GEK-114903 OC6000e Hardware Manual - V2.0

GE Energy
OC 6000e
Hardware Manual
GEK-114903
Version No. 2.0
These instructions do not purport to cover all details or variations in equipment, nor to
provide for every possible contingency to be met during installation, operation, and
maintenance. The information is supplied for informational purposes only, and GE makes
no warranty as to the accuracy of the information included herein. Changes,
modifications and/or improvements to equipment and specifications are made
periodically and these changes may or may not be reflected herein. It is understood that
GE may make changes, modifications, or improvements to the equipment referenced
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sufficiently for the purchasers purpose, the matter should be referred to:
GE Energy
Control Solutions
1800 Nelson Road
Longmont, CO 80501
energy.controlsolutions@ge.com
http://www.ge-energy.com/oc
Phone: + 1 (800) 835-5182, United State)
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2012 General Electric Company, USA. All rights reserved.
Safety Symbols
Indicates a procedure or condition that, if not strictly

observed, could result in personal injury or death.
Indicates a procedure or condition that, if not strictly

observed, could result in damage or destruction of
equipment.
Indicates a procedure, condition, or statement that should

be strictly followed in order to optimize these applications.
Note Indicates an essential or important procedure or statement.
Tip Provides essential information that is not normally defined in regular use
but from an experienced user.
Contents
Chapter 1 UCSA Controller 1
1.1 Operation 1
1.2 Configuration 2
1.3 Installation 2
1.4 UCSA overview 2
1.5 LEDs 3
1.6 UCSA Specifications 4
Chapter 2 IO Module 5
2.1 MAI10 Analog Input with 16 channels of mA/V 5
2.2 MAI20 Analog Input with 16 channels of RTD/TC 14
2.3 MAO10 Analog Output with 8 channels 23
2.4 MDI10 Configurable Digital input /Pulse input with 16 channels 31
2.5 MDO10 16 channels of Digital Output 39
2.6 MVP10 Valve Position Control Module 46
2.7 MVP11 Valve Position Control Module 59
2.8 MSP10 Speed Measurement and Protection Module 72
2.9 TMR 2oo3 Voting & Extension Relay Module 88
2.10 MAI12 Analog Input with 16 channels of mA/V 93
2.11 MAI22 Analog Input with 16 channels of RTD/TC 102
2.12 MDI12 Configurable Digital input /Pulse input with 24 channels 111
2.13 MDO11 16 channels of Digital Output 118
Chapter 3 IO Base 125
3.1 BAI10 Analog Input base with 16 channels of mA/V 125
3.2 BAI20 Analog Input Base with 16 channels of RTD/TC 129
3.3 BAO10 Analog Output Base with 8 channels 132
3.4 BDI10 Digital input /Pulse input Base with 16 channels 135
3.5 BDO10 Digital Output Base with AC relay 140
3.6 BVP10 Valve Position Control Base 145
3.7 BSP10 Speed Measurement and Protection Base 152
3.8 BAI11 Analog Input Base with 16 channels of mA/V 155
3.9 BAI21 Analog Input Base with 16 channels of RTD/TC 157
3.10 BAO21 Analog Output Base with 8 channels 160
3.11 BDI11 Digital input /Pulse input Base with 24 channels 163
3.12 BDO11 Digital Output Base 167
3.13 BDO12 relay module with 16 DO 220VAC relays 169
3.14 BDO20 relay terminal board with 16 DO 220VDC relays 174
Chapter 4 Communication Module 178
4.1 MCI10 Communication Module with 8 Channels of RS-485 178
4.2 MCI11 Communication Module with 4 Channels of isolated RS-485 182
4.3 MCI12 Communication Module with 8 Channels of isolated RS-485 186
4.4 MCI20 Communication Module with 2 Channels of Ethernet 190
4.5 MDP Profibus-DP Communication Module 194
Chapter 5 OC 6000e input/output Module Packages 195
5.1 Module Package overview 195
5.2 Installation 195
5.3 Disconnection 198
GEK-114903 OC 6000e Hardware Manual i

