Remoted I/O System Kvara

Hardware Manual (HW)

Manufacturer's Documentation

Valid for:

Product:
BRD.007.444.Rev 0
BRD.007.448.Rev 0
BRD.007.450.Rev 0
BRD.007.454.Rev 0
BRD.007.458.Rev 0
BRD.014.014.Rev 0
BRD.018.401.Rev 0
BRD.018.402.Rev 0
BRD.019.025.Rev 0
BRD.021.405.Rev 0
BRD.021.412.Rev 0

Edition: April 2002

Code: 00009.HW.0.GB

Esa/Gv s.r.l.
15 via Zamboni, CP 43
41011 Campogalliano Modena Italy
tel. +39 059 851414 - fax +39 059 851313
http://www.esagv.it - E-mail: [email protected]
Restrictions Duplication, transmission and use of this document or its contents shall be considered
prohitibed unless prior authorization has been received from Esa/Gv. All rights are
reserved.
Even when authorized, modification of this document (either by computer or on paper)
voids the guarantees specified below.

Guarantees The product may offer performances that are not described in these manuals. Esa/Gv
shall neither be obliged to maintain these functions in new versions of the product nor
to guarantee the relative assistance.

Checks have been carried out in order to ensure that the contents of these manuals
correspond to the documented product. Despite this fact, there may be discrepancies.
Esa/Gv therefore offers no guarantees as to the full compliance and completeness of the
texts.
The information in this document is periodically revised and new editions are issued
when necessary.

This manual has been compiled in partial compliance with ANSI/IEEE std 1063-1987
“IEEE Standard for software User Documentation”.

Editions This document is liable to be modified without prior notice. These modifications may
involve further editions or revisions of the document.
Further editions imply complete substitution of the document.
Revision involves replacement/addition/elimination of pages of the document.
Each page is identified by the code of the document at the bottom.

Notes
MS-DOS® Trademark registered by Microsoft Corporation.

ii 00009.HW.0.GB Esa/Gv
 The chronological list of editions of this document is given in the following table:

Evolution of the document

Edition Document Code Release Type of edition
04/04/2002 00009.HW.0.GB 0 Original

Modifications
Release Chapters - Pages Description

Esa/Gv 00009.HW.0.GB iii

iv 00009.HW.0.GB Esa/Gv
HW Hardware Manual

Hardware Manual

Notes for the reader....................................................................................................... i

Explanation of the symbols............................................................................................................ ii
Printer’s conventions .................................................................................................................... iii
Glossary ....................................................................................................................................... iv

1 General information ................................................................................................... 1

1.1 Description of the product ........................................................................................................ 1
1.2 Identification of the parts.......................................................................................................... 1
1.3 Identification labels.................................................................................................................. 2
1.4 Accessories ............................................................................................................................. 5

2 Installation .................................................................................................................. 1
2.1 Environmental conditions......................................................................................................... 1
2.1.1 Climatic conditions during operation............................................................................ 1
2.1.2 Transport and storage conditions ................................................................................ 1
2.1.3 Electromagnetic compatibility...................................................................................... 1
2.1.4 Exposure to polluting external substances................................................................... 2
2.1.5 Power supply .............................................................................................................. 2
2.1.6 Ground connection...................................................................................................... 2
2.1.7 Suppression of interference......................................................................................... 2
2.1.8 Selection of the receiver node address........................................................................ 3
2.1.9 Optic fiber specifications ............................................................................................. 4
2.2 How to assemble the remote I/O system .................................................................................. 5
2.2.1 Overall dimensions ..................................................................................................... 5
2.2.2 How to fix the modules................................................................................................ 5
2.2.3 How to connect the modules ....................................................................................... 5
2.2.4 Module connection example........................................................................................ 6

2A Installation of board BRD.007.444 with 16 1A outputs......................................... 1

2A.A Electrical specifications......................................................................................................... 1
2A.A.A Overall dimensions and weight ................................................................................ 2
2A.B Location of the components .................................................................................................. 2
2A.C Connection examples ........................................................................................................... 4
2A.D Technical notes about the connections.................................................................................. 6

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2B Installation of board BRD.007.448 with 16 inputs ................................................ 1

2B.A Electrical specifications......................................................................................................... 1
2B.A.A Overall dimensions and weights............................................................................... 1
2B.B Location of the components .................................................................................................. 2
2B.C Connection examples ........................................................................................................... 5
2B.D Technical notes about the connections.................................................................................. 8

2C Installation of BRD.007.450 Board with node + 16 In + 16 Out .........................C.1

2C.A Electrical specifications..................................................................................................... C.1
2C.A.A Inputs .................................................................................................................. C.2
2C.A.B Outputs................................................................................................................ C.3
2C.A.C Overall dimensions and weight ............................................................................ C.3
2C.B Location of the components .............................................................................................. C.4
2C.B.A Selection of the node address.............................................................................. C.8
2C.C Connection examples ....................................................................................................... C.9
2C.D Technical notes about then connections...........................................................................C.14
2C.D.A Node ..................................................................................................................C.14
2C.D.B Inputs .................................................................................................................C.15
2C.D.C Outputs ..............................................................................................................C.15

2D Installation of board BRD.007.454 with 16 1A outputs......................................... 1

2D.A Electrical specifications......................................................................................................... 1
2D.A.A Overall dimensions and weight ................................................................................ 2
2D.B Location of the components .................................................................................................. 3
2D.C Connection examples ........................................................................................................... 6
2D.D Technical notes about the connections ................................................................................. 7

2E Installation of board BRD.007.458 with 16 inputs................................................. 1

2E.A Electrical specifications......................................................................................................... 1
2E.A.A Overall dimensions and weights............................................................................... 1
2E.B Location of the components .................................................................................................. 2
2E.C Connection examples ........................................................................................................... 4
2E.D Technical notes about the connections.................................................................................. 7

2F Installation of the BRD.014.014 Board with drive for proportional valves.......... 1

2F.A Electrical specifications ......................................................................................................... 1
2F.A.A Output for proportional valve.................................................................................... 2

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2F.A.B Analog output........................................................................................................... 2

2F.A.C Overall dimensions and weight ................................................................................ 2
2F.B Location of components ........................................................................................................ 3
2F.C Connection examples............................................................................................................ 6
2F.D Technical notes about the connections.................................................................................. 6

2G Installation of board BRD.018.401 with 8 analog inputs...................................... 1

2G.A Electrical specifications ........................................................................................................ 1
2G.A.A Analog inputs........................................................................................................... 2
2G.A.B Overall dimensions and weight ................................................................................ 2
2G.B Location of the components.................................................................................................. 3
2G.C Connection examples ........................................................................................................... 7
2G.D Technical notes about the connections ................................................................................. 9

2H Installation of board BRD.018.402 with 8 analog outputs ................................... 1

2H.A Electrical specifications......................................................................................................... 1
2H.A.A Analog outputs......................................................................................................... 2
2H.A.B Overall dimensions and weight ................................................................................ 2
2H.B Location of components........................................................................................................ 3
2H.C Connection examples ........................................................................................................... 7
2H.D Technical notes about the connections ............................................................................... 10

2I Installation of the BRD.019.025 reception node board .......................................... 1

2I.A Electrical specifications .......................................................................................................... 1
2I.A.A Overall dimensions and weight.................................................................................. 1
2I.B Location of the components.................................................................................................... 2
2I.B.A Selection of the node address ................................................................................... 3
2I.C Connection examples............................................................................................................. 4
2I.D Technical notes about the connections................................................................................... 7

2L Installation of board BRD.021.405 with node + two 5V axes ............................... 1

2L.A Electrical specifications ......................................................................................................... 1
2L.A.A Inputs via encoder.................................................................................................... 2
2L.A.B Analog outputs ......................................................................................................... 3
2L.A.C Overall dimensions and weight................................................................................. 3
2L.B Location of the components................................................................................................... 4
2L.B.A Selection of the node address .................................................................................. 7

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2L.C Connection examples............................................................................................................ 8

2L.D Technical notes about the connections ................................................................................ 11
2L.D.A Node ...................................................................................................................... 11
2L.D.B Inputs via encoder.................................................................................................. 12
2L.D.C Analog outputs....................................................................................................... 12

2M Installation of BRD.021.412 Board with node + two 12V axes ............................ 1

2M.A Electrical specifications ........................................................................................................ 1
2M.A.A Inputs via encoder................................................................................................... 2
2M.A.B Analog outputs ........................................................................................................ 2
2M.A.C Overall dimensions and weights.............................................................................. 2
2M.B Location of components........................................................................................................ 3
2M.B.A Selection of node address ....................................................................................... 6
2M.C Connection examples........................................................................................................... 7
2M.D Technical notes about the connections ................................................................................. 9
2M.D.A Node ....................................................................................................................... 9
2M.D.B Inputs via encoder................................................................................................. 10
2M.D.C Analog outputs...................................................................................................... 11

3 Diagnostics................................................................................................................. 1
3.1 LEDs........................................................................................................................................ 1
3.1.1 LEDs on boards BRD.007.448 and BRD.007.458 ........................................................ 1
3.1.2 LEDs on boards BRD.007.444 and BRD.007.454 ........................................................ 1
3.1.3 LEDs on board BRD.007.450 ...................................................................................... 2
3.1.4 LEDs on board BRD.014.014 ...................................................................................... 4
3.1.5 LEDs on board BRD.018.401 ...................................................................................... 6
3.1.6 LEDs on board BRD.018.402 ...................................................................................... 6
3.1.7 LEDs on board BRD.019.025 ...................................................................................... 7
3.1.8 LEDs on boards BRD.021.405 and BRD.021.412 ........................................................ 8

4 Service and maintenance .......................................................................................... 1

4.1 Spare parts .............................................................................................................................. 1
4.2 WARNING ............................................................................................................................... 1
4.3 Module replacement ................................................................................................................ 2
4.3.1 Replacement of boards BRD.007.444 and BRD.007.448............................................. 2
4.3.2 BRD.007.450 board replacement ................................................................................ 2
4.3.3 Replacement of boards BRD.007.454 and BRD.007.458............................................. 3
4.3.4 BRD.014.014 board replacement ................................................................................ 3

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4.3.5 BRD.018.401 board replacement ................................................................................ 3

4.3.6 BRD.018.402 board replacement ................................................................................ 3
4.3.7 BRD.019.025 board replacement ................................................................................ 4
4.3.8 Replacement of boards BRD.021.405 and BRD.021.412............................................. 4

END OF SUMMARY

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vi 00009.HW.0.GBI Esa/Gv
HW Notes for the reader

Notes for the reader

General information The information in this manual only applies to the software versions indicated on the
frontispiece.

Not all the available functions may be described in this manual. In these cases, Esa/Gv
shall be obliged to neither guarantee these functions nor include them in future
versions.

Purpose This document contains information allowing technicians to correctly service the
product described on the frontispiece.

Users This document contains information for:

ù Specialized installer technicians/specialized test technicians with a good working
knowledge of the numeric control and machine. Basic knowledge of
electromechanics and indusCNl control panels.

Use of the document The document is divided into chapters that describe a well defined characteristic of
the product.

Notification of Please contact Esa/Gv if any difficulties should arise when this manual is used.
difficulties

Esa/Gv 00009.HW.0.GBI i
Notes for the reader HW

Explanation of the symbols

Graphic symbols may appear beside the text. These are used to emphasize information
of particular importance.

Attention
This symbol is used when failure to take the appropriate precautions could cause
slight damage to persons and property.

Danger
This symbol appears when failure to take the appropriate precautions or
accomplishment of incorrect manoeuvres could cause serious damage to persons
and/or property.

Important
This symbol appears in the manual to indicate information of particular importance. It
is essential to read these sections in order to fully understand the manual.

Option
This symbol indicates sections of the manual that describe optional functions or parts.
Use of optional performances must be established with the machine manufacturer.

Manufacturer
This symbol indicates those sections of the manual reserved to the machine
manufacturer.

Password
This symbol indicates sections of the manual that describe functions access to which is
safeguarded by software passwords.

CN
This symbol indicates sections of the manual that describe functions only available in
CN and not in the PC.

PC
This symbol indicates sections of the manual that describe functions only available in
the PC and not in CN.

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HW Notes for the reader

Printer’s conventions

Particular printer’s conventions are used to make it easier to identify the information in
this manual. These conventions are illustrated below.

Keyboard and video The following conventions are used.

ù The names of the screen-printed keys are indicated in boldface and are enclosed
within square brackets. If the name of the key is preceded by “button”, reference is
being made to a key on the push button panel.
− [ENTER]. Identifies the key that bears the word ENTER.
− [+] indicates the + key of the keyboard, while button [+] indicates the + key of
the push button panel.
ù The names of the function keys are indicated in boldface italics and are enclosed
within square brackets.
− [Plc Menu]. Identifies the function key that bears the words Plc Menu.
ù References to fields and/or messages on the video are written in boldface italics.
ù The specific text to be digitized by the user is underlined.
− If the manual indicates “digitize ok, the user must digitize exactly “ok”.
ù DIRECTION or DIRECTIONAL keys is the collective name used to indicate the
UP, DOWN, LEFT and RIGHT keys.
ù Pressure, in sequence, on a series of keys is written by separating the identifiers of
the required keys with the “>“ character.
− [Manual] > [START]. Describes pressure, in sequence, on the [Manual] and
[START] keys.
ù Pressure on several keys at the same time is indicated by separating the identifiers
of the keys themselves with the “+” character.
− à] Describes contemporaneous pressure on the [SHIFT] and [à
[SHIFT] + [à à]
keys.

Text The following conventions are used.

ù Italics are used to identify specialistic terms.
ù Boldface is used to emphasize words of particular importance.

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Glossary

CNC This is an abbreviation of Computerized Numerical Control and indicates the

instrument that governs the machine, i.e. the electronic device through which the
machining cycles are programmed, the axes moved, etc..
It corresponds to one of the devices whose operation is described in this manual.

NC Represents the Normally Closed status of an input or an output.

NO Represents the Normally Open status of an input or an output.

