) 14 14
COM DO04 (Runback)
15 15
NC 24V
16 16
NO 24V
(Runback Relay) 17 17
COM Logic Ground
18
18 18
NC Logic Ground
Notes: Install jumpers W1 – W6

All sensor inputs have a common signal return connection

24V Active Speed Sensors Powered by Module
Field P2 P1 Module
1 1
Field 24V Field 24V
2 2
Active Sensor In 1 Field 24V
3 3
Field Ground
4 4
Field Ground Field Ground
5 5
Field 24V Frequency 1
6 6
Active Sensor In 2
7 7
Frequency 2
8 8
Field Ground
9 9
Field 24V Frequency 3
10 10
Active Sensor 0 In 3 0
11 11
12 12
Field Ground
13 13
NO DO02 (Trip)
(Trip Relay) 14 14
COM DO04 (Runback)
15 15
NC 24V
16 16
NO 24V
COM Logic Ground
18 18
18
NC Logic Ground
Notes: Install Jumpers W1, W3, W5

Remove Jumpers W2, W4, W6
The 24V Field voltage and ground are common to all three input channels.
The 24V Field voltage comes from the Overspeed Module
14-10
24V Active Speed Sensors with External Power
Field P2 P1 Module
1 1
24V Field 24V
2 2
Active Sensor In 1 Field 24V
3 3
Field Ground
4 4
24V Rtn
Field Ground Field Ground
5 5
24V Frequency 1
6 6
Active Sensor In 2
7 7
Frequency 2
8 8
24V Rtn
Field Ground
9 9
24V Frequency 3
10 10
Active Sensor 0 In 3 0
11 11
12 12
24V Rtn
Field Ground
13 13
NO DO02 (Trip)
(Trip Relay) 14 14
COM DO04 (Runback)
15 15
NC 24V
16 16
NO 24V
COM Logic Ground
18
18 18
NC Logic Ground
Notes: Remove Jumpers W1 – W6

The 24V Return is common to all three input channels

P2 P1 P3
A O 0 1 (4 -2 0 m a )
1 W 15 A
A O 0 1 ( + /- 1 0 V )
A
W 11
A u x A I0 1
B
1 F1
24V F1
2 2 W 12
A
24V F1 C A I0 1
B
100K
3 A W 13
W 14
3 B th e r m
F1
4 sh un t
4
F1
F1
A O 0 2 (4 -2 0 m a )
W 29
5
A
A u x A I0 2
W 21 B
24V F1
F1
6 A C
A I0 2
W 22 B
W 23 100K
7 A
B th e r m W 24
F1
sh un t
8
F1
14-12

P2 P1 P3
A O 0 3 (4 -2 0 m a )
9 W 35 A
A O 0 3 ( + /- 1 0 V )
A
W 31
A u x A I0 1
B
F2
24V F2
10 W 32
A
C A I0 3
B
100K
11 A W 33
W 34
B th e r m
F2
12 sh un t
F2
A O 0 4 (4 -2 0 m a )
W 49
13
A
A u x A I0 4
W 41 B
24V F2
F2
14 A C
A I0 4
W 42 B
W 43 100K
15 A
B th e r m W 44
F2
sh un t
16
F2

Digital I/O Configuration
P2 Termination P1 P2 Module
W1
24VF1
12
5 3
DIO1
13
W2
14
Conditioning
15 Circuit
W3
24VF1
12
7 7
DIO3
13
W4
14
Conditioning
15 Circuit
W5
24VF1
12 9 11
DIO5
13
W6
14
Conditioning
15 Circuit 2
13
DO02
13
14 (Trip Relay)
15
14 6
DO04
16
15
17 (Runback Relay) 16 17
24V
18
17
18 18
GND
14-14
Specifications
Frequency Input:
Frequency Range: 100Hz - 10KHz
Accuracy (FastF1 value): +/- 3Hz from 100Hz - 5KHz
+/-15Hz from 5.001KHz – 10KHz.
Passive Sensor Input: 0.2Vrms to 10Vrms
Active Sensor Input: 0VDC/24VDC @ 10mA (bi-level input)
Isolation: The three frequency inputs are optically isolated from the DPU.
The three inputs share a common field supply and field ground.
Digital Output
Form C Relay
5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC
RS232 Port: 9600 baud
Power:
Temperature: 0-60 degrees C
Humidity: 0-90% non-condensing
Surge Withstand (Termination Module field connections): IEEE-472-1974