Chapter 1 UCSA Controller
The UCSA controller is a stand-alone computer that runs the application code. The
controller mounts in a panel, and communicates with the I/O packs through on-board
I/O network interfaces. The controller operating system (OS) is QNX Neutrino, a real
time, multitasking OS designed for high-speed, high reliability industrial applications.
Five communication ports provide links to I/O, operator, and engineering interfaces are
as follows.
Ethernet connection for the Unit Data Highway (UDH) for communication with HMIs,
and other control equipment
Ethernet connection for the R, S, and T I/O network
RS-232C connection for setup using the COM1 port
Note: The I/O networks are private special-purpose Ethernet that support only the I/O
packs and the controllers.
The stand-alone controllers offer the following advantages.
Single module
No jumper settings required
No battery
No fan
Smaller panel footprint
Easy access to Compact Flash
1.1 Operation
The controller is loaded with software specific to its application, which includes but is
not limited to, steam, gas, hydro, or balance of plant (BOP) products. The IEEE1588
protocol is used through the R, S, and T IONets to synchronize the clock of the I/O packs
and controllers to within 100 microseconds.
External data is transferred to and from the control system database in the controller
over the R, S, and T IONets.
In a simplex system, this includes process inputs/outputs to the I/O packs.
In a dual system:
Process inputs/outputs to the I/O packs
Internal state values and initialization information from the designated controller
Status and synchronization information from both controllers
GEK-114903 OC 6000e Hardware Manual 1

1.2 Configuration
The controller must be configured with a TCP/IP address prior to connecting to the UDH
Ethernet. This can be achieved using one of the following methods.
Through the COM1 serial port. A RJ45 to DB9 adapter is required along with an
Ethernet cable.
Through a Compact Flash programmer. The Compact Flash programmer can be a
PCMCIA adapter or a USB device.
1.3 Installation
The controller is contained in a single module that mounts directly to the panel sheet
metal. The following diagram shows the module envelope and mounting dimensions.
Figure 1.3-1 Module Envelope and Mounting Dimensions
1.4 UCSA overview

The UCSA Module contains a 667 MHz Power QUICC II Pro Free scale processor. Two
10/100BaseTX Ethernet ports provide connectivity to the UDH, and three additional
10/100Base TX Ethernet ports provide connectivity to the IONets.
2 GEK-114903 OC 6000e Hardware Manual

Figure 1.4-1 UCSA Front View
1.5 LEDs
The UCSA module has the following LEDs:
Link displays solid green if the Ethernet PHY on the UCSA has established a link with
an Ethernet switch port.
Act indicates packet traffic on an Ethernet interface. This LED may blink if the traffic
is low, but is solid green in most systems.
Power displays solid Green when the internal 5 V supply is up and regulating. The
UCSA converts the incoming 24 V dc to 5 V dc. All other internal power planes are
derived from the 5 V.
Boot displays solid red or blinking red during the boot process. The boot LED is lit
continuously during the boot process unless an error is detected. If an error is
detected, the LED blinks at a 1 Hz frequency. The LED, when blinking, is on for 500
ms and off for 500 ms. The number of blinks indicates the failed state. After the LED

blinks on momentarily, it then blinks off for three seconds. The boot blink codes are
described below.
Failed Serial Presence Detect (SPD) EEPROM.
Failed to initialize DRAM or DRAM tests failed.
Failed NOR flash file system check.
Failed to load FPGA or PCI failed.
CompactFlash device not found.
Failed to start IDE driver
CompactFlash image not valid.
If the CompactFlash image is valid but the runtime firmware has not been loaded,
the boot LED blinks continuously at a 1 Hz rate. Once the firmware is loaded, the
boot LED turns off.
Online displays solid green when the controller is online and running application
code.
Flash blinks amber when any flash device is being accessed.
DC displays solid green when the controller is the designated controller.
Diag displays solid red when the controller has a diagnostic available. The
diagnostic can be viewed and cleared using the SystCFG or Diagnostics application.
On displays solid green when the USB is active.
If the controller does not go online, use the SystCFG application to determine why the
controller is blocked. Once the IP address has been assigned, all the configuration is
through the Ethernet.
1.6 UCSA Specifications