END OF PREFACE

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HW General information

1 General information

1.1 Description of the product

The remote I/O system consists of two types of board:

1) single receiver node to which up to 8 I/O boards can be connected;
2) receiver node plus I/O in a single module.

The single receiver node (type 1) can handle the following boards:
ù 16 digital inputs
ù 16 digital outputs
ù 8 12-bit analog inputs
ù 8 16-bit analog outputs
ù 2 outputs for proportional valves

The following modules complete with node plus I/O (type 2) are available:
ù receiver node + 16 digital inputs and 16 digital outputs
ù receiver node + two 5V inputs via encoder and 2 analog outputs
ù receiver node + two 12V inputs via encoder and 2 analog outputs

The remote I/O system allows up to 16 type 1 or type 2 receiver nodes to be connected.

Connection between the receiver node (or nodes if there are more than one) and the
numeric control is made by means of two optic fiber cables.

All modules can be fixed on OMEGA type DIN BARS in order to be mounted straight
into the electric panel of the machine.

View of the product

from above

Termination
Receiver node Input module Input module Output module Output module

Figure 1.1 - View from above

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General information HW

An example of a remote I/O system formed by a single receiver node (type 1) and 4 I/O
modules (2 input and 2 output types) is shown in the figure above.

1.2 Identification of the parts

The remote I/O system includes the following parts.

CODE DESCRIPTION
BRD.007.444 Board with 16 outputs and spring terminals
BRD.007.448 Board with 16 outputs and spring terminals
BRD.007.450 Board with node + 16 inputs + 16 outputs
BRD.007.454 Board with 16 outputs and removable terminal strip
BRD.007.458 Board with 16 inputs and removable terminal strip
BRD.012.053 I/O BUS resistive termination
BRD.014.014 Piloting board for 2 proportional valves
BRD.018.401 Board with 8 12-bit analog inputs
BRD.018.402 Board with 8 16-bit analog outputs
BRD.019.025 Receiver node board
BRD.021.405 Board with node + 2 axes for 5V encoder
BRD.021.412 Board with node + 2 axes for 12V encoder

1.3 Identification labels

Each board has a Perspex cover bearing:

ù Esa/Gv trademark with an indication as to the type of board
ù CE mark
ù indication about the connectors and leds
ù location of the signals in the connectors
ù jumper personalization

There are also 3 white labels with the code, revision and serial number of the board.

From October 2001 onwards, these 3 labels have been replaced by a single label with a
bar code that gives the same information.

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HW General information

An example of a cover panel is given in the following figure.

Figure 1.1 - Example of a cover panel

1) board code label

2) board revision label
3) Esa/Gv trademark with an indication as to the type of board
4) indication about the leds
5) location of the signals in the connectors
6) label with the serial number of the board
7) CE mark
8) indication about the connectors
9) jumper personalization

An example of a bar code label is given in the following figure.

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General information HW

Figure 1.1 - Example of a bar code label

ù board code
ù board revision
ù board serial number

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HW General information

1.4 Accessories

The following list includes the accessories that can be supplied with the boards of the
remote I/O system so that they can be correctly installed.

BOARD CODE QUANTITY

BRD.007.450 MRS.005.030 3 Terminal strip 18p FM
BRD.007.454 MRS.007.027 2 Terminal strip 11p FM
BRD.007.458 MRS.007.026 2 Terminal strip 10p FM
BRD.018.401 MRS.007.022 1 Terminal strip 3p FM
MRS.008.033 8 Terminal strip 4p FM
BRD.018.402 MRS.007.022 1 Terminal strip 3p FM
CNN.020.092 2 Connector 15p MS
BRD.021.405 MRS.007.022 1 Terminal strip 3p FM
CNN.020.002 2 Connector 9p MS
CNN.020.092 1 Connector 15p MS
BRD.021.412 MRS.007.022 1 Terminal strip 3p FM
CNN.020.002 2 Connector 9p MS
CNN.020.092 1 Connector 15p MS
BRD.012.053 Note 1 Resistive termination for I/O BUS
OPF.005.001 Note 2 Optic fiber HP HFBR-RU100

Note 1: one is required for each individual receiver node installed.

Note 2: length in meters to specify on order.

END OF CHAPTER

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2 Installation

2.1 Environmental conditions

The remote I/O system has been designed and tested to suit the environmental
conditions indicated in this chapter.
To obtain correct operation, it is necessary to:
ù respect the environmental conditions during operation, transport and storage;
ù correctly install the product.

Information and Contact the Esa/Gv “Assistance Department” if assistance or information is required.
assistance

2.1.1 Climatic conditions during operation

Use a heat exchanger or a conditioner if it is impossible to comply with the specified
limit values.

Specification Limit value

Operating temperature 5-55 °C
Humidity 5-95 %
Condensation Not permitted
Maximum tolerated altitude 2000 m

2.1.2 Transport and storage conditions

The following specifications only apply to modules in their original packaging.

Specification Limit value

Temperature -25 to 70 °C
Humidity 5 to 95 %
Condensation Not permitted
Maximum altitude 3000 m

2.1.3 Electromagnetic compatibility

Emission Generic standard for industrial environments: EN50081-2 .

Basic standard EN55011 is used.

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Test Limit
Interferences conducted along the powering cables Class A
Radiated interference Class A

Immunity Generic standard for industrial environments: EN50082-2

The following basic standards are used.

Test Limit
Electromagnetic field at conducted radio- Test voltage: 10 V rms
frequency ENV50141
Frequency: 0.15 to 80 MHz
80% modulation AM 1 KHz
Electromagnetic field at radiated radio- Field intensity: 10 V/m
frequency ENV50140
Frequency: 80-1000 MHz
80% modulation AM 1KHz
Magnetic field at mains frequency Field intensity: 30A/m
EN61000-4-8
Frequency: 50 Hz
Fast transients (burst) EN61000-4-4 Test voltage: 2 KV
Electrostatic discharges EN61000-4-2 Test voltage by contact: 4 KV
Test voltage in air: 8 KV
Duration of test: 10 discharges
Repeats: 1 discharge/s

Radio-frequency suppression must be considered if the product is to be correctly

installed. Particular attention must be paid to cable routing. Contact Esa/Gv if further
information is required. Refer to the ”Guide to installation in compliance with EMC
and LVD directives” available from Esa/Gv which gives instructions on how to
correctly install the product in relation to EMC problems.

2.1.4 Exposure to polluting external substances

The presence of dust (iron, sawdust, etc.) or soil in the place where the modules
operate can prevent these latter from operating properly. The modules must operate in
an electric panel with adequate changes of appropriately filtered air in order to
guarantee that they are cooled. Periodically check the filters and replace them when
necessary.

2.1.5 Power supply

The power supply of the remote I/O system is located on the receiver node.
Refer to the electrical specifications of the individual boards given further on in this
chapter.

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2.1.6 Ground connection

The system must be correctly grounded in order to ensure that it operates properly and
is immune from interference. To do this, it is essential for the negative reference of the
+24 V DC power supply voltage to be grounded.
Refer to the ground connection required by the individual boards described further on
in this chapter.

An incorrect ground connection can jeopardize both the operators' safety and
prevent the modules from operating properly.

2.1.7 Suppression of interference

In addition to the protective ground connection, take particular care when routing the
wires in the electric panel in order to ensure that there is no interference when the
remote I/O system operates.

Definition of the Signal cables

cables
ù +24 V DC ON/OFF inputs and outputs
ù analog inputs and outputs
ù inputs via encoder

Power cables
ù Power supply cables (380 V AC, 220 V AC)
ù Drive - motor connection cables
ù Connection cables with inductive loads powered with 110 V AC voltage or higher.

Installation rules Comply with the following rules to guarantee the maximum immunity from
interference.
ù Install the signal cables as far as possible from the power cables.
ù Do not route signal cables near to intense magnetic fields generated by motors or
transformers for example.
ù Route the signal cables well away from neon lights as they generate interference.
ù Cables that convey impulsive signals with fast voltage and current variations must
be completely separate from all the others. If they cannot be sufficiently separated,
route the signal wires in screened metal ducts.
ù Route the modules that form the remote I/O system well away from intense
electromagnetic fields, neon lights and power cables.

Failure to comply with the following rules will prevent the remote I/O system from
working properly.

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Installation HW

Filters to suppress Filters can be mounted straight on to the source of the interference or as near as
interference possible to it in order to eliminate interference generated by coils, solenoid valves,
hydraulic valves, remote control switches, motors and other inductive loads. The filter
must be firmly fixed in order to prevent it from breaking.

2.1.8 Selection of the receiver node address

Each receiver node has a 16-position rotary dip switch (SW1) to determine the address
of that board.

If several receiver nodes are used, two or more modules cannot have the same address
(same rotary dip switch position). If this happens, the system will be unable to operate
correctly.

Use a small screwdriver to change the position of the dip switch. The standard position
is 0 (zero).

The first node connected to the optic fiber can have any address.

2.1.9 Optic fiber specifications

Specification Value
Type Plastic
Diameter 2.2 mm
Maximum attenuation 0.27 dB/m
Maximum extension force 1N
Minimum radius of curvature 35 mm
Maximum length on TX output 20 m
Maximum transmission speed 2 Mb/s
Storage temperature -55 to 85°C
Installation and operating temperature -20 to 85°C

Order the required quantity of optic fiber from Esa/Gv. Customers can also buy it on
their own so long as the specifications given in the previous table are complied with.

If the optic fiber is of poor quality and the specifications are not complied with, the
entire remote I/O system may be prevented from operating properly.

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2.2 How to assemble the remote I/O system

2.2.1 Overall dimensions

The dimensions of the remote I/O system vary depending on how the actual system is
formed. It can consist of a single receiver node and a variable number (up to 8) of I/O
modules or consist of a single board that comprises both the receiver node and the I/O.
The dimensions of the individual boards are given further on in this chapter.

2.2.2 How to fix the modules

Each module is mounted on a plastic support that can be fixed to an OMEGA type DIN
BAR.

2.2.3 How to connect the modules

The receiver node has a 34-pole male flat connector able to receive the 34-pole loose
female flat connector on each board on either the input or output. Connect the I/O
module together in the same way.
Once the connections have been made, all the modules can be neared to each other to
shorten the overall length of the entire system.

The resistive termination of the BRD.012.053 I/O BUS must be mounted on the last
I/O board to ensure that everything operates properly.
In order to be correctly assembled, the components must point towards the internal part
of the board that receives this termination.

Resistive termination
BRD.012.053

Figure 2.1 - Resistive termination BRD.012.053

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Installation HW

Module connection
example

Termination
Receiver node Input module Input module Output module Output module

Figure 2.1 - Module connection example

2.2.4 Module connection example

Refer to the following sections that describe the individual boards forming the remote
I/O system when connecting the modules (power supply, optic fiber, inputs and
outputs).

END OF CHAPTER

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HW Installation of board BRD.007.444 with 16 1A outputs

2A Installation of board BRD.007.444 with 16 1A

outputs

2A.A Electrical specifications

Specification Value
Number of outputs 16
Typical output power supply voltage rating +24 V DC
Maximum output power supply voltage rating +28.8 V DC
Minimum output power supply voltage rating +20.4 V DC
Outputs decoupled in relation to the I/O BUS YES
Insulation voltage 500 V DC
Maximum direct current on the output 1 A (Note 1)
Typical output current 10 mA-700mA
Maximum direct current on the output (2 outputs in parallel) 1.5 A
Maximum direct current on the output (4 outputs in parallel) 3.0 A
Maximum current on the output common contact 4A
Maximum commutation frequency for Io=0.7 A 3 KHz
Protection against short-circuits YES
Protection against overloads/overtemperatures YES
Protection against undervoltages YES
Protection against overvoltages Max. +36V DC
Maximum demagnetizing energy of an inductive load that can be 60 mJ
dissipated
Minimum ON output voltage for Io=0.7 A with +24V DC power 23.8 V
supply
Maximum OFF output voltage with +24V DC power supply 0.l V
Output resetting intervention time in the absence of optic fiber 50 ms
connection (LED LINK on BRD.019.025 off)
Operating time 5-55°C

Note 1: this is the maximum value possible prior to current limitation or protection
against short-circuits.

The power supply voltage of the outputs can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

Esa/Gv 00009.HW.0.GB A.1

Installation of board BRD.007.444 with 16 1A outputs HW

Some devices used at 1A may access the thermal protection status owing to the
tolerance values they have been given.

2A.A.A Overall dimensions and weight

Specification Value
Length 95 mm
Width 100 mm
Height 65 mm
Weight 175 g

2A.B Location of the components

Figure A.1 - Location of the components

1. J1: I/O BUS signal interface (input)

A.2 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.444 with 16 1A outputs

2. J2: I/O BUS signal interface (output)

3. Leds 12-15: power supply leds for outputs 13 - 16
4. Leds 4-7: power supply leds for outputs 5 - 8
5. Leds 0-3: power supply leds for outputs 1 - 4
6. Leds 8-11: power supply leds for outputs 9 - 12
7. J4: connector for outputs 9 - 16
8. J3: connector for outputs 1 - 8
9. Leds 8-15: signalling leds for outputs 9 - 16
10. Leds 0-7: signalling leds for outputs 1 - 8

Output connector Name of connector: J3 and J4

Type of connector: WAGO terminal strip series 236, 2 x 11 poles pitch 5 mm with
screw fastening.