Chapter 15
HART 8 Channel Input Module IOP307

HART 16 Channel Input Module IOP308
HART Output Module IOP322
HART Transceiver Module IOP364
Overview
The set of HART maxPAC I/O modules provide isolated HART channels
with an independent HART modem/UART per channel. The analog input
and output modules support standard 4-20 ma signals in addition to the
digital HART data. The HART Transceiver card provides the same HART
interface without analog input or output capability; it is intended for adding
HART capability to other analog input or analog output modules. Two
HART analog input modules are provided: an eight-channel module and a
sixteen-channel module.
H
F e a tu r e s
A
R
T F u lly is o la t e d c h a n n e ls
H a rt m o d e m p e r c h a n n e l
1 6 b it A /D a n d D /A P e r fo r m a n c e
S t a n d a r d v a r ia b le s a v a ila b le in
m a x D P U F f o r u s e in c o n tr o l
C u s to m in t e r fa c e fo r s p e c ia l
p u rp o s e c o n tro l
A s s e t M a n a g e m e n t th ro u g h
H a r t M o d u le
M e ts o F ie ld C a r e P r o d u c t lin e

LED Indication
when power is on and the DPU is communicating with the module. The
upper green LED at the bottom of the front panel indicates that loop power is
turned on.
The following are the jumper settings for the various HART modules
Analog Output Module

W1 MaxPAC-8 address * HART – 2 address
Definitions:
Hold Output or Reset Output – Hold output will retain the last value if
communication is lost to the DPU. The Reset Output will reset the output to
0ma if communications is lost to the DPU for more than 700ms. When
communications has been lost due to a reset of the DPU, the initialization
logic of the user configuration will determine the initial value of the Analog
Output.
Secondary or Primary – for Redundant I/O set the card associated with the
Primary DPU to Primary and the card associated with the Secondary DPU to
Secondary.
Common I/O or Redundant I/O – set to Common I/O if using a single card or
to Redundant I/O if using two cards configured as redundant I/O.
maxPAC-8 address or 2 address burst mode – maxPAC-8 address is used for

compatibility when the DPU is using the 8 address mode. When this mode is
set, the HART Analog Output card can be used as a direct replacement for
an IOP320. The HART-2 address-burst mode is the normal option and must
be used if HART communications is used.
Analog Input and Transceiver Modules

W2 ** 50Hz 60Hz
15-2
HART 8-Input Module IOP307
** AI Module, Not used in Transceiver Module
The 16-channel AI modules also have jumpers for the input options. Refer
to the Analog Input wiring diagrams section of this chapter.
Bus Address
These modules normally consume two bus addresses. The HART Output
module consumes eight addresses if set to be compatible with a standard
maxPAC analog output module.
DPU Compatibility
These modules are only compatible with DPU4F.
Module Operation
These microprocessor-based modules provide eight isolated channels of 4-20
ma inputs or outputs, including the HART interface for each channel.

associated memory. A FPGA provides support logic including parity and the
I/O bus control logic. Optical isolators and a DC/DC converter per channel
provide channel to channel and field to logic isolation. Isolated 24V field
power is provided by each of the channels. Eight (or 16) UARTS provide
the interface to the HART modems via the optical isolators. The transceiver
module does not include the AI or AO circuits.

H a r t M o d u le
D C /D C 24V
4 -2 0 m a
AI or AO *
O p tic a l
I s o la tio n
H a rt
M odem
UART
I/O B u s
(8 o r 1 6 ) I /O B u s
I n te r fa c e
D C /D C
FPG A RAM
4 -2 0 m a AI or AO * FLASH 64K
I s o la tio n
H a rt
M odem
68332G C LO C K
P ro c e s s o r
25M H z
* N o t in c lu d e d in T r a n c e iv e r M o d u le
R S232
Diagnostics

FPGA Error 0x37
Parity Error 0x39
15-4
HART 8-Channel Input Field Connections
P2 P3
1 1
24V 24V
2 2
4 -2 0 m a 4 -2 0 m a
CH1 CH5
3 3
4
4
GND GND
5 5
24V 24V
6 6
4 -2 0 m a 4 -2 0 m a
CH2 CH6
7 7
8 8
GND GND
9 9
24V 24V
10
10
4 -2 0 m a 0
4 -2 0 m a 0
CH3 CH7
11 11
12 12
GND GND
13 13
24V 24V
14 14
4 -2 0 m a 4 -2 0 m a
CH4 CH8
15 15
16 16
GND GND