Controller, its I/O modules and cabinets number are calculated according to the IO
quantity and design limits.
Table 1.6-1 UCSA specification
Item Specification
Microprocessor Power QUICC II PRO 667 MHz
256 MB DDR SDRAM
Memory Flash-backed SRAM - 8K allocated as NVRAM for controller functions
CompactFlash size is dependent on the application
Operating System QNX Neutrino
Control block language with analog and discrete blocks; Boolean logic
Programming
represented in relay ladder diagram format.
UDH Ethernet Interface Twisted pair 10BaseT/100BaseTX, RJ-45 connectors
IONET Ethernet Interface Twisted pair 10BaseT/100BaseTX, RJ-45 connectors
Power Requirements +32 V dc to 18 V dc ( 12 W (typical preliminary), 13 W (maximum))
Operating: 0 to +65C (32 to +149 F)
Environmental Specifications Storage: -40 to +85C (-40 to +185 F)
Relative humidity: 5% to 95%, no-condensing

Chapter 2 IO Module
2.1 MAI10 Analog Input with 16 channels of mA/V
2.1.1 Functional description

The MAI10 module is capable of handling up to 16 mA/V analog inputs. Each one can be
configured as 5 V or 10 V inputs, or 0-20 mA current loop inputs. The module contains
a processor board, and two acquisition boards specific to the mA/V analog input
function, which is mounted on a base specific to the analog input function. The load
terminal resistors for current loop inputs are located on the acquisition board and
voltage is sensed across these resistors. The module provides the electrical interface
between one or two I/O Ethernet networks called IONET and field analog input signals.
The module connects directly with the associated baseboard through a 64-pin
connector and two 48-pin connectors. The 64-pin connector is used to connect the
processor board. The 48-pin connector is used to connect the acquisition board.
On the base, the signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors
and the 4-pin power supply wire are connected directly to the 64-pin connector. Eight
analog input signals are connected directly to the 48-pin connector. Visual diagnostics
are provided through indicator LED, as follows.
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

BAI10 AI base board
Processor board with 64
MAI10 AI module pin connector
8 analog input
with mA/V
Dual 24VDC
power supply
100M
8 analog input Ethernet A
with mA/V
100M
Ethernet B
AI acquisition board
with 48 pin connector
Figure 2.1-1 16 Analog Input with mA/V schematic diagram
2.1.2 Groups & Compatibility

The MAI10 AI module is compatible with the analog Input base BAI10 AI base.
2.1.3 Installation
Securely mount the desired base BAI10.
Directly plug one MAI10 AI module into the BAI10 base. On both the BAI10 base and
the AI module, there are keyed connectors to avoid incorrect assembly. One key
accomodates a specific IO module type and another key accomodates a different
IO module. If an attempt is made to plug the MAI10 AI module into the wrong base,
the connector keys will not match up.
Plug in one or two Ethernet cables depending on the system configuration. The AI
module will operate over either port.
Apply power to the pack by plugging in the connector on the side of the AI module.
Configure AI module as necessary.

2.1.4 Operation
2.1.4.1 Processor subsystem
The processor board in the IO module contains the following:
High-speed processor with RAM and flash memory
Two fully independent 100Mbps Ethernet ports
Hardware watchdog timer and reset circuit
Status indication LED
Electronic ID and the ability to read IDs on other boards
Substantial programmable logic supporting the acquisition board
Capability of hot plug in and pull out/current limiter
Local dual power supplies, including monitoring function
Ability to download firmware and logic by IONET
Ability to download the boot loader through RS232 ports
System time synchronization with 100s of precision is accomplished by IEEE1588
high precision timing protocol
The processor board connects to two acquisition boards specific to the I/O module
function, by the connector on the top side of processor board, and connects to the base
with a 64-pin connector. When power is applied, the soft-start circuit ramps up the
voltage available on the processor board. The local power supplies are sequenced on,
and the processor reset is removed. The firmware reads board ID information through
the FPGA. The processor attempts to establish Ethernet communications, starting with a
request for network address. The address request uses the industry standard dynamic
host configuration protocol (DHCP). If the processor board was installed without
firmware and FPGA logic, you will need to download correct firmware and FPGA logic
through the Ethernet. If there is FPGA logic and firmware, then the firmware reads FPGA
logic specific to the IO module from flash memory and writes it to the FPGA. After
initializing the FPGA clock and completing self-diagnostics of RAM, Flash, EEPROM and
set point in RAM and EEPROM, then the firmware checks the firmware type, base type, IO