Figure A.2 - Output connector

Esa/Gv 00009.HW.0.GB A.3

Installation of board BRD.007.444 with 16 1A outputs HW

Pins Name Type

1 OUTPUT 1 O
2 OUTPUT 2 O
3 OUTPUT 3 O
4 OUTPUT 4 O
5 OUTPUT 5 O
6 OUTPUT 6 O
7 OUTPUT 7 O
8 OUTPUT 8 O
9 OUTPUT 9 O
10 OUTPUT 10 O
11 OUTPUT 11 O
12 OUTPUT 12 O
13 OUTPUT 13 O
14 OUTPUT 14 O
15 OUTPUT 15 O

Continued ...
Pins Name Type
16 OUTPUT 16 O
17 +24 V DC (OUTPUTS 1-4) VI
18 +24 V DC (OUTPUTS 5-8) VI
19 FIELD GND (GROUND) REF
20 +24 V DC (OUTPUTS 9-12) VI
21 +24 V DC (OUTPUTS 13-16) VI
22 FIELD GND (GROUND) REF

Name of signal:
OUTPUT 1-16 output signal
+24V DC output common contact (+24 V DC power supply)
FIELD GND output power supply reference

Type of signal:
VI input voltage
REF reference
O output signal

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HW Installation of board BRD.007.444 with 16 1A outputs

2A.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure A.3 - Grounding

+24V DC Solenoid
valve

Figure A.4 - +24V DC Solenoid valve

Esa/Gv 00009.HW.0.GB A.5

Installation of board BRD.007.444 with 16 1A outputs HW

+24V DC Relay

Figure A.5 - +24V DC Relay

External PLC

Figure A.6 - External PLC

Note The protection device indicated with an asterisk * is not always necessary when it
comes to dissipating the demagnetization energy of an inductive load. However, it is
necessary if one considers the electromagnetic compatibility aspects. The protective
device notably reduces the interference issued by the load during its commutations.

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HW Installation of board BRD.007.444 with 16 1A outputs

2A.D Technical notes about the connections

If pins 19 and 22 (FIELD GND) of the output connector are disconnected, all the
outputs are deactivated (OFF).

General information The output MOS device is equipped with a clamp circuit to dissipate the
demagnetization energy produced by an inductive load. The maximum value of the
energy that can be dissipated is 60 mJ. An external protection device must be installed
if the energy produced is higher.
Use the following formula to calculate the demagnetization energy:

E = 0.5 x L x Io²

where L is the value in H of the inductive load and Io the current absorbed by the load.

The external devices used can be TRANSIL P6KE36P and 1.5KE36P one-way types,
P6KE36CP and 1.5KE36CP two-way types or similar. Normal 1N4004/1N4007 diodes
can be used but they are much slower than the TRANSIL devices. This can lead to the
device becoming more greatly heated with subsequent activation of the
overtemperature protection.

The demagnetization power must also be considered. If this is more than 1.5 W, it will
lead to the device becoming heated and, thus, activation of the protection against
overtemperatures.
Use the following formula to calculate the demagnetization power:

Pd = 0.5 x L x Io² x 2.14 x f

where L is the value in H of the inductive load, Io the current absorbed and f the
commutation frequency of the load.
An external protection device must be installed if a higher demagnetization power is
developed.

Protection fuse Since the device is protected against short-circuits, there is no need to install a fuse in
series with each output. If a fuse is installed, its value must equal the maximum current
that the output can deliver. A fuse cannot be installed in series with the power supply
since the activation current must be 4 times more than that of each individual output.
In this case, activation of the device's protection against short-circuits will ensure that
the fuse never burns out.

Cable section The section of the connection cables is bound to both the value of the output current
(1A) and mechanical traction due to the weight of the cables connected to the terminal
strip. A 1mm² section will not cause particular mechanical or electrical problems.
Larger sections could make the cables difficult to fix. The maximum section tolerated
by the terminal strips is 2.5 mm².

END OF CHAPTER

Esa/Gv 00009.HW.0.GB A.7

Installation of board BRD.007.444 with 16 1A outputs HW

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HW Installation of board BRD.007.448 with 16 inputs

2B Installation of board BRD.007.448 with 16 inputs

2B.A Electrical specifications

Specification Value
Number of inputs 16
Typical input voltage rating +24 V DC
Maximum input voltage rating +30 V DC
Minimum input voltage rating +10 V DC
Typical input current 10.6 mA
Maximum input current 15.2 mA
Minimum input current 2 mA
Hardware filter 10 ms
Maximum commutation frequency 46 Hz
Delay on energizing 4.4 ms
Delay on de-energizing 4.3 ms
Protection against polarity reversal YES
Protection against overvoltages NO
Inputs decoupled in relation to I/O BUS YES
Insulation voltage 500 V
Operating temperature 5-55°C

The input voltage can come from a power supplier obtained from a threephase
transformer with diodes and condenser. The peak value at peak residue alternate
voltage (ripple) must comply with the minimum and maximum values given in the
table.

2B.A.A Overall dimensions and weights

Specification Value
Length 85 mm
Width 100 mm
Height 65 mm
Weight 150 g

Esa/Gv 00009.HW.0.GB B.1

Installation of board BRD.007.448 with 16 inputs HW

2B.B Location of the components

Figure B.1 - Location of the components

1. J1: I/O BUS signal interface (input)

2. J2: I/O BUS signal interface (output)
3. Leds 0-7: signalling leds for inputs 1 - 8
4. Leds 8-15: signalling leds for inputs 9 - 16
5. J4: connector for inputs 9 - 16
6. J3: connector for inputs 1 - 8

Input connector Name of connector: J3 and J4.

Type of connector: WAGO terminal strip series 236, 2 x 10 poles pitch 5 mm with
screw fastening.

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HW Installation of board BRD.007.448 with 16 inputs

Figure B.2 - External signal connector

Pins Name Type

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 INPUT 5 I
6 INPUT 6 I
7 INPUT 7 I
8 INPUT 8 I
9 INPUT 9 I
10 INPUT 10 I
11 INPUT 11 I
12 INPUT 12 I
13 INPUT 13 I

Continued ...

Esa/Gv 00009.HW.0.GB B.3

Installation of board BRD.007.448 with 16 inputs HW

... continued

Pins Name Type

14 INPUT 14 I
15 INPUT 15 I
16 INPUT 16 I
17 FIELD GND (GROUND) REF
18 FIELD GND (GROUND) REF
19 FIELD GND (GROUND) REF
20 FIELD GND (GROUND) REF

Name of signal:
INPUT 1-16 input signal
FIELD GND input reference

Type of signal:
REF reference
I input signal

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HW Installation of board BRD.007.448 with 16 inputs

2B.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure B.3 - Grounding

Limit switch or relay

contact

Figure B.4 - Limit switch or relay contact

Esa/Gv 00009.HW.0.GB B.5

Installation of board BRD.007.448 with 16 inputs HW

Open collector
sensor

Figure B.5 -Open collector sensor

Push-pull sensor

Figure B.6 -Push-pull sensor

B.6 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.448 with 16 inputs

Parallel inputs

Figure B.7 - Parallel inputs

Esa/Gv 00009.HW.0.GB B.7

Installation of board BRD.007.448 with 16 inputs HW

2B.D Technical notes about the connections

General information The contact of a limit switch or relay connected to the input terminal strip of the board
must be absolutely without further connections to voltages pertaining to the auxiliary
circuit of the machine.
Do not use a limit switch with double contact if one of the two is connected to the
auxiliary 110V AC voltage or higher. The presence of moisture could lead to a
discharge between the two sections.
Failure to comply with these instructions could damage the input circuit of the board.

Parallel inputs If the same contact must be used with another similar input (e.g. an external PLC or
another input of the control unit), install a decoupling diode in series as indicated in
the “Connection examples” section.

Characteristics of the When choosing the characteristics of the contact of the relay or limit switch for
contact example, take care to check the minimum commutable voltage and current values: the
commutation voltage is 24V DC while the current is about 10 mA.

Cable section The section of the connection cables is not bound to the value of the input signal which
is minimum, but to the mechanical traction due to the weight of the cables connected to
the terminal strip. A 1 mm² section will not cause particular problems. Larger sections
could make the cables difficult to fix. The maximum section tolerated by the terminal
strips is 2.5 mm².

END OF CHAPTER

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HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

2C Installation of BRD.007.450 Board with node + 16

In + 16 Out

2C.A Electrical specifications

Specifications Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current 60 mA
Maximum power used 1.5 W
Protection against polarity reversal YES
Protection against overvoltages YES, max. 60V
Protection against an alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB C.1

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

2C.A.A Inputs

Specification Value
Number of inputs 16
Typical input voltage +24 V DC
Maximum input voltage +30 V DC
Minimum input voltage +11 V DC
Typical input current 6 mA
Maximum input current 8 mA
Minimum input current 2.7 mA
Hardware filter 7 ms
Maximum commutation frequency 46 Hz
Delay on energizing 2 ms
Delay on de-energizing 5 ms
Protection against polarity reversal YES
Protection against overvoltages NO

The input voltage can come from a power supplier obtained from a threephase
transformer with diodes and condenser. The peak value at peak residue alternate
voltage (ripple) must comply with the minimum and maximum values given in the
table.

C.2 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

2C.A.B Outputs

Specification Value
Number of outputs 16
Typical output power supply voltage rating +24 V DC
Maximum output power supply voltage rating +28.8 V DC
Minimum output power supply voltage rating +20.4 V DC
Typical output current 10 mA-700mA
Maximum direct current on the output 1 A (Note 1)
Maximum direct current on the output (2 outputs in parallel) 1.5 A
Maximum direct current on the output (4 outputs in parallel) 3.0 A
Maximum current on the output common contact 4A
Maximum commutation frequency for Io=0.7 A 3 KHz
Protection against short-circuits YES
Protection against overloads/overtemperatures YES
Protection against overvoltages Max. +36V DC
Maximum demagnetizing energy of an inductive load that can be 60 mJ
dissipated
Minimum ON output voltage for Io=0.7 A with +24V DC power 23.8 V
supply
Maximum OFF output voltage with +24V DC power supply 0.l V
Output resetting intervention time in the absence of optic fiber 50 ms
connection (LED LINK off)

Note 1: this is the maximum value possible prior to current limitation or protection
against short-circuits.

Some devices used at 1A may access the thermal protection status owing to the
tolerance values they have been given.

The power supply voltage of the outputs can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

Esa/Gv 00009.HW.0.GB C.3

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

2C.A.C Overall dimensions and weight

Specification Value
Length 125 mm
Width 122 mm
Height 65 mm
Weight 200 g

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HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

2C.B Location of the components

Figure C.1 - Location of the components

. RX: Optic fiber receiver

. TX: Optic fiber transmitter
. SW1: node address dip switch
. POWER OK Led
. Leds 0-7: power supply leds for outputs 1 - 8
. Leds 8-15: power supply leds for outputs 9 - 16
. J1: connector for inputs 1 -16 + board power supply
. J2: connector for outputs 1 -16 + output power supply
. J3: common connector for inputs and outputs

Esa/Gv 00009.HW.0.GB C.5

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

. +5V Led
. LINK Led
. OUTPUTS 1 - 16 Leds: signalling leds for outputs 1 - 16
. INPUTS 1 - 16 Leds: signalling leds for inputs 1 - 16

Input connector Name of connector: J1

Type of connector: SAURO CIM18E05 terminal strip, 18 poles pitch 5.08 mm.

Figure C.2 - External signal connector

Pins Name Type

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 INPUT 5 I
6 INPUT 6 I
7 INPUT 7 I
8 INPUT 8 I
9 INPUT 9 I
10 INPUT 10 I
11 INPUT 11 I
12 INPUT 12 I
13 INPUT 13 I
14 INPUT 14 I
15 INPUT 15 I
16 INPUT 16 I
17 FIELD GND REF
18 +24V DC VI

C.6 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

Signal name:
INPUT 1-16 input signal
FIELD GND - board power supply
+24V DC + board power supply

Type of signal:
VI input voltage
REF reference
I input signal

Output connector Name of connector: J2

Type of connector: SAURO CIM18E05 terminal strip, 18 poles pitch 5.08 mm.

Figure C.3 - External signal connector

Pins Name Type

1 OUTPUT 1 O
2 OUTPUT 2 O
3 OUTPUT 3 O
4 OUTPUT 4 O
5 OUTPUT 5 O
6 OUTPUT 6 O
7 OUTPUT 7 O
8 OUTPUT 8 O
9 OUTPUT 9 O
10 OUTPUT 10 O
11 OUTPUT 11 O
12 OUTPUT 12 O
13 OUTPUT 13 O
14 OUTPUT 14 O
15 OUTPUT 15 O

Continued ...

Esa/Gv 00009.HW.0.GB C.7

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

.... continued

Pins Name Type

16 OUTPUT 16 O
17 +24 V DC (OUTPUTS 1-8) VI
18 +24 V DC (OUTPUTS 9-16) VI

Name of signal:
OUTPUTS 1-16 output signal
+24V DC output common contact (+24 V DC power supply)

Type of signal:
VI input voltage
O output signal

Common connector Name of connector: J3

Type of connector: SAURO CIM18E05 terminal strip, 18 poles pitch 5.08 mm.

Figure C.4 - External signal connector

Pins Name Type

1 FIELD GND REF
2 FIELD GND REF
3 FIELD GND REF
4 FIELD GND REF
5 FIELD GND REF
6 FIELD GND REF
7 FIELD GND REF
8 FIELD GND REF
9 FIELD GND REF
10 FIELD GND REF
11 FIELD GND REF

Continued ...

C.8 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

Continued...
Pins Name Type
12 FIELD GND REF
13 FIELD GND REF
14 FIELD GND REF
15 FIELD GND REF
16 FIELD GND REF
17 FIELD GND REF
18 FIELD GND REF

Name of signal:
FIELD GND input and output reference

Type of signal:
REF reference

2C.B.A Selection of the node address

The board has a 16-position rotary dip switch (SW1) to determine the address of the
receiver node.

If several receiver nodes are used, two or more modules cannot have the same address
(rotary dip switch in the same position). The system cannot operate correctly.

Use a small screwdriver to change the position of the dip switches. The standard
position is 0 (zero).