HART 16-Channel Input Field Connections

P2 P3
1 1
2 4 V , In (-) 2 4 V , In (-)
2 2
In (+ ) In (+ )
3 3
2 4 V , I n ( -) 2 4 V , In (-)
4 4
In (+ ) In (+ )
5 5
2 4 V , In (-) 2 4 V , I n ( -)
In (+ ) In (+ )
7 7
2 4 V , In (-) 2 4 V , In (-)
In (+ ) In (+ )
9 9
2 4 V , In (-) 2 4 V , In (-)
10
10
In (+ ) In (+ )
11 11
2 4 V , In (-) 2 4 V , In (-)
In (+ ) In (+ )
13 13
2 4 V , In (-) 2 4 V , I n ( -)
In (+ ) In (+ )
15 15
2 4 V , In (-) 2 4 V , In (-)
16
In (+ ) In (+ )
On-board jumpers change the function of the odd-numbered terminals from supplying
24V loop power to accepting the minus (return) side of an externally powered 4-
20mA signal. Refer to the jumper drawings shown later in this chapter.
15-6
HART Analog Output
P2
1
(+)
CH1 4-20ma in 2
(-)
3
(+)
CH2 4-20ma in 4
(-)
5
(+)
CH3 4-20ma in 6
(-)
7
(+)
CH4 4-20ma in 8
(-)
9
(+)
CH5 4-20ma in 10
(-) 0
11
(+)
CH6 4-20ma in 12
(-)
13
(+)
CH7 4-20ma in 14
(-)
15
(+)
CH8 4-20ma in 16
(-)

HART Transceiver Field Connections
P2 P3
1 1
2 2
(+ )
(+ )
CH1 CH5
3 3
4
4
(-) (-)
5 5
6 6
(+ ) (+ )
CH2 CH6
7 7
8 8
(-) (-)
9 9
10
10
(+ ) 0
(+ ) 0
CH3 CH7
11 11
12 12
(-) (-)
13 13
14 14
(+ ) (+ )
CH4 CH8
15 15
16 16
(-) (-)
15-8
Transceiver to Analog Input Wiring
Shared IO: Two-wire Transmitter
A I M o d u le - I O P 3 0 1 2 4 V (+ )
1A 1B F r o m B a c k p la n e
200
2 4 V (-)
4 -2 0 m a 2
Rs
+
100
Rp A /D
X m itte r
1D -
1
1E
1C
T r a n s c e iv e r M o d u le - I O P 3 6 4
4
HART
2
M ODEM

Shared IO: Four-wire Transmitter
A I M o d u le - I O P 3 0 1 2 4 V (+ )
F ro m
b a c k p la n e
2 4 V (-)
1A 1B
200
4 -2 0 m a 2
Rs
+
100
Rp A /D
X m itte r
1D -
1
1E
1C
HART
2
M ODEM
15-10
Redundant IO: Two-wire Transmitter
(-)
24V
(+ ) S u p p ly A I M o d u le - I O P 3 0 1
2 4 V (+ )
F ro m
b a c k p la n e
2 4 V (-)
1A 1B
200
200 2
Rs
X m itte r
+
100
100 Rp A /D
1D -
1
1E
1C
A I M o d u le - I O P 3 0 1
2 4 V (+ )
F ro m
b a c k p la n e
2 4 V (-)
1A 1B
200
2
Rs
+
100
Rp A /D
1D -
1
1E
1C
HART
M ODEM
2

Redundant IO: Four-wire Transmitter
A I M o d u le - I O P 3 0 1
2 4 V (+ )
F ro m
b a c k p la n e
2 4 V (-)
1A 1B
200
200 2
Rs
+
100
100 Rp A /D
X m itte r
1D -
1
1E
1C
A I M o d u le - I O P 3 0 1
2 4 V (+ )
F ro m
b a c k p la n e
2 4 V (-)
1A 1B
200
2
Rs
+
100
Rp A /D
1D -
1
1E
1C
HART
M ODEM
2
15-12
Transceiver to Output Driver Wiring
O u tp u t D r iv e r - I O P 1 1 6
4 -2 0 m a 16
O u tp u t
D e v ic e D /A
17
HART
2
M ODEM

Transceiver to Analog Output Wiring
A n a lo g O u tp u t – I O P 3 2 0
4 -2 0 m a 1
O u tp u t
D e v ic e D /A
HART
2
M ODEM
15-14
HART 8-channel Analog Input Wiring
T w o - W ir e T r a n s m itte r
4 -2 0 m a 1 8 -C h a n n e l H A R T A I
24V
T R A N S M IT T E R D is c o n n e c t f o r r e d u n d a n t
m o d u le i n p u t
2 200 ohm
100 ohm T O A /D
sh un t
4
T o H A R T m odem
F o u r - W ir e T r a n s m itte r
1
8 -C h a n n e l H A R T A I
N O T U SED 24V
D is c o n n e c t f o r r e d u n d a n t
m o d u le i n p u t
4 -2 0 m a 2 200 ohm
T r a n s m itte r 100 ohm T O A /D

T R A N S M IT T E R
Pow er sh un t
4
T o H A R T m odem


Redundant Modules: Two-Wire Transmitter (DCS Powered)
1 8 -C h a n n e l H A R T
24V
AI
D is c o n n e c t fo r r e d u n d a n t m o d u le
T R A N S M IT T E R
in p u t. O n w h e n D P U a c tiv e
2 200 ohm
100ohm T O A /D
shu nt
4
N .C . T o H A R T m odem
1 8 -C h a n n e l H A R T
24V
AI
in p u t. O n w h e n D P U a c tiv e
200 ohm
2
T O A /D
100ohm
shu nt
4
N .C . T o H A R T m odem
( N .C . = n o c o n n e c t)
15-16
Redundant Modules: Two-Wire Transmitter (Field Powered)
24V (+) 1 8-Channel HART

24V
(N.C.) AI
Disconnect for redundant module

TRANSMITTER
input. On when DPU active
2 200 ohm
100ohm TO A/D
shunt
4
24V (-)
To HART modem
1 8-Channel HART
24V
(N.C.) AI

input. On when DPU active
200 ohm
2
100ohm TO A/D
shunt
4
To HART modem
(N.C. = no connect)


Redundant Modules: Four-Wire Transmitter
1 8-Channel HART AI
24V

input. Closed when DPU is active
2 200 ohm
Transmitter 100ohm TO A/D

Power TRANSMITTER shunt
4
To HART modem
1 8-Channel HART AI
24V

input. Closed when DPU is active
200 ohm
2
100ohm TO A/D
shunt
4
To HART modem
15-18
Jumper Options
2 C o n ta c t
200
100 T o A /D
X m itte r
A
B
1
C F
A
24V F
T o H A R T C ir c u i t
J u m p ers:
A , B – L o o p is P o w e r e d b y D C S ( 2 - w ir e tr a n s m itte r )
C – L o o p is R e m o te l y P o w e r e d b y D e v ic e ( 4 - w ir e tr a n s m itte r )
O p t ic a l R e la y C o n t a c t :
C lo s e d if m o d u le is c o n n e c te d to a n A c ti v e D P U
Jumpers A & B Installed for Channel 1 (2W transmitter)
Jumper C installed for Channel 1 (4W transmitter)
Notes: Jumper positions shown are typical for all 16 channels.

Jumper W8 is always installed (typical for 16 channels).

Redundant Modules: Two-wire Transmitter

2 C o n ta c t
200
100 A /D
A
B
1
C F
A
24V F
2 C o n ta c t
200
100 A /D
Transmitter
A
B
1
C F
A
24V F
15-20
Redundant Modules: Four-wire Transmitter

2 C o n ta c t
200
100 A /D
Transmitter
A
B
1
C F
A
24V F
2 C o n ta c t
200
100 A /D
A
B
1
C F
A
24V F

HART Analog Output Wiring
H A R T A O M o d u le
in p u t. C lo s e d w h e n D P U a c tiv e 2 4 V (+ )
1
4 -2 0 m a
D /A HART
M ODEM
OUTPUT
D E V IC E
2
2 4 V (-)
Redundant Modules
15-22
Disconnect for redundant module W2 – as needed HART AO Module
input. Closed when DPU active W3 – not installed
W5 – not installed 24V(+)
1
4-20 ma HART
D/A
MODEM
OUTPUT
DEVICE
2
24V(-)
W2 – as needed HART AO Module

W3 – installed
W5 – not installed 24V(+)
1
D/A HART
MODEM
2
24V(-)

Specifications
I/O Bus Addresses per Module: 2
Input Specifications
Channels per Module: 8 (or 16)
Type: 4-20ma
Resolution: 16 bits, A/D per channel
Scan time: 20mS (8 channel AI)
60mS (16 channel AI)
Accuracy: +/- 0.15% of full scale
Normal Mode Voltage: 50 volts DC or peak AC
Normal Mode Rejection: 60 db @ 50 or 60 Hz
Common Mode Voltage: 250VAC RMS or 320 VDC
Common Mode Rejection: 120 db @ 50 or 60 Hz with 100ohm imbalance (8 channel AI)
100 db @ 50 or 60 Hz with 100ohm imbalance (16 channel AI)
Isolation: Channel to channel and field to logic
Output Specifications
Channels per Module: 8
Type: 4-20ma
Accuracy: +/- 0.25% of full scale
Resolution: 16 bits, D/A per channel
Slew Time: 10mS
Load: 250 – 600 ohms
Common Mode Voltage: 150 volts DC or peak AC
HART
Meets the HART Foundation physical layer requirements
Power
Humidity 0-90% non-condensing
Surge IEEE-472-1974
15-24
Chapter 16
Serial Communications Module IOP365

Serial Termination Assembly ITP201
Overview
The maxPAC Serial Communications module provide three isolated and
independent serial channels. The Serial Termination assembly provides a
user selectable RS232 or RS485 connection for each channel.
10101
F e a tu r e s
F u lly is o la te d c h a n n e ls
U AR T per channel
R S232 or R S485
S e r ia l C o m m u n ic a tio n s M o d u le
LED Indication
when power is on and the DPU is communicating with the module.