Esa/Gv 00009.HW.0.GB C.9

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

2C.C Connection examples

Board power supply

Figure C.5 - Board power supply

C.10 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

Limit switch or relay

contact

Figure C.6 - Limit switch or relay contact

Open collector
sensor

Figure C.7 - Open collector sensor

Esa/Gv 00009.HW.0.GB C.11

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

Push-pull sensor

Figure C.8 - Push-pull sensor

Parallel inputs

Figure C.9 - Parallel inputs

C.12 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

+24V DC solenoid
valve

Figure C.10 - +24V DC solenoid valve

+24V DC relay

Figure C.11 - +24V DC relay

Esa/Gv 00009.HW.0.GB C.13

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

External PLC

Figure C.12- External PLC

Note The protection device indicated with an asterisk * is not always necessary when it
comes to dissipating the demagnetization energy of an inductive load. However, it is
necessary if one considers the electromagnetic compatibility aspects. The protective
device notably reduces the interference issued by the load during its commutations.

C.14 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

2C.D Technical notes about then connections

2C.D.A Node

Optic fiber Proceed in the following way to correctly connect the optic fiber to the TX transmitter
connection and RX receiver modules:
ù cut the ends using a cutter or knife;
ù insert the optic fiber into the modules as far as it will go;
ù to remove the optic fiber, push the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure C.13 - Example of optic fiber removal

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring as they could break and remain inside the module.

Proceed in the following way to use the optic fiber correctly:

ù prevent dirt or dust from entering the TX and RX modules;
ù do not use acids or alkaline solvents on the modules and do not inject these
substances into the optic fiber hole. Use a cotton swab should this occur;
ù do not bend or stretch the optic fiber beyond the value given in the specifications
as it could break.

Take great care when routing the optic fiber to prevent it from breaking. There are no
particular interference problems in view of the optic nature of the signal that travels
along the fiber.

Esa/Gv 00009.HW.0.GB C.15

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

Powering cable The section of the powering cables is not bound to the value of the input current which
sections is minimum, but to the mechanical traction due to the weight of the cables connected to
the terminal strip. A 1 mm² section will not cause particular problems. Larger sections
could make the cables difficult to fix. The maximum section tolerated by the terminal
strips is 2.5 mm².

2C.D.B Inputs

General information The contact of a limit switch or relay connected to the input terminal strip of the board
must be absolutely without further connections to voltages pertaining to the auxiliary
circuit of the machine.
Do not use a limit switch with double contact if one of the two is connected to the
auxiliary 110V AC voltage or higher. The presence of moisture could lead to a
discharge between the two sections.
Failure to comply with these instructions could damage the input circuit of the board.

Parallel inputs If the same contact must be used with another similar input (e.g. an external PLC or
another input of the control unit), install a decoupling diode in series as indicated in
the “Connection examples” section.

Characteristics of the When choosing the characteristics of the contact of the relay or limit switch for
contact example, take care to check the minimum commutable voltage and current values: the
commutation voltage is 24V DC while the current is about 10 mA.

Cable section The section of the connection cables is not bound to the value of the input current
which is minimum, but to the mechanical traction due to the weight of the cables
connected to the terminal strip. A 1 mm² section will not cause particular problems.
Larger sections could make the cables difficult to fix. The maximum section tolerated
by the terminal strips is 2.5 mm².

2C.D.C Outputs

All the outputs will be deactivated (OFF) if at least one pin (FIELD GND) of the
common connector is not connected.

General information The output MOS device is equipped with a clamp circuit to dissipate the
demagnetization energy produced by an inductive load. The maximum value of the
energy that can be dissipated is 60 mJ. An external protection device must be installed
if the energy produced is higher.
Use the following formula to calculate the demagnetization energy:

E = 0.5 x L x Io²

where L is the value in H of the inductive load and Io is the current absorbed by the
load.

C.16 00009.HW.0.GB Esa/Gv

HW Installation of BRD.007.450 Board with node + 16 In + 16 Out

The external devices used can be TRANSIL P6KE36P and 1.5KE36P on-way types,
P6KE36CP and 1.5KE36CP two-way types or similar. Normal 1N4004/1N4007 diodes
can be used but they are much slower than the TRANSIL devices. This can lead to the
device becoming more greatly heated with subsequent activation of the
overtemperature protection.

The demagnetization power must also be considered. If this is more than 1.5 W, it will
lead to the device becoming heated and, thus, activation of the overtemperature
protection.
Use the following formula to calculate the demagnetizing power:

Pd = 0.5 x L x Io² x 2.14 x f

where L is the value in H of the inductive load, Io the current absorbed and f the
commutation frequency of the load.
An external protection device must be installed if a higher demagnetization power is
developed.

Protection fuse Since the device is protected against short-circuits, there is no need to install a fuse in
series with each output. If a fuse is installed, its value must equal the maximum current
that the output can deliver. A fuse cannot be installed in series with the power supply
since the activation current must be 4 times more than that of each individual output.
In this case, activation of the device's protection against short-circuits will ensure that
the fuse never burns out.

Cable section The section of the connection cables is not bound to the value of the input current
which is minimum, but to the mechanical traction due to the weight of the cables
connected to the terminal strip. A 1 mm² section will not cause particular problems.
Larger sections could make the cables difficult to fix. The maximum section tolerated
by the terminal strips is 2.5 mm².

END OF CHAPTER

Esa/Gv 00009.HW.0.GB C.17

Installation of BRD.007.450 Board with node + 16 In + 16 Out HW

C.18 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.454 with 16 1A outputs

2D Installation of board BRD.007.454 with 16 1A

outputs

2D.A Electrical specifications

Specification Value
Number of outputs 16
Typical output power supply voltage +24 V DC
Maximum output power supply voltage +28.8 V DC
Minimum output power supply voltage +20.4 V DC
Outputs decoupled in relation to the I/O BUS YES
Insulation voltage 500 V DC
Maximum direct current on the output 1 A (Note 1)
Typical output current 10 mA-700mA
Maximum direct current on the output (2 outputs in parallel) 1.5 A
Maximum direct current on the output (4 outputs in parallel) 3.0 A
Maximum current on the output common contact 4A
Maximum commutation frequency for Io=0.7 A 3 KHz
Protection against short-circuits YES
Protection against overloads/overtemperatures YES
Protection against undervoltages YES
Protection against overvoltages Max. +36V DC
Maximum demagnetizing energy of an inductive load that can be 60 mJ
dissipated
Minimum ON output voltage for Io=0.7 A with +24V DC power 23.8 V
supply
Maximum OFF output voltage with +24V DC power supply 0.l V
Output resetting intervention time in the absence of optic fiber 50 ms
connection (LED LINK on BRD.019.025 off)
Operating temperature 5-55°C

Note 1: this is the maximum value possible prior to current limitation or protection
against short-circuits.

The power supply voltage of the outputs can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

Esa/Gv 00009.HW.0.GB D.1

Installation of board BRD.007.454 with 16 1A outputs HW

Some devices used at 1A may access the thermal protection status owing to the
tolerance values they have been given.

2D.A.A Overall dimensions and weight

Specification Value
Length 95 mm
Width 100 mm
Height 65 mm
Weight 175 g

D.2 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.454 with 16 1A outputs

2D.B Location of the components

Figure D.1 - Location of the components

1. J1: I/O BUS signal interface (input)

2. J2: I/O BUS signal interface (output)
3. Leds 12-15: power supply leds for outputs 13 -16
4. Leds 4-7: power supply leds for outputs 5 - 8
5. Leds 0-3: power supply leds for outputs 1 - 4
6. Leds 8-11: power supply leds for outputs 9 -12
7. J4: connector for outputs 9-16
8. J3: connector for outputs 1-8
9. Leds 8-15: signalling leds for outputs 9 - 16
10. Leds 0-7: signalling leds for outputs 1 - 8

Output connector Name of connector: J3 and J4

Esa/Gv 00009.HW.0.GB D.3

Installation of board BRD.007.454 with 16 1A outputs HW

Type of connector: Phoenix MSTBV terminal strip, 2 x 11 poles pitch 5.08 mm

Figure D.2 - Output connector

Pins Name Type

1 OUTPUT 1 O
2 OUTPUT 2 O
3 OUTPUT 3 O
4 OUTPUT 4 O
5 OUTPUT 5 O
6 OUTPUT 6 O
7 OUTPUT 7 O
8 OUTPUT 8 O
9 OUTPUT 9 O
10 OUTPUT 10 O
11 OUTPUT 11 O
12 OUTPUT 12 O
13 OUTPUT 13 O
14 OUTPUT 14 O
15 OUTPUT 15 O
16 OUTPUT 16 O
17 +24 V DC (OUTPUTS 1-4) VI

Continued ...

D.4 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.454 with 16 1A outputs

Continued...

Pins Name Type

18 +24 V DC (OUTPUTS 5-8) VI
19 FIELD GND (GROUND) REF
20 +24 V DC (OUTPUTS 9-12) VI
21 +24 V DC (OUTPUTS 13-16) VI
22 FIELD GND (GROUND) REF

Name of signal:
OUTPUT 1-16 output signal
+24V DC output common contact (+24 V DC power supply)
FIELD GND output power supply reference

Type of signal:
VI input voltage
REF reference
O output signal

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Installation of board BRD.007.454 with 16 1A outputs HW

2D.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure D.3 - Grounding

+24V DC solenoid
valve

Figure D.4 - +24V DC solenoid valve

D.6 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.454 with 16 1A outputs

+24V DC relay

Figure D.5 - +24V DC relay

External PLC

Figure D.6 - External PLC

Note The protection device indicated with an asterisk * is not always necessary when it
comes to dissipating the demagnetization energy of an inductive load. However, it is
necessary if one considers the electromagnetic compatibility aspects. The protective
device notably reduces the interference issued by the load during its commutations.

Esa/Gv 00009.HW.0.GB D.7

Installation of board BRD.007.454 with 16 1A outputs HW

2D.D Technical notes about the connections

If pins 19 and 22 (FIELD GND) of the output connector are disconnected, all the
outputs are deactivated (OFF).

General information The output MOS device is equipped with a clamp circuit to dissipate the
demagnetization energy produced by an inductive load. The maximum value of the
energy that can be dissipated is 60 mJ. An external protection device must be installed
if the energy produced is higher.
Use the following formula to calculate the demagnetization energy:

E = 0.5 x L x Io²

where L is the value in H of the inductive load and Io the current absorbed by the load.

The external devices used can be TRANSIL P6KE36P and 1.5KE36P one-way types,
P6KE36CP and 1.5KE36CP two-way types or similar. Normal 1N4004/1N4007 diodes
can be used but they are much slower than the TRANSIL devices. This can lead to the
device becoming more greatly heated with subsequent activation of the
overtemperature protection.

The demagnetization power must also be considered. If this is more than 1.5 W, it will
lead to the device becoming heated and, thus, activation of the protection against
overtemperatures.
Use the following formula to calculate the demagnetization power:

Pd = 0.5 x L x Io² x 2.14 x f

where L is the value in H of the inductive load, Io the current absorbed and f the
commutation frequency of the load.
An external protection device must be installed if a higher demagnetization power is
developed.

Protection fuse Since the device is protected against short-circuits, there is no need to install a fuse in
series with each output. If a fuse is installed, its value must equal the maximum current
that the output can deliver. A fuse cannot be installed in series with the power supply
since the activation current must be 4 times more than that of each individual output.
In this case, activation of the device's protection against short-circuits will ensure that
the fuse never burns out.

Cable section The section of the connection cables is bound to both the value of the output current
(1A) and mechanical traction due to the weight of the cables connected to the terminal
strip. A 1 mm² section will not cause particular mechanical or electrical problems.
Larger sections could make the cables difficult to fix. The maximum section tolerated
by the terminal strips is 2.5 mm².

END OF CHAPTER

D.8 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.007.458 with 16 inputs

2E Installation of board BRD.007.458 with 16 inputs

2E.A Electrical specifications

Specification Value
Number of inputs 16
Typical input voltage rating +24 V DC
Maximum input voltage rating +30 V DC
Minimum input voltage rating +10 V DC
Typical input current 10.6 mA
Maximum input current 15.2 mA
Minimum input current 2 mA
Hardware filter 10 ms
Maximum commutation frequency 46 Hz
Delay on energizing 4.4 ms
Delay on de-energizing 4.3 ms
Protection against polarity reversal YES
Protection against overvoltages NO
Inputs decoupled in relation to I/O BUS YES
Insulation voltage 500 V
Operating temperature 5-55°C

The input voltage can come from a power supplier obtained from a threephase
transformer with diodes and condenser. The peak value at peak residue alternate
voltage (ripple) must comply with the minimum and maximum values given in the
table.

2E.A.A Overall dimensions and weights

Specification Value
Length 85 mm
Width 100 mm
Height 65 mm
Weight 150 g

Esa/Gv 00009.HW.0.GB E.1

Installation of board BRD.007.458 with 16 inputs HW

2E.B Location of the components

Figure E.1 - Location of the components

1. J1: I/O BUS signal interface (input)

2. J2: I/O BUS signal interface (output)
3. Leds 0-7: signalling leds for inputs 1 - 8
4. Leds 8 -15: signalling leds for inputs 9 - 16
5. J4: connector for inputs 9-16
6. J3: connector for inputs 1-8

Input connector Name of connector: J3 and J4

Type of connector: Phoenix MSTBV terminal strip, 2 x 10 poles pitch 5.08 mm.

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HW Installation of board BRD.007.458 with 16 inputs

Figure E.2 - External signal connector

Pins Name Type

1 INPUT 1 I
2 INPUT 2 I
3 INPUT 3 I
4 INPUT 4 I
5 INPUT 5 I
6 INPUT 6 I
7 INPUT 7 I
8 INPUT 8 I
9 INPUT 9 I
10 INPUT 10 I
11 INPUT 11 I
12 INPUT 12 I
13 INPUT 13 I
14 INPUT 14 I
15 INPUT 15 I
16 INPUT 16 I
17 FIELD GND (GROUND) REF
18 FIELD GND (GROUND) REF
19 FIELD GND (GROUND) REF
20 FIELD GND (GROUND) REF

Name of signal:
INPUT 1-16 input signal
FIELD GND input reference

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Installation of board BRD.007.458 with 16 inputs HW

Type of signal:
REF reference
I input signal

2E.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure E.3 - Grounding

Limit switch or relay

contact

Figure E.4 - Limit switch or relay contact

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HW Installation of board BRD.007.458 with 16 inputs

Open collector
sensor

Figure E.5 - Open collector sensor

Push-pull sensor

Figure E.6 - Push-pull sensor

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Installation of board BRD.007.458 with 16 inputs HW

Parallel inputs

Figure E.7 - Parallel inputs

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HW Installation of board BRD.007.458 with 16 inputs

2E.D Technical notes about the connections

General information The contact of a limit switch or relay connected to the input terminal strip of the board
must be absolutely without further connections to voltages pertaining to the auxiliary
circuit of the machine.
Do not use a limit switch with double contact if one of the two is connected to the
auxiliary 110V AC voltage or higher. The presence of moisture could lead to a
discharge between the two sections.
Failure to comply with these instructions could damage the input circuit of the board.