The following are the jumper settings for the Termination Assembly
Channel Jumper Installed Not Installed

1 W11 RS232 RS485
1 W12 RS485 Terminator installed RS485 Terminator not installed
2 W21 RS232 RS485
3 W31 RS232 RS485
Channel Jumper Position A Position B

1 W13 CTS connected RTS CTS connected to Field CTS (P3-8)
1 W14 Field RTS (P3-7) connected to Field RTS (P3-7) is connected to
5 Volts * RTS
5 Volts * RTS
5 Volts * RTS
* The RTS pin can source up to 50ma when connected to 5 volts.
Bus Address
These modules consume two bus addresses.
DPU Compatibility
These modules are only compatible with DPU4F.
16-2
Module Operation
This microprocessor-based module provides three isolated serial
communication channels. The microprocessor circuit includes a 25MHz
68332 processor and associated memory. A FPGA provides support logic
including parity and the I/O bus control logic. A quad UART with FIFO
buffers provides the data formatting for the serial communication channels.
The microprocessor interfaces with the UART via the memory bus.
S e r ia l C o m m u n ic a t io n s M o d u le
RS232
UART
I/O B u s
(3 ) I /O B u s
I n te r f a c e
RS232
FPG A RAM
FLASH 64K
2 M b it P a r ity
RS232 68332G C LO C K
P ro c e sso r
25M H z
R S232
Termination Assembly Operation

The termination assembly provides an optically isolated RS232 or RS485 for
each of the three channels. Each channel is multiplexed from two
redundant ports. These can be from redundant modules or a pair of

channels from the same module. The selection of the active port (P1 or P2)
is based on detection of the active RTS signal. The P1 and P2 input
connectors receive the RS232 inputs from the Serial Communications
Module. Three pair of connectors provide the field interface for the isolated
RS232 or RS485 outputs.
LED indication for the active port, receive data (RD) and transmit data (TD)
is provided for each of the three channels. The meanings of the LEDs are
listed below.
Active Port: Green = P1 is active

Red = P2 is active
RD: Green = Data is being received
TD: Green = Data is being transmitted
Note that when using the serial module in receive-only mode (e.g., as with a
GE markIV link) the current firmware causes the serial module to sometimes
send out a single unexpected byte and to briefly blink the TD LED. This
happens because of a timeout that occurs when the end device is not
connected or when communications parameters are not set correctly. This
does not cause any operational problems. It is only a cosmetic issue.
Diagnostics

FPGA Error 0x37
Parity Error 0x39
16-4
Serial Communications Module Field Connections
P3
1
TD
2
RD
3
CH1 RTS
4
CTS
5
GND
TD
7
RD
8
CH2 RTS
9
CTS
10
GND 0
11
TD
12
RD
13
CH3 RTS
14
CTS
15
GND
16
24V **
**24V at P3-16 is not available for field use. It is provided for use only by the Serial
Termination Assembly

Termination Assembly Input Connections
P1 P2
1 1
TD TD
2 2
RD RD
3 3
RTS C H 1 -B RTS
C H 1 -A
4 4
CTS CTS
5 5
GND GND
6 6
TD TD
7 7
RD RD
8 8
C H 2 -A RTS C H 2 -B RTS
9 9
CTS CTS
10 10
GND 0 GND 0
11 11
TD TD
12 12
RD RD
13 13
C H 3 -A RTS C H 3 -B RTS
14 14
CTS CTS
15 15
GND GND
16 16
24V ** 24V **
16-6
Termination Assembly Output Connections

RS232 9-PIN DB9 Male (P3, P5, P7)
(Mating Cable defined by C-SD-230)

Function Pin
TX 3
RX 2
RTS 7
CTS 8
GND 5
RS485 5-POS TERMINAL PLUG (P4, P6, P8)

Function Pin
TX+ (B) 1
TX- (A) 2
RX+ (B) 3
RX- (A) 4
GND 5
Note that the RS485 port only operates in 2-wire mode (TX+ is internally connected to RX+ and TX-
is internally connected to RX-).
Redundant Modules
Serial
Communications
Module
IOP365 Termination Connection to Field
Assembly Devices
CH1 ITP201
P3 CH2 RS232
CH1A P3
CH1
RS485
CH3 CH2A P4
P1
CH3A
RS232
Serial P5
Communications RS485 CH2
Module P6
IOP365
CH1B
CH1
CH2B RS232
P7
P2 RS485 CH3
CH3B
P3 CH2
P8
CH3