Parallel inputs If the same contact must be used with another similar input (e.g. an external PLC or
another input of the control unit), install a decoupling diode in series as indicated in
the “Connection examples” section.

Characteristics of the When choosing the characteristics of the contact of the relay or limit switch for
contact example, take care to check the minimum commutable voltage and current values: the
commutation voltage is 24V DC while the current is about 10 mA.

Cable section The section of the connection cables is not bound to the value of the input signal which
is minimum, but to the mechanical traction due to the weight of the cables connected to
the terminal strip. A 1 mm² section will not cause particular problems. Larger sections
could make the cables difficult to fix. The maximum section tolerated by the terminal
strips is 2.5 mm².

END OF CHAPTER

Esa/Gv 00009.HW.0.GB E.7

Installation of board BRD.007.458 with 16 inputs HW

E.8 00009.HW.0.GB Esa/Gv

HW Installation of the BRD.014.014 Board with drive for proportional valves

2F Installation of the BRD.014.014 Board with drive

for proportional valves

2F.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current (valves excluded) 200 mA
Maximum power used 5W
Protection against polarity reversal NO
Protection against overvoltages Yes with MOV
27V
Protection against alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB F.1

Installation of the BRD.014.014 Board with drive for proportional valves HW

2F.A.A Output for proportional valve

Specification Value
Number of outputs 2
Operating voltage rating 24 V
Minimum output current 0 mA
Typical output current 700 mA
Maximum output current 2A

2F.A.B Analog output

Specification Value
Number of outputs 2
Output voltage range 0 -10 V
Maximum output current 10 mA
Output impedance within signal range <100 Ω
Output ripple 78 mV
Digital resolution 8 bit
Value of least significant bit 39 mV

2F.A.C Overall dimensions and weight

Specification Value
Length 110 mm
Width 100 mm
Height 65 mm
Weight 300 g

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HW Installation of the BRD.014.014 Board with drive for proportional valves

2F.B Location of components

Figure F.1 - Location of components

1. J1: I/O BUS signal interface (input)

2. -5V led
3. +15V led
4. CH1 OK led: output status LED for proportional valve 1
5. CH2 OK led: output status LED for proportional valve 2
6. GAIN ADJ CH2: output 2 current regulating trimmer
7. GAIN ADJ CH1: output 1 current regulating trimmer
8. J3: connector for proportional valves and board power supply
9. FT1: terminal for ground connection

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Installation of the BRD.014.014 Board with drive for proportional valves HW

10. J2: analog output connector

Analog output Name of connector: J2

terminal strip
Type of connector: WAGO terminal strip series 236, 4 poles pitch 5 mm with spring
fastening.

Figure F.2 - Analog output terminal strip

Pins Name Type

1 OUTPUT 1 O
2 GND REF
3 OUTPUT 2 O
4 GND REF

Name of signal:
OUTPUTS 1 analog output
and 2
GND analog output reference

Type of signal:
O output signal
REF reference

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HW Installation of the BRD.014.014 Board with drive for proportional valves

Proportional valve Name of connector: J3

terminal strip
Type of connector: WAGO terminal strip series 236, 8 poles pitch 5 mm with spring
fastening.

Figure F.3 - Proportional valve terminal strip

Pins Name Type

1 +24V DC VI
2 +24V DC VI
3 GND REF
4 GND REF
5 +CH1 IO
6 -CH1 II
7 +CH2 II
8 -CH2 IO

Name of signal:
+24V DC positive power supply voltage
GND negative power supply voltage
+CH1 current output for proportional valve
-CH1 current return
+CH2 current output for proportional valve
-CH2 current return

Type of signal:
VI input voltage
REF reference
IO output current
II input current

Esa/Gv 00009.HW.0.GB F.5

Installation of the BRD.014.014 Board with drive for proportional valves HW

2F.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure F.4 - Grounding

Proportional valve

Figure F.5 - Proportional valve connection

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HW Installation of the BRD.014.014 Board with drive for proportional valves

2F.D Technical notes about the connections

Cable section The section of the connection cables is bound to both the value of the output current
(2A) and mechanical traction due to the weight of the cables connected to the terminal
strip. A 1 mm² section will not cause particular mechanical or electrical problems.
Larger sections could make the cables difficult to fix. The maximum section tolerated
by the terminal strips is 2.5 mm².

END OF CHAPTER

Esa/Gv 00009.HW.0.GB F.7

Installation of the BRD.014.014 Board with drive for proportional valves HW

F.8 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.018.401 with 8 analog inputs

2G Installation of board BRD.018.401 with 8 analog

inputs

2G.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current 240 mA
Maximum power used 6W
Protection against polarity reversal YES
Protection against overvoltages YES, max. 36V
Protection against an alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB G.1

Installation of board BRD.018.401 with 8 analog inputs HW

2G.A.A Analog inputs

Specification Value
Number of inputs 8
Resolution 12 bits
Maximum calibrating frequency 40 KHz
Maximum calibrating frequency of each individual channel 5 KHz
Sensor power supply voltage rating 10 V @ 40 mA
Optoinsulated inputs YES
Single ended input with 0 - 5 V voltage YES
Single ended input with 0 - 10 V voltage YES
Single ended bipolar input with ±10 V voltage YES
Input with 0 - 20 mA current YES
Input with 4 - 20 mA YES

2G.A.B Overall dimensions and weight

Specification Value
Length 140 mm
Width 100 mm
Height 65 mm
Weight 200 g

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HW Installation of board BRD.018.401 with 8 analog inputs

2G.B Location of the components

Figure G.1 - Location of the components

1. J1: I/O BUS signal interface (input)

2. -15V led
3. +15V led
4. +5V led
5. Jumpers FS ADC: converter full scale selection
6. J2: I/O BUS signal interface (output)
7. JP11: selection of input 8 in current
8. J11: connector for analog input 8
9. JP10: selection of input 7 in current
10. J10: connector for analog input 7
11. JP9: selection of input 6 in current

Esa/Gv 00009.HW.0.GB G.3

Installation of board BRD.018.401 with 8 analog inputs HW

12. J9: connector for analog input 6

13. JP21: selection of input 5 in current
14. J8: connector for analog input 5
15. JP20: selection of input 4 in current
16. J7: connector for analog input 4
17. JP19: selection of input 3 in current
18. J6: connector for analog input 3
19. JP18: selection of input 2 in current
20. J5: connector for analog input 2
21. JP17: selection of input 1 in current
22. J4: connector for analog input 1
23. J3: power supply terminal strip

Power supply Name of connector: J3

terminal strip
Type of connector: Phoenix MSTBV 2,5/3-GF-5.08 terminal strip, 3 poles pitch 5.08
mm.

Figure G.2 - Power supply terminal strip

Pins Name Type

1 0V VI
2 FIELD GND (GROUND) REF
3 +24 V DC VI

Name of signal:
FIELD GND ground reference
+24V DC positive power supply voltage
0V negative power supply voltage

Type of signal:
VI input voltage

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HW Installation of board BRD.018.401 with 8 analog inputs

Analog input terminal Name of connector: J4-J11

strip
Type of connector: Phoenix MCV 1,5/4-GF-3.81 terminal strip, 4 poles pitch 3.81
mm.

Figure G.3 - Power supply terminal strip

Pins Name Type

1 +10 V VO
2 INPUT I
3 0V VO
4 FIELD GND (GROUND) REF

Name of signal:
FIELD GND ground reference
+10 V power supply voltage rating of external sensor
0V analog input reference
INPUT analog input

Type of signal:
VO output voltage
REF reference
I input signal

Selection of input 1 in Use of this jumper customizes input 1 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP17

Input 1 in current DISABLED ENABLED

(default)

Esa/Gv 00009.HW.0.GB G.5

Installation of board BRD.018.401 with 8 analog inputs HW

Selection of input 2 in Use of this jumper customizes input 2 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP18

Input 2 in current DISABLED ENABLED

(default)

Selection of input 3 in Use of this jumper customizes input 3 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP19

Input 3 in current DISABLED ENABLED

(default)

Selection of input 4 in Use of this jumper customizes input 4 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP20

Input 4 in current DISABLED ENABLED

(default)

Selection of input 5 in Use of this jumper customizes input 5 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP21

Input 5 in current DISABLED ENABLED

(default)

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HW Installation of board BRD.018.401 with 8 analog inputs

Selection of input 6 in Use of this jumper customizes input 6 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP9

Input 6 in current DISABLED ENABLED

(default)

Selection of input 7 in Use of this jumper customizes input 7 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP10

Input 7 in current DISABLED ENABLED

(default)

Selection of input 8 in Use of this jumper customizes input 8 in current. The full scale of ADC must be
current customized at +5V to handle inputs in current.

JP11

Input 8 in current DISABLED ENABLED

(default)

Selection of ADC full Use of these jumpers allows the ADC (analog digital converter) full scale to be selected
scale from amongst the values given below.

JP12 - JP16

ADC full scale Unipolar Unipolar Bipolar

+10V (default) +5V +/- 10V

Esa/Gv 00009.HW.0.GB G.7

Installation of board BRD.018.401 with 8 analog inputs HW

2G.C Connection examples

Potentiometer

Figure G.4 - Potentiometer

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HW Installation of board BRD.018.401 with 8 analog inputs

2G.D Technical notes about the connections

ù A potentiometer must be connected with a screened cable. The screen must only be
connected on the CNC side.
ù If the cable must be sectioned with a removable connector, the input wire must
never be fixed in the same connector as the power cables. The braid is interrupted
in the section where the contacts pass and is therefore unable to act as a screen,
thus allowing spurious signals to enter.
ù If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

END OF CHAPTER

Esa/Gv 00009.HW.0.GB G.9

Installation of board BRD.018.401 with 8 analog inputs HW

G.10 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.018.402 with 8 analog outputs

2H Installation of board BRD.018.402 with 8 analog

outputs

2H.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current 270 mA
Maximum power used 6W
Protection against polarity reversal YES
Protection against overvoltages YES, max. 36V
Protection against an alternate voltage NO
Operating temperature 5÷55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB H.1

Installation of board BRD.018.402 with 8 analog outputs HW

2H.A.A Analog outputs

Specification Value
Number of outputs 8
Output voltage range -10 -10 V
Maximum output current 10 mA
Output impedance within signal range 68 Ω
Output ripple 610 µV
Analog output error
ù Maximum error at 25°C ±0.03% F.S.
ù Temperature coefficient ±0.001% F.S.
Maximum error throughout entire temperature range ±0.1% F.S.
Digital resolution 16 bits
Value of least significant bit 305 µV

2H.A.B Overall dimensions and weight

Specification Value
Length 110 mm
Width 100 mm
Height 65 mm
Weight 200 g

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HW Installation of board BRD.018.402 with 8 analog outputs

2H.B Location of components

Figure H.1 - Location of components

1. J1: I/O BUS signal interface (input)

2. +15V led
3. -15V led
4. +5V led
5. J2: I/O BUS signal interface (output)
6. J5: connector for analog outputs 5-8
7. J4: connector for analog outputs 1-4
8. J3: power supply terminal strip

Esa/Gv 00009.HW.0.GB H.3

Installation of board BRD.018.402 with 8 analog outputs HW

Power supply Name of connector: J3

terminal strip
Type of connector: Phoenix MSTBV 2,5/3-GF-5.08 terminal strip, 3 poles pitch 5.08
mm.

Figure H.2 - Power supply terminal strip

Pins Name Type

1 0V VI
2 FIELD GND (GROUND) REF
3 +24 V DC VI

Name of signal:
FIELD GND ground reference
+24V DC positive power supply voltage
0V negative power supply voltage

Type of signal:
VI input voltage
REF reference

Connector for analog Name of connector: J4

outputs 1-4
Type of connector: D-sub 15 poles female

Figure H.3 - Analog output connector

H.4 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.018.402 with 8 analog outputs

Pins Name Type

1 OUTPUT 1 O
2 NC
3 OUTPUT 2 O
4 NC
5 NC
6 OUTPUT 3 O
7 NC
8 OUTPUT 4 O
9 GND REF
10 NC
11 GND REF
12 NC
13 GND REF
14 NC
15 GND REF
CAP SCREEN SCH

Name of signal:
OUTPUTS 1 - 4 analog output
GND analog output reference
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

Type of signal:
O output signal
REF reference
SCH screen
NC not connected

Esa/Gv 00009.HW.0.GB H.5

Installation of board BRD.018.402 with 8 analog outputs HW

Connector for analog Name of connector: J5

outputs 5-8
Type of connector: D-sub 15 poles female

Figure H.4 - Analog output connector

Pins Name Type

1 OUTPUT 5 O
2 NC
3 OUTPUT 6 O
4 NC
5 NC
6 OUTPUT 7 O
7 NC
8 OUTPUT 8 O
9 GND REF
10 NC
11 GND REF
12 NC
13 GND REF
14 NC
15 GND REF
CAP SCREEN SCH

Name of signal:
OUTPUTS 5 - 8 analog output
GND analog output reference
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

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HW Installation of board BRD.018.402 with 8 analog outputs

Type of signal:
O output signal
REF reference
SCH screen
NC not connected

2H.C Connection examples

Grounding For better immunity against interference, make the ground connection with the shortest
cable possible, as indicated in the figure.

Figure H.5 - Grounding

Esa/Gv 00009.HW.0.GB H.7

Installation of board BRD.018.402 with 8 analog outputs HW

Analog outputs

Figure H.6 - Connection of analog ⇔ drive outputs

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HW Installation of board BRD.018.402 with 8 analog outputs

Screen

Press the screen between

the core hitch and the two
metallized caps

Figure H.7 - Screen connection

Esa/Gv 00009.HW.0.GB H.9

Installation of board BRD.018.402 with 8 analog outputs HW

2H.D Technical notes about the connections

• It is absolutely essential for the connection to be made with a screened cable and
with the screen connected from the CNC side. In general, it is also advisable to
connect it from the drive side even though the situation worsens owing to the
differences in the potential amongst the various ground connections. Contact the
Esa/GV Service if you have doubts about how to make the connections.
• If the cable must be sectioned with a removable connector, the input wire must
never be fixed in the same connector as the power cables. The braid is interrupted
in the section where the contacts pass and is therefore unable to act as a screen,
thus allowing spurious signals to enter.
• If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

Characteristics of the Use the connector and cap supplied with the board. If other connectors are used, make
connector sure that they have the following characteristics:
ù contact resistance = 10 mÙ
ù insulation resistance = 5000 MÙ
ù operating temperature -55 to 125°C
ù gilded contact
ù performance level 2 guaranteed for at least 200 activations/deactivations according
to standard DIN41652 part 2.

The cap must be conductive for EMI/EMC requirements. It can be made of metal or
conductive plastic.

END OF CHAPTER

H.10 00009.HW.0.GB Esa/Gv

HW Installation of the BRD.019.025 reception node board

2I Installation of the BRD.019.025 reception node

board

2I.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current 180 mA
Maximum power used 5W
Power supply decoupled in relation to the I/O BUS YES
Insulation voltage 500 V DC
Protection against polarity reversal YES
Protection against overvoltages YES with
varistor
Protection against an alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

2I.A.A Overall dimensions and weight

Specification Value
Length 110 mm
Width 100 mm
Height 65 mm
Weight 200 g

Esa/Gv 00009.HW.0.GB I.1

Installation of the BRD.019.025 reception node board HW

2I.B Location of the components

Figure I.1 - Location of the components

1. J2: I/O BUS signal connector

2. TX: Optic fiber transmitter
3. RX: Optic fiber receiver
4. LINK led
5. SW1: node address dip switch
6. POWER OK led
7. J1: power supply terminal strip

I.2 00009.HW.0.GB Esa/Gv

HW Installation of the BRD.019.025 reception node board

Power supply Name of connector: J1

terminal strip
Type of connector: WAGO terminal strip series 236 3 poles pitch 5 mm with spring
fastening.

Figure I.2 - Power supply terminal strip

Pins Name Type

1 FIELD GND (GROUND) VI
2
3 +24 V DC VI

Name of signal:
FIELD GND power supply voltage reference
+24V DC power supply voltage rating

Type of signal:
VI input voltage

2I.B.A Selection of the node address

The board has a 16-position rotary dip switch (SW1) to determine the address of the
receiver node.

If several receiver nodes are used, two or more modules cannot have the same address
(same rotary dip switch position). If this happens, the system will be unable to operate
correctly.

Use a small screwdriver to change the position of the dip switch. The standard position
is 0 (zero).

Esa/Gv 00009.HW.0.GB I.3

Installation of the BRD.019.025 reception node board HW

2I.C Connection examples

Power supply and For better immunity against interference, connect the power supply negative to ground
grounding with the shortest cable possible.

Figure I.3 - Power supply and grounding

Connection of I/O
boards on I/O BUS

Reception node Input module Output module Resistive

BRD.019.025 BRD.007.448 BRD.007.444 termination
BRD.012.053

Figure I.4 - Connection of I/O Boards on I/O BUS

I.4 00009.HW.0.GB Esa/Gv

HW Installation of the BRD.019.025 reception node board

Optic fiber
connection

Receiver node
Transmitter node
BRD.019.025

Figure I.5 - Optic fiber connection

Esa/Gv 00009.HW.0.GB I.5

Installation of the BRD.019.025 reception node board HW

Connection of optic
fiber with several
reception nodes

Receiver node 0
Transmitter mode
BRD.019.025

Receiver node n
BRD.019.025

Figure I.6 - Connection of optic fiber with several reception nodes

I.6 00009.HW.0.GB Esa/Gv

HW Installation of the BRD.019.025 reception node board

2I.D Technical notes about the connections

I/O board connection To connect the I/O boards to the reception node, insert the loose female flat connector
of the I/O board into the relative male connector of the reception board, taking care to
prevent the relative pins from being damaged. This operation should also be carried out
in order to connect the I/O boards together. Near the boards to each other once the
connections have been made.

Do not connect the I/O boards to the I/O BUS with the board powered. This could
cause both the I/O module and reception node to break

Optic fiber Proceed in the following way to correctly connect the optic fiber to the TX transmitter
connection and RX receiver modules:
ù cut the ends using a cutter or knife;
ù insert the optic fiber into the modules as far as it will go;
ù to remove the optic fiber, push the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure I.7 - Example of optic fiber removal

Esa/Gv 00009.HW.0.GB I.7

Installation of the BRD.019.025 reception node board HW

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring as they could break and remain inside the module

Proceed in the following way to use the optic fiber correctly:

ù prevent dirt or dust from entering the TX and RX modules;
ù do not use acids or alkaline solvents on the modules and do not inject these
substances into the optic fiber hole. Use a cotton swab should this occur;
ù do not bend or stretch the optic fiber beyond the value given in the specifications
as it could break.

Take great care when routing the optic fiber to prevent it from breaking. There are no
particular interference problems in view of the optic nature of the signal that travels
along the fiber.

Powering cable The section of the powering cables is not bound to the value of the input current which
sections is minimum, but to the mechanical traction due to the weight of the cables connected to
the terminal strip. A 1 mm² section will not cause particular problems. Larger sections
could make the cables difficult to fix. The maximum section tolerated by the terminal
strips is 2.5 mm².

END OF CHAPTER

I.8 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

2L Installation of board BRD.021.405 with node +

two 5V axes

2L.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current (encoders excluded) 300 mA
Maximum power used 7W
Protection against polarity reversal YES
Protection against overvoltages YES, max. 36V
Protection against an alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB L.1

Installation of board BRD.021.405 with node + two 5V axes HW

2L.A.A Inputs via encoder

Specification Value
Number of inputs 2
Type of encoder NPN open collector,
Push-Pull,
Line Driver
Encoder power supply voltage rating +5V
Maximum encoder power supply current 600 mA
Maximum input voltage rating +7V DC
Typical input current 2.3 mA
Input impedance 2.2 KΩ
Hardware filter 470 ns
Maximum commutation frequency 200 KHz
Minimum width of zero mark signal 50 µs
Protection against polarity reversal NO
Protection against overvoltages NO
Differential inputs NO
Encoder error input NO
Encoder presence circuit NO
Type of cable to use for encoder connection Screened with 0.22mm
² section
Maximum cable length at maximum frequency 25 m

L.2 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

2L.A.B Analog outputs

Specification Value
Number of outputs 2
Output voltage range -10 to 10 V
Maximum output current 5 mA
Output impedance within signal range 68 Ω
Output ripple 9.6 mV
Analog output error
• Maximum error at 25°C ±0.03% F.S.
• Temperature coefficient ±0.001% F.S.
Maximum error throughout entire temperature range ±0.1% F.S.
Digital resolution 12 bits
Value of least significant bit 4.8 mV

2L.A.C Overall dimensions and weight

Specification Value
Length 140 mm
Width 100 mm
Height 65 mm
Weight 300 g

Esa/Gv 00009.HW.0.GB L.3

Installation of board BRD.021.405 with node + two 5V axes HW

2L.B Location of the components

Figure L.1 - Location of the components

1. +5V led
2. +Venc led
3. +15V led
4. -15V led
5. POWER OK led
6. RX: Optic fiber receiver
7. TX: Optic fiber transmitter

L.4 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

8. LINK led
9. SW1: node address dip switch
10. J4: analog output connector
11. J3: encoder 2 input connector
12. J2: encoder 1 input connector
13. J1: power supply terminal strip

Power supply Name of connector: J1

terminal strip
Type of connector: Phoenix MSTBV 2,5/3-GF-5.08 terminal strip, 3 poles pitch 5.08
mm.

Figure L.2 - Power supply terminal strip

Pins Name Type

1 0V VI
2 FIELD GND (GROUND) REF
3 +24 V DC VI

Name of signal:
FIELD GND ground reference
+24V DC positive power supply voltage
0V negative power supply voltage

Type of signal:
VI input voltage
REF reference

Encoder input Name of connector: J2 and J3.

connector
Type of connector: D-sub 9 poles female.

Esa/Gv 00009.HW.0.GB L.5

Installation of board BRD.021.405 with node + two 5V axes HW

Figure L.3 - Encoder input connector

Pins Name Type

1
2 +VE VO
3 GND VO
4
5 PHASE A I
6
7
8 0 MARK I
9 PHASE B I
CAP SCREEN SCH

Name of signal:
+VE positive encoder power supply
GND negative encoder power supply
PHASE A PHASE A of the encoder
PHASE B PHASE B of the encoder
0 MARK 0 MARK of the encoder
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

Type of signal:
VO output voltage
I input signal
SCH screen

Analog output Name of connector: J4.

connector
Type of connector: D-sub 15 poles female.

L.6 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

Figure L.4 - Analog output connector

Pins Name Type

1 OUTPUT 1 O
2 NC
3 OUTPUT 2 O
4 NC
5 NC
6 NC
7 NC
8 NC
9 GND REF
10 NC
11 GND REF
12 NC
13 NC
14 NC
15 NC
CAP SCREEN SCH

Name of signal:
OUTPUTS 1 analog output
and 2
GND analog output reference
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

Type of signal:
O output signal
REF reference
SCH screen
NC not connected

Esa/Gv 00009.HW.0.GB L.7

Installation of board BRD.021.405 with node + two 5V axes HW

2L.B.A Selection of the node address

The board has a 16-position rotary dip switch (SW1) to determine the address of the
receiver node.

If several receiver nodes are used, two or more modules cannot have the same address
(rotary dip switch in the same position). The system cannot operate correctly.

Use a small screwdriver to change the position of the dip switches. The standard
position is 0 (zero).

2L.C Connection examples

Encoder

Figure L.5 - Encoder connection

L.8 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

Analog outputs

Figure L.6 - Connection of the analog ⇔ drive outputs

Esa/Gv 00009.HW.0.GB L.9

Installation of board BRD.021.405 with node + two 5V axes HW

Screen

Press the screen between

the core hitch and the two
metallized caps

Figure L.7 - Screen connection

L.10 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

2L.D Technical notes about the connections

2L.D.A Node

Optic fiber Proceed in the following way to correctly connect the optic fiber to the TX transmitter
connection and RX receiver modules:
ù cut the ends using a cutter or knife;
ù insert the optic fiber into the modules as far as it will go;
ù to remove the optic fiber, push the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure L.8 - Example of optic fiber removal

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring as they could break and remain inside the module

Proceed in the following way to use the optic fiber correctly:

ù prevent dirt or dust from entering the TX and RX modules;
ù do not use acids or alkaline solvents on the modules and do not inject these
substances into the optic fiber hole. Use a cotton swab should this occur;
ù do not bend or stretch the optic fiber beyond the value given in the specifications
as it could break.

Take great care when routing the optic fiber to prevent it from breaking. There are no
particular interference problems in view of the optic nature of the signal that travels
along the fiber.

Esa/Gv 00009.HW.0.GB L.11

Installation of board BRD.021.405 with node + two 5V axes HW

Powering cable A 1 mm² section will not cause particular problems. Larger sections could make the
sections cables difficult to fix. The maximum section tolerated by the terminal strips is 2.5 mm
².

2L.D.B Inputs via encoder

ù The encoder connection cable must necessarily be the screened type. The screen
must only be connected from the CNC side and not from the encoder side, so long
as this is fixed to a grounded metal support. If the encoder is insulated from the
ground, the screen must also be connected to the encoder.
ù If the cable must be sectioned with a removable connector, never fix the encoder
cable together with the power cables in the same connector. The braid is
interrupted in the section where the contacts pass and is therefore unable to act as a
screen, thus allowing spurious signals to enter.
ù If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

Characteristics of the Use the connector and cap supplied with the board. If other connectors are used, make
connector sure that they have the following characteristics:
ù contact resistance = 10 mÙ
ù insulation resistance = 5000 MÙ
ù operating temperature -55 to 125°C
ù gilded contact
ù performance level 2 guaranteed for at least 200 activations/deactivations according
to standard DIN41652 part 2.
The cap must be conductive for EMI/EMC requirements. It can be made of metal or
conductive plastic.

Cable sections The section of the cables must not be less than 0.2 mm² and should be chosen by
considering the distance and power draw of the encoder (a cable with 0.22 mm²
section conductors is normally used).

L.12 00009.HW.0.GB Esa/Gv

HW Installation of board BRD.021.405 with node + two 5V axes

2L.D.C Analog outputs

ù It is absolutely essential for the connection to be made with a screened cable and
with the screen connected from the CNC side. In general, it is also advisable to
connect it from the drive side even though the situation worsens owing to the
differences in the potential amongst the various ground connections. Contact the
Esa/GV Service if you have doubts about how to make the connections.
ù If the cable must be sectioned with a removable connector, the input wire must
never be fixed in the same connector as the power cables. The braid is interrupted
in the section where the contacts pass and is therefore unable to act as a screen,
thus allowing spurious signals to enter.
ù If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

Characteristics of the Use the connector and cap supplied with the board. If other connectors are used, make
connector sure that they have the following characteristics:
ù contact resistance = 10 mÙ
ù insulation resistance = 5000 MÙ
ù operating temperature -55 to 125°C
ù gilded contact
ù performance level 2 guaranteed for at least 200 activations/deactivations according
to standard DIN41652 part 2.
The cap must be conductive for EMI/EMC requirements. It can be made of metal or
conductive plastic.