Specifications
Channels per Module: 3
I/O Bus Address per Module: 2
I/O Type: RS232
UART: one per channel
Max Baud Rate: 115K Baud
Isolation: None
Environmental: Temperature 0-60 degrees C
Power: 24Vdc system supply 100 ma
Termination Assembly Specifications

Input Type: RS232
Output Type: RS232 or RS485
RS485 Terminator: 120 ohms jumper selectable.
Common mode between channels: 350vdc or peak ac
Galvanic isolation between field and logic: 500vdc or peak ac
Environmental: Temperature 0-60 degrees C
Surge IEEE-472-1974
Power: 24Vdc system supply 250 ma
16-8
Chapter 17
I-module CPO403
Overview
The maxPAC I-module is an intelligent I/O failover device that is used in
systems containing mixed (redundant + common) I/O.
I-modules are used in pairs. One I-module is connected between the primary
DPU and the Common I/O. The other is connected between the secondary
DPU and the Common I/O. The I-module’s function is to connect the
Common I/O to a DPU only if the DPU is active and if Common Bus is
healthy. The I-module that is connected to the inactive DPU keeps the
Common Bus disconnected from that DPU regardless of the health of the
Common Bus.
The I-module provides enhanced functionality as compared to the CPO401

Y-module. Specifically, two major advantages of the I-module are:
 It tests the Common I/O Bus and disconnects it from the DPU if it
detects a problem with the bus. This prevents a Common Bus fault
(e.g., a short) from disrupting the operation of the DPU(s).
 Two identical, but independent, I-modules are used in a system.

This implementation allows the inactive I-module and its associated
cables to be removed for service without disturbing the active DPU
or its I/O.
Features
 Intelligent
 Continuously tests the Common Bus
 Protects the DPU and Redundant I/O
 Automatic reconnection of the Common I/O if the fault clears
 Same size as Termination modules
 Dual independent architecture for ease of repair
 Uses standard maxPAC cables for I/O and power
 DIN rail mount

Both the active and inactive I-modules run continuous tests. The active I-
module (the I-module that is connected to the active DPU) tests the integrity
of the Common Bus.
The inactive I-module runs a test that verifies the integrity of its bus isolation
and interface circuitry.
The following figure shows how a pair of I-modules is installed in a system

and how that compares to a Y-module installation. Note the positions of the
switches. They show that only the active DPU is connected to the Common
I/O.
( A c tiv e D P U ) ( A c tiv e D P U )
P r im a r y D P U S e co n d ary D P U P r im a r y D P U S e co n d ary D P U
& & & &
R e d u n d a n t I/O R e d u n d a n t I/O R e d u n d a n t I/O R e d u n d a n t I/O
Y - M o d u le I- M o d u le I- M o d u le
C om m on C om m on
I/O I/O
Y-module vs. I-module
If an active I-module detects a Common Bus fault, it opens its switch to

disconnect the faulty bus from the active DPU. The active DPU will still be
able to access its redundant I/O. The active DPU will get card alarms for the
Common I/O during the time that the Common Bus is disconnected. The I-
module will continue to test the Common Bus so that it can automatically
reconnect it to the active DPU if the fault clears.
Disconnection of the Common I/O does not, in itself, cause a DPU failover.
Normally, the active DPU will stay active when the Common Bus is
disconnected. However, it takes a small amount of time for the I-module to
detect a bus fault and disconnect the bus. Thus, it is possible that a DPU
failover could occur if the bus fault occurred at the same instant that the
DPU was talking to an I/O module on the redundant bus and if that module
was configured to cause a failover during an error condition.
17-2
I-module CPO403
If a DPU failover does occur, the newly active DPU will be able to access its
redundant I/O. If the Common Bus fault clears, or if the detected fault was
caused by a problem with the previously active I-module, the Common I/O
will be connected to the newly active DPU.
LED Indications
There are three status LEDs on the I-module. They are labeled “I/O
Interface”, “Module Status” and “I/O Bus Status”. Their function is
dependent upon operating mode and is explained below. The on time of the
fault LEDs is stretched to the actual fault duration + 100mS to make even
very short duration faults visible.
LED Descriptions
Normal Operation
“I/O Interface”
 Off (reserved for possible future use)
“Module Status”
 Solid Green = the module is active (this module is connected to the
active DPU). The Common Bus is connected to the active DPU if
the I/O Bus Status is OK (see below).
 Solid Yellow = the module is inactive (this module is connected to

the inactive DPU) and the Common Bus is disconnected from the
inactive DPU.
 Solid Red = an INT/Alt-INT fault has occurred (the INT and Alt-
INT signal receivers either indicate that both DPUs are active or
their redundant receiver outputs do not agree). The Common Bus is
disconnected from the DPU.
“I/O Bus Status”

 Solid Green = OK. No I/O bus faults have are detected.
 Solid Red = I/O bus fault detected. The Common Bus is

disconnected from the DPU.
When no faults have been detected, the “Module Status” and “I/O Status
LED”s on the active I-module will be green. On the inactive module, the
“Module Status” LED will be yellow and the “I/O Bus Status” LED will be
green.

Special Conditions
All 3 LEDs = Off

 This means that the I-module is either broken or does not have
24VDC power.
All 3 LEDs = Yellow

 This happens when the I-module is in Reset.
Three jumpers are located beneath the I-module’s cover. They are reserved
for possible future use. Leave them in their factory-installed positions.
Bus Address
The I-module does not consume any I/O addresses nor does it require any
configuration. It does not have an entry in the maxTOOLS database.
Compatibility
The I-module is compatible with the maxDPU4F and maxPAC I/O.
Although compatibility testing has been concentrated on the maxDPU4F and

maxPAC I/O, it is likely that the I-module is also compatible with older
systems (e.g., maxDPU4E) as well. I-module compatibility with older
systems should be verified before committing to its use. Please consult with
Lansdale.
It is not recommended to pass I-module signals through a BEM. If your

application requires this, please consult with Lansdale.
17-4
I-module CPO403
Module Operation
A simplified block diagram of the I-module is shown below. An FPGA
(Field Programmable Gate Array) contains most of the logic of the I-module.
The FPGA contains logic for control, bus testing and bus gating.
Redundant
Bus
B us B us
D r iv e r R e c e iv e r
A C K /M A C K
D r iv e r
FPG A
E n a b le 1
E n a b le 2
B us C o n tro l
T e s te r L o g ic
A C K /M A C K
R e c e iv e r
C om m on B us
S w i tc h
Com m on
Bus
Block Diagram of the I-module
The Control Logic is the heart of the I-module. It determines when the
module should be active, it runs the bus tests, it controls the gating of signals
to and from the Common Bus, and it disconnects the Common Bus from the
I-module (by opening the Common Bus Switch) when its associated DPU is
inactive.

Mounting
The I-module is designed to be mounted on a DIN rail. Place the DIN rail in
the DPU cabinet. The right hand side of the cabinet is usually a good
location. Position the I-modules to minimize the length of the I/O bus
cables.
The DIN rail should be connected to the cabinet ground via a short and
direct low inductance connection.
Cabling
Each I-module requires three cable connections.
One cable (Metso #047494) is used to supply 24VDC power to the I-module.
One end of this cable has bare wire for connection to the same supply that
powers the DPU and I/O. The other end of this cable is terminated with a
polarized connector that plugs into the I-module. If the primary and
secondary DPUs are powered from different 24V supplies, each I-module
should be powered from the same supply that powers its associated DPU.
The other two cables are the connections to the Redundant I/O and Common
I/O racks. Use standard maxPAC cables for these connections. The I-
module has polarized latching connectors for that purpose. To preserve I/O
bus signal quality, do not use cables that are longer than necessary. The
longest cable that should be used is Metso #CPO307 (7 foot).
All connectors are clearly labeled on the I-module’s cover.
A Metso CPO309 cable must be connected between the maxPAC racks that
contain the DPUs. This cable makes each DPU’s INT signal available (as
Alt-INT) for the other DPU and I-module.
The following figure shows a basic I-module installation. Note the “flow
through” cabling scheme discussed in Chapter 1 of this manual had to be
modified. In order to minimize the length of the I-module cables, the
Redundant Bus and Common Bus connections were both made to the right
hand side of the racks. That is the side closest to where the I-modules are
mounted in the cabinet. This forced the trade off of making the second
Redundant Bus rack appear as a stub instead of a “flow through” segment.
Also note that both ends of the Redundant Bus are terminated, as are both
ends of the Common Bus. Each I-module contains a built-in switched
terminator on its Common Bus side so it automatically terminates that end of
the bus when the module is active.
17-6
I-module CPO403
C P O 3 0 9 In t/ A lt- In t C a b le
D P U w /R e d u n d a n t I/ O D P U w /R e d u n d a n t I/ O
T T
D D
P IO IO IO IO IO IO IO P IO IO IO IO IO IO IO
U U
T T
IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO
"I " "I "
24VD C M o d u le 24VD C M o d u le
T ** T **
T * * = b u ilt - in , s w it c h e d ,
T e r m in a t o r
C o m m o n I/ O
IO IO IO IO IO IO IO IO m a x P A C I /O c a b le s
T m a x P A C T e r m in a to r
IO IO IO IO IO IO IO IO
Basic I-module Cabling Scheme