END OF CHAPTER

Esa/Gv 00009.HW.0.GB L.13

Installation of board BRD.021.405 with node + two 5V axes HW

L.14 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

2M Installation of BRD.021.412 Board with node +

two 12V axes

2M.A Electrical specifications

Specification Value
Typical power supply voltage rating +24 V DC
Maximum power supply voltage rating +28.8 V DC
Minimum power supply voltage rating +20.4 V DC
Maximum powering current (encoders excluded) 300 mA
Maximum power used 7W
Protection against polarity reversal YES
Protection against overvoltages YES, max. 36V
Protection against an alternate voltage NO
Operating temperature 5-55°C

The power supply voltage of the board can be obtained from a threephase transformer
with diodes and condenser. The peak value at peak residue alternate voltage (ripple)
must comply with the minimum and maximum values given in the table.

It is advisable to use a stabilized power supplier as the board will signal error if the
voltage drops below the minimum value.

The +24V DC voltage that powers the system must be brought to FIELD GND
(GROUND) and must not be generated by means of an autotransformer in order
to guarantee secure insulation.

Esa/Gv 00009.HW.0.GB M.1

Installation of BRD.021.412 Board with node + two 12V axes HW

2M.A.A Inputs via encoder

Specification Value
Number of inputs 2
Type of encoder NPN open collector
Push-Pull
Encoder power supply voltage +12V
Maximum encoder power supply current 600 mA
Maximum input voltage rating +14V DC
Typical input current 2.3 mA
Input impedance 2.2 KΩ
Hardware filter 470 ns
Maximum commutation frequency 200 KHz
Minimum width of zero mark signal 50 µs
Protection against polarity reversal NO
Protection against overvoltages NO
Differential inputs NO
Encoder error input NO
Encoder presence circuit NO
Type of cable to use for encoder connection Screened with 0.22mm
² section
Maximum cable length at maximum frequency 25 m

2M.A.B Analog outputs

Specification Value
Number of outputs 2
Output voltage range -10 to 10 V
Maximum output current 5 mA
Output impedance within signal range 68 Ω
Output ripple 9.6 mV
Analog output error
• Maximum error at 25°C ±0.03% F.S.
• Temperature coefficient ±0.001% F.S.
Maximum error throughout entire temperature range ±0.1% F.S.
Digital resolution 12 bits
Value of least significant bit 4.8 mV

M.2 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

2M.A.C Overall dimensions and weights

Specification Value
Length 140 mm
Width 100 mm
Height 65 mm
Weight 300 g

2M.B Location of components

Figure M.1 - Location of components

Esa/Gv 00009.HW.0.GB M.3

Installation of BRD.021.412 Board with node + two 12V axes HW

1. +5V led
2. +Venc led
3. +15V led
4. -15V led
5. POWER OK led
6. RX: Optic fiber receiver
7. TX: Optic fiber transmitter
8. LINK led
9. SW1: node address dip switch
10. J4: analog output connector
11. J3: encoder 2 input connector
12. J2: encoder 1 input connector
13. J1: power supply terminal strip

Power supply Name of connector: J1

terminal strip
Type of connector: Phoenix MSTBV 2,5/3-GF-5.08 terminal strip, 3 poles pitch 5.08
mm.

Figure M.2 - Power supply terminal strip

Pins Name Type

1 0V VI
2 FIELD GND (GROUND) REF
3 +24 V DC VI

Name of signal:
FIELD GND ground reference
+24V DC positive power supply voltage
0V negative power supply voltage

Type of signal:
VI input voltage
REF reference

M.4 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

Encoder input Name of connector: J2 and J3

connector
Type of connector: D-sub 9 poles female

Figure M.3 - Encoder input connector

Pins Name Type

1
2 +VE VO
3 GND VO
4
5 PHASE A I
6
7
8 0 MARK I
9 PHASE B I
CAP SCREEN SCH

Name of signal:
+VE positive encoder power supply
GND negative encoder power supply
PHASE A PHASE A of the encoder
PHASE B PHASE B of the encoder
0 MARK 0 MARK of the encoder
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

Type of signal:
VO output voltage
I input signal
SCH screen

Esa/Gv 00009.HW.0.GB M.5

Installation of BRD.021.412 Board with node + two 12V axes HW

Analog output Name of connector: J4

connector
Type of connector: D-sub 15 poles female

Figure M.4 - Analog output connector

Pins Name Type

1 OUTPUT 1 O
2 NC
3 OUTPUT 2 O
4 NC
5 NC
6 NC
7 NC
8 NC
9 GND REF
10 NC
11 GND REF
12 NC
13 NC
14 NC
15 NC
CAP SCREEN SCH

Name of signal:
OUTPUTS 1 analog output
and 2
GND analog output reference
SCREEN Cable screening to squash between the two halves of the metallized
cap of the connector

M.6 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

Type of signal:
O output signal
REF reference
SCH screen
NC not connected

2M.B.A Selection of node address

The board has a 16-position rotary dip switch (SW1) to determine the address of the
receiver node.

If several receiver nodes are used, two or more modules cannot have the same address
(rotary dip switch in the same position). The system cannot operate correctly.

Use a small screwdriver to change the position of the dip switches. The standard
position is 0 (zero).

2M.C Connection examples

Encoder

Figure M.5 - Encoder connection

Esa/Gv 00009.HW.0.GB M.7

Installation of BRD.021.412 Board with node + two 12V axes HW

Analog outputs

Figure M.6 - Connection of analog ⇔ drive outputs

M.8 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

Screen

Press the screen between

the core hitch and the two
metallized caps

Figure M.7 - Screen connection

Esa/Gv 00009.HW.0.GB M.9

Installation of BRD.021.412 Board with node + two 12V axes HW

2M.D Technical notes about the connections

2M.D.A Node

Optic fiber Proceed in the following way to correctly connect the optic fiber to the TX transmitter
connection and RX receiver modules:
ù cut the ends using a cutter or knife;
ù insert the optic fiber into the modules as far as it will go;
ù to remove the optic fiber, push the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure M.8 - Example of optic fiber removal

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring as they could break and remain inside the module

Proceed in the following way to use the optic fiber correctly:

ù prevent dirt or dust from entering the TX and RX modules;
ù do not use acids or alkaline solvents on the modules and do not inject these
substances into the optic fiber hole. Use a cotton swab should this occur;
ù do not bend or stretch the optic fiber beyond the value given in the specifications
as it could break

Take great care when routing the optic fiber to prevent it from breaking. There are no
particular interference problems in view of the optic nature of the signal that travels
along the fiber.

M.10 00009.HW.0.GB Esa/Gv

HW Installation of BRD.021.412 Board with node + two 12V axes

Powering cable A 1 mm² section will not cause particular problems. Larger sections could make the
sections cables difficult to fix. The maximum section tolerated by the terminal strips is 2.5 mm
².

2M.D.B Inputs via encoder

ù The encoder connection cable must necessarily be the screened type. The screen
must only be connected from the CNC side and not from the encoder side, so long
as this is fixed to a grounded metal support. If the encoder is insulated from the
ground, the screen must also be connected to the encoder.
ù If the cable must be sectioned with a removable connector, never fix the encoder
cable together with the power cables in the same connector. The braid is
interrupted in the section where the contacts pass and is therefore unable to act as a
screen, thus allowing spurious signals to enter.
ù If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

Characteristics of the Use the connector and cap supplied with the board. If other connectors are used, make
connector sure that they have the following characteristics:
ù contact resistance = 10 mÙ
ù insulation resistance = 5000 MÙ
ù operating temperature -55 to 125°C
ù gilded contact
ù performance level 2 guaranteed for at least 200 activations/deactivations according
to standard DIN41652 part 2.
The cap must be conductive for EMI/EMC requirements. It can be made of metal or
conductive plastic.

Cable sections The section of the cables must not be less than 0.2 mm² and should be chosen by
considering the distance and power draw of the encoder (a cable with 0.22 mm²
section conductors is normally used).

Esa/Gv 00009.HW.0.GB M.11

Installation of BRD.021.412 Board with node + two 12V axes HW

2M.D.C Analog outputs

ù It is absolutely essential for the connection to be made with a screened cable and
with the screen connected from the CNC side. In general, it is also advisable to
connect it from the drive side even though the situation worsens owing to the
differences in the potential amongst the various ground connections. Contact the
Esa/GV Service if you have doubts about how to make the connections.
ù If the cable must be sectioned with a removable connector, the input wire must
never be fixed in the same connector as the power cables. The braid is interrupted
in the section where the contacts pass and is therefore unable to act as a screen,
thus allowing spurious signals to enter.
ù If the cable must be sectioned with a removable connector, connect the screen from
both sides of the connector so that it is unbroken.

Characteristics of the Use the connector and cap supplied with the board. If other connectors are used, make
connector sure that they have the following characteristics:
ù contact resistance = 10 mÙ
ù insulation resistance = 5000 MÙ
ù operating temperature -55 to 125°C
ù gilded contact
ù performance level 2 guaranteed for at least 200 activations/deactivations according
to standard DIN41652 part 2.
The cap must be conductive for EMI/EMC requirements. It can be made of metal or
conductive plastic.

END OF CHAPTER

M.12 00009.HW.0.GB Esa/Gv

HW Diagnostics

3 Diagnostics

3.1 LEDs

3.1.1 LEDs on boards BRD.007.448 and BRD.007.458

There are 16 LEDs that indicate the status of the inputs.

INPUT LEDs They can be in the following conditions.

ù LED on/off: the input is correctly stimulated by the electromechanical device to
which it is connected.
ù LED permanently on: the input is constantly stimulated. This may be caused by:
− regular operation as the device has been wired in this way;
− breakage of the electromechanical device to which the led is connected;
− short-circuit towards a +24 V DC voltage source.
ù LED permanently off: the input is not stimulated. This may be caused by:
− input not connected, either because it has been wired in this way, because it has
detached or because the connecting cable is broken;
− breakage of the electromechanical device to which the led is connected;
− short-circuit towards FIELD GND (GROUND);
− broken input module.

3.1.2 LEDs on boards BRD.007.444 and BRD.007.454

There are 16 LEDs which indicate the status of the outputs and 4 LEDs which indicate
that +24V DC power supply voltage is present for the output power devices.

POWER SUPPLY These may be in the following conditions.

LEDs
ù LED on:
− the power devices are powered.
ù LED off:
− the power device is not powered;
− the board is broken.

OUTPUT LEDs These may be in the following conditions.

ù LED on/off with load stimulated: operation is regular.
ù LED on/off with load not stimulated:
− the connection cable has detached or is broken;
− the load device is broken.

Esa/Gv 00009.HW.0.GB 3.1

Diagnostics HW

ù LED permanently on: the output is constantly stimulated. This may be caused by:
− regular operation since it has been set up in this way by the SW;
− short-circuit towards a +24 V DC voltage source;
− the board is broken.
ù LED permanently off: the output is not stimulated. This may be caused by:
− regular operation since it has been set up in this way by the SW;
− short-circuit towards FIELD GND (GROUND). The numeric control will
display the “00041 I/O Error: OUTPUT IN PROTECTION STATUS” alarm;.
− the LED has burnt out if the output correctly pilots the load;
− the board is broken.

3.1.3 LEDs on board BRD.007.450

There are 16 LEDs that indicate the status of the inputs, 16 LEDs that indicate the
status of the outputs and 2 LEDs that indicate the presence of +24V DC power for the
output power devices: POWER LED, LINK LED and +5V LED.

INPUT LEDs These may be in the following conditions.

ù LED on/off: the input is correctly stimulated by the electromechanical device to
which it is connected.
ù LED permanently on: the input is constantly stimulated. This may be caused by:
− regular operation as the device has been wired in this way;
− breakage of the electromechanical device to which the led is connected;
− short-circuit towards a +24 V DC voltage source.
ù LED permanently off: the input is not stimulated. This may be caused by:
− input not connected, either because it has been wired in this way, because it has
detached or because the connecting cable is broken;
− breakage of the electromechanical device to which the led is connected;
− short-circuit towards FIELD GND (GROUND);
− broken input module.

OUTPUT POWER These may be in the following conditions.

SUPPLY LEDs
ù LED on:
− the power devices are powered.
ù LED off:
− the power device is not powered;
− the board is broken.

3.2 00009.HW.0.GB Esa/Gv

HW Diagnostics

OUTPUT LEDs These may be in the following conditions.

ù LED on/off with load stimulated: operation is regular.
ù LED on/off with load not stimulated:
− the connection cable has detached or is broken;
− the load device is broken.
ù LED permanently on: the output is constantly stimulated. This may be caused by:
− regular operation since it has been set up in this way by the SW;
− short-circuit towards a +24 V DC voltage source;
− the board is broken.
ù LED permanently off: the output is not stimulated. This may be caused by:
− regular operation since it has been set up in this way by the SW;
− short-circuit towards FIELD GND (GROUND). The numeric control will
display the “00041 I/O Error: OUTPUT IN PROTECTION STATUS" alarm;.
− the LED has burnt out if the output correctly pilots the load;
− the board is broken.

POWER LED The following conditions may occur.

ù LED on:
− +24 V DC power is present and is within the minimum and maximum limits
indicated by the specifications.
ù LED off:
− the powering voltage is off limits. The numeric control will display the “00040
I/O Error: NODE POWER SUPPLY KO” alarm;
− there is no powering voltage. The numeric control will display the “00033 I/O
Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs, the module must be replaced.

The module has a self-resetting fuse as protection on the +24 V DC voltage source.

Esa/Gv 00009.HW.0.GB 3.3

Diagnostics HW

LINK LED The following conditions may occur, considering that the POWER LED is on.
ù LED on:
− the optic fiber serial connection with the transmitter node is present. The
module operates regularly.
ù LED off:
− operation is regular as it is not addressed by the SW;
− the optic fiber has not been cut or butted correctly. The numeric control will
display the “00032 I/O Error: CRC” or “00033 I/O Error: TIMEOUT” alarms.
Check the optic fiber;
− the optic fiber is not connected or is broken. The numeric control will display
the “00033 I/O Error: TIMEOUT” alarm. Check the optic fiber;
− the board is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs the module must be replaced;
− the multifunction board in the numeric control is broken. The numeric control
will display the “00033 I/O Error: TIMEOUT” alarm. If this occurs the
multifunction board must be replaced;
− the position of the rotary dip switch used to select the board address is
incorrect. The numeric control will display the “00034 I/O Error: NACK”
alarm;
− the type of I/O board defined does not correspond to the board actually
addressed (e.g. board 1 has been defined as input but an output one has been
mounted). The numeric control will display the “00035 I/O Error: Invalid Id”
alarm.

When off, LINK LED causes all the outputs to reset. The activation time of the output
RESET signal is 50 ms from the moment in which there is no more optic fiber serial
connection and the LINK LED goes out.

+5V LED The following conditions may occur.

ù LED on:
− the +5V DC internal power supply voltage is present.
ù LED off:
− there is no power supply voltage. The numeric control will display the “00033
I/O Error: TIMEOUT” alarm;
− the module is broken. The numeric control displays the “00033 I/O Error:
TIMEOUT” alarm. If this occurs the module must be replaced.

3.1.4 LEDs on board BRD.014.014

There are 2 LEDs which indicate that the +15V and -5V power supply voltage and the
CH1 OK and CH2 OK leds are present.

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HW Diagnostics

+15V LED The following conditions may occur.

ù LED on:
− the 24V DC power supply voltage is present.
ù LED off:
− there is no power supply voltage. The numeric control will display the “00042
I/O Error: NO 24V” alarm;
− the board is broken. If this occurs the module must be replaced.

-5V LED The following conditions may occur.

ù LED on:
− -5V DC internal voltage is present.
ù LED off:
− the board is broken. In this case, it must be replaced;
− there is no powering voltage in the node board. The numeric control will
display the “00033 I/O Error: TIMEOUT” alarm.
− one of the I/O boards connected to the node board is broken. The numeric
control will display the “00033 I/O Error: TIMEOUT” alarm. Detach one
board at a time to identify the faulty one.

CH1 OK LED The following conditions may occur.

ù LED on:
− the load is connected to output 1.
ù LED off:
− the load is not connected to output 1;
− the load device is broken;
− the board is broken. In this case it must be replaced.

CH2 OK LED The following conditions may occur.

ù LED on:
− the load is connected to output 2.
ù LED off:
− the load is not connected to output 2;
− the load device is broken;
− the board is broken. In this case it must be replaced.

Esa/Gv 00009.HW.0.GB 3.5

Diagnostics HW

3.1.5 LEDs on board BRD.018.401

There are 3 LEDs indicating that +15V, -15V and +5V power supply voltages are
present.

+15V LED The following conditions may occur.

ù LED on:
− +15V DC internal voltage is present.
ù LED off:
− the +24V powering voltage of the board is not present. The numeric control
will display the “00043 I/O Error: ADC Busy” alarm.
− the board is broken. In this case the module must be replaced.

-15V LED The following conditions may occur.

ù LED on:
− -15V DC internal voltage is present.
ù LED off:
− the +24V powering voltage of the board is not present. The numeric control
will display the “00043 I/O Error: ADC Busy” alarm.
− the board is broken. In this case the module must be replaced.

+5V LED The following conditions may occur.

ù LED on:
− +5V DC internal voltage is present.
ù LED off:
− the +24V powering voltage of the board is not present. The numeric control
will display the “00043 I/O Error: ADC Busy” alarm.
− the board is broken. In this case the module must be replaced.

3.1.6 LEDs on board BRD.018.402

There are 3 LEDs indicating that +15V, -15V and +VCC power supply voltages are
present.

+15V LED The following conditions may occur.

ù LED on:
− +15V DC internal voltage is present.
ù LED off:
− +24V board voltage is not present;
− the board is broken. In this case the module must be replaced.

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HW Diagnostics

-15V LED The following conditions may occur.

ù LED on:
− -15V DC internal voltage is present.
ù LED off:
− +24V board voltage is not present;
− the board is broken. In this case the module must be replaced.

VDC LED The following conditions may occur.

ù LED on:
− +5V DC internal voltage is present.
ù LED off:
− +24V board voltage is not present;
− the board is broken. In this case it must be replaced.

3.1.7 LEDs on board BRD.019.025

There are 2 LEDs, POWER and LINK.

POWER LED The following conditions may occur:

ù LED on:
− +24 V DC power supply voltage is present and within the minimum and
maximum limits indicated by the specifications.
ù LED off:
− the power supply voltage is off limits. The numeric control displays the “00040
I/O Error: NODE POWER SUPPLY KO” alarm;
− there is no powering voltage. The numeric control will display the “00033 I/O
Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs, the module must be replaced.

The module has a self-resetting fuse as protection on the +24 V DC voltage source.

LINK LED The following conditions may occur, considering that the POWER LED is on.
ù LED on:
− optic fiber serial connection with the transmitter node is present. The module
operates regularly.
ù LED off:
− operation is regular as it is not addressed by the SW;
− the optic fiber has not been cut or butted correctly. The numeric control will
display the “00032 I/O Error: CRC” or “00033 I/O Error: TIMEOUT” alarms.
Check the optic fiber;

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Diagnostics HW

− the optic fiber is not connected or is broken. The numeric control will display
the “00033 I/O Error: TIMEOUT” alarm. Check the optic fiber;
− the board is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs the module must be replaced;
− the multifunction board in the numeric control is broken. The numeric control
will display the “00033 I/O Error: TIMEOUT” alarm. If this occurs the
multifunction board must be replaced;
− the position of the rotary dip switch used to select the board address is
incorrect. The numeric control will display the “00034 I/O Error: NACK”
alarm;
− the type of I/O board defined does not correspond to the board actually
addressed (e.g. board 1 has been defined as input but an output one has been
mounted). The numeric control will display the “00035 I/O Error: Invalid Id”
alarm;
− an addressed I/O board is not connected or is broken. The numeric control will
display the “00046 I/O Error: BOARD NOT PRESENT” alarm.

When off, LINK LED causes all the outputs connected to the I/O BUS to reset. The
activation time of the output RESET signal is 50 ms from the moment in which there
is no more optic fiber serial connection and the LINK LED goes out.

3.1.8 LEDs on boards BRD.021.405 and BRD.021.412

There are 4 LEDs indicating that +15V, -15V, +5V and V enc power voltage is present
plus the POWER and LINK leds.

POWER LED The following conditions may occur.

ù LED on:
− +24 V DC powering voltage is present and within the minimum and maximum
limits indicated by the specifications.
ù LED off:
− the power supply voltage is off limits. The numeric control displays the “00040
I/O Error: NODE POWER SUPPLY KO” alarm;
− there is no powering voltage. The numeric control will display the “00033 I/O
Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs, the module must be replaced.

The module has a self-resetting fuse as protection on the +24 V DC voltage source.

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HW Diagnostics

LINK LED The following conditions may occur, considering that the POWER LED is on.
ù LED on:
− optic fiber serial connection with the transmitter node is present. The module
operates regularly.
ù LED off:
− operation is regular as it is not addressed by the SW;
− the optic fiber has not been cut or butted correctly. The numeric control will
display the “00032 I/O Error: CRC” or “00033 I/O Error: TIMEOUT” alarms.
Check the optic fiber;
− the optic fiber is not connected or is broken. The numeric control will display
the “00033 I/O Error: TIMEOUT” alarm. Check the optic fiber;
− the board is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. If this occurs the module must be replaced;
− the multifunction board in the numeric control is broken. The numeric control
will display the “00033 I/O Error: TIMEOUT” alarm. If this occurs the
multifunction board must be replaced;
− the position of the rotary dip switch used to select the board address is
incorrect. The numeric control will display the “00034 I/O Error: NACK”
alarm;
− the type of I/O board defined does not correspond to the board actually
addressed (e.g. board 1 has been defined as input but an output one has been
mounted). The numeric control will display the “00035 I/O Error: Invalid Id”
alarm.

When off, LINK LED causes all the outputs to reset. The activation time of the output
RESET signal is 50 ms from the moment in which there is no more optic fiber serial
connection and the LINK LED goes out.

+5V LED The following conditions may occur.

ù LED on:
− +5V DC internal voltage is present.
ù LED off:
− power supply voltage is not present. The numeric control will display the
“00033 I/O Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. In this case the module must be replaced.

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Diagnostics HW

+15V LED The following conditions may occur.

ù LED on:
− +15V DC internal power supply voltage is present.
ù LED off:
− power supply voltage is not present. The numeric control will display the
“00033 I/O Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. In this case the module must be replaced.

-15V LED The following conditions may occur.

ù LED on:
− -15V DC internal voltage is present.
ù LED off:
− power supply voltage is not present. The numeric control will display the
“00033 I/O Error: TIMEOUT” alarm;
− the module is broken. The numeric control will display the “00033 I/O Error:
TIMEOUT” alarm. In this case the module must be replaced.

+V enc LED The following conditions may occur.

ù LED on:
− +V enc internal power supply voltage is present.
ù LED off:
− power supply voltage is not present. The numeric control will display the
“00033 I/O Error: TIMEOUT” alarm;
− short-circuit towards FIELD GND (GROUND) owing to an encoder or the
wiring. detach the encoders and check;
− Power draw more than 1A. Detach the encoders and check;
− the module is broken. The numeric control could display the “00033 I/O Error:
TIMEOUT” alarm. In this case the module must be replaced.

END OF CHAPTER

3.10 00009.HW.0.GB Esa/Gv

HW Service and maintenance

4 Service and maintenance

4.1 Spare parts

CODE DESCRIPTION
BRD.007.444 Board with 16 outputs with spring terminals
BRD.007.448 Board with 16 inputs with spring terminals
BRD.007.450 Board with node + 16 inputs + 16 outputs
BRD.007.454 Board with 16 outputs with removable terminal board
BRD.007.458 Board with 16 inputs with removable terminal board
BRD.012.053 I/O BUS resistive termination
BRD.014.014 Piloting board for 2 proportional valves
BRD.018.401 Board with 8 12-bit analog inputs
BRD.018.402 Board with 8 16-bit analog outputs
BRD.019.025 Receiver node board
BRD.021.405 Board with node + 2 axes for 5V encoder
BRD.021.412 Board with node + 2 axes for 12V encoder
OPF.005.001 HP HFBR-RU100 optic fiber

4.2 WARNING

Dangerous voltage is present in certain parts of the electric panel during operation.
Maintenance operations carried out in the incorrect way may damage the remote I/O
system.

Interventions must be carried out in the following way:

ù maintenance must only be carried out by qualified personnel;
ù each module must be disconnected from the electric power source before any
operations are carried out;
ù comply with the instructions given further on in the text.

Esa/Gv 00009.HW.0.GB 4.1

Service and maintenance HW

4.3 Module replacement

4.3.1 Replacement of boards BRD.007.444 and BRD.007.448

Procedure ù Disconnect the electric power source.

ù Disconnect the wires from the spring terminal strip by levering with a small
screwdriver in the relative opening or take out the removable terminal board.
ù Disconnect the 34-pin flat cables.
ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

4.3.2 BRD.007.450 board replacement

Procedure ù Disconnect the electric power source.

ù Remove the loose terminal strips from the board connectors.
ù Disconnect the optic fiber cables.

To remove the optic fiber, push the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press

Optic fiber

Figure 4.1 - Example of optic fiber removal

4.2 00009.HW.0.GB Esa/Gv

HW Service and maintenance

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring because it could break and remain inside the module

ù Detach the module from the OMEGA type DIN BAR.

ù Replace the defective module.
ù Reconnect everything before powering again.

4.3.3 Replacement of boards BRD.007.454 and BRD.007.458

Procedure ù Disconnect the electric power source.

ù Disconnect the wires from the spring terminal strip by levering with a small
screwdriver in the relative opening or take out the removable terminal board.
ù Disconnect the 34-pin flat cables.
ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

4.3.4 BRD.014.014 board replacement

Procedure ù Disconnect the electric power source.

ù Disconnect the wires from the spring terminal strip by levering with a small
screwdriver in the relative opening.
ù Disconnect the 34-pin flat cables.
ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

4.3.5 BRD.018.401 board replacement

Procedure ù Disconnect the electric power source.

ù Take the removable terminal strips out of the board connectors.
ù Disconnect the 34-pin flat cables.
ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

Esa/Gv 00009.HW.0.GB 4.3

Service and maintenance HW

4.3.6 BRD.018.402 board replacement

Procedure ù Disconnect the electric power source.

ù Take the removable powering terminal strip and the multiple connectors out of the
board connectors.
ù Disconnect the 34-pin flat cables.
ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

4.3.7 BRD.019.025 board replacement

Procedure ù Disconnect the electric power source.

ù Disconnect the wires from the spring terminal strip by levering with a small
screwdriver in the relative opening.
ù Disconnect the optic fiber cables.

To remove the optic fiber, push on the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure 4.2 - Example of optic fiber removal

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring because it could break and remain inside the module

ù Disconnect the 34-pin flat cable of the I/O board.

ù Detach the module from the OMEGA type DIN BAR.
ù Replace the defective module.
ù Reconnect everything before powering again.

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HW Service and maintenance

4.3.8 Replacement of boards BRD.021.405 and BRD.021.412

Procedure ù Disconnect the electric power source.

ù Remove the loose terminal strip and multiple connectors from the board
connectors.
ù Disconnect the optic fiber cables.

To remove the optic fiber, push on the outer ring and pull the fiber as indicated in the
figure.

Outer ring

Press

Pull
Press
Optic fiber

Figure 4.3 - Example of optic fiber removal

Do not remove the optic fiber from the TX or RX modules without pressing the
outer ring because it could break and remain inside the module

ù Detach the module from the OMEGA type DIN BAR.

ù Replace the defective module.
ù Reconnect everything before powering again.

END OF CHAPTER

Esa/Gv 00009.HW.0.GB 4.5

Service and maintenance HW

4.6 00009.HW.0.GB Esa/Gv

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