Specifications
Mounting: DIN-rail
Size: 11”H x 5”W x 2.5”D
I/O Bus Addresses per Module: None
I/O Type: 564-Bus
Isolation: None
Power: 24VDC +/- 4VDC @ < 0.2A
Operating Temperature: 0-60 degrees C
Operating Humidity: 5 - 90% RH, non-condensing
Storage Temperature: -25 – 70 degrees C
Storage Humidity: 5 – 90% RH, non-condensing
Surge Withstand: None
17-8

Maxpac - B7

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maxPAC Hardware

Copyright © 2013 by Metso Automation USA Inc.

Metso Automation  278596 

CHAPTER 1 ...................................................................................................................... 1-1

maxPAC Input/Output Subsystem ............................................................................................................................. 1-1

CHAPTER 2 ...................................................................................................................... 2-1

Analog Input Modules Isolated Input Module IOP301 ............................................................................................ 2-1

Metso Automation  278596 

CHAPTER 3 ...................................................................................................................... 3-1

CHAPTER 4 ...................................................................................................................... 4-1

Analog Input Modules 3 Wire RTD Module IOP303 .............................................................................................. 4-1

CHAPTER 5 ...................................................................................................................... 5-1

Analog Input Modules TC Module IOP304 ............................................................................................................. 5-1

Metso Automation  278596 

CHAPTER 6 ...................................................................................................................... 6-1

Analog Output Modules 4-20 mA Output Module IOP320 .....................................................................................6-1

4-20 mA Isolated Output Module IOP321 .................................................................................................................6-1

CHAPTER 7 ...................................................................................................................... 7-1

CHAPTER 8 ...................................................................................................................... 8-1

CHAPTER 9 ...................................................................................................................... 9-1

Digital Input Modules Counter Timer Module IOP335 ........................................................................................... 9-1

CHAPTER 10 .................................................................................................................. 10-1

CHAPTER 11 .................................................................................................................. 11-1

Bus Extender Module Module IOP371 .................................................................................................................. 11-1

CHAPTER 12 .................................................................................................................. 12-1

QuadPAT Module IOP336 ..................................................................................................................................... 12-1

QuadPAT Termination Module IOP337 ............................................................................................................... 12-1

Metso Automation  278596 

QuadPAT Termination .................................................................................................................................... 12-5

CHAPTER 13 .................................................................................................................. 13-1

Turbine Valve Positioner Module IOP341 .............................................................................................................13-1

Turbine Valve Termination Module IOP342 .........................................................................................................13-1

CHAPTER 14 .................................................................................................................. 14-1

Overspeed Trip Module IOP345 ............................................................................................................................. 14-1

Overspeed Termination Module IOP346 ................................................................................................................14-1

Module Field Connections ...................................................................................................................................14-8

CHAPTER 15 .................................................................................................................. 15-1

HART 8 Channel Input Module IOP307 ................................................................................................................ 15-1

HART 16 Channel Input Module IOP308 .............................................................................................................. 15-1

HART Output Module IOP322 ............................................................................................................................... 15-1

HART Transceiver Module IOP364 ....................................................................................................................... 15-1

CHAPTER 16 .................................................................................................................. 16-1

Serial Communications Module IOP365................................................................................................................. 16-1

Serial Termination Assembly ITP201 ..................................................................................................................... 16-1

Metso Automation  278596 

Module Operation ................................................................................................................................................ 16-3

CHAPTER 17 .................................................................................................................. 17-1

I-module CPO403 ......................................................................................................................................................17-1

This publication, which describes the installation and operation of maxPAC,

Book No. Book Title

Metso Automation  278596 

Model IOP I/O Subsystem

 Welded steel construction

Optional Cabinet styles and sizes are also available.

Metso Automation  278596 

Figure 1-1. Typical Cabinet Arrangement, Front and Rear Views

 IOP382 Eight-pack assembly to accommodate up to eight maxPAC I/O

 IOP383 Six-pack assembly to accommodate a DPU4E or a Model 564 I/O

 IOP381 Four-pack assembly to accommodate four maxPAC or Model 564

1-2 Metso Automation  278596 

The backplane also contains ribbon cable connectors to interconnect chassis

Figure 1-2. Eight-Pack Rack

Figure 1-3. Six Wide Rack with DPU4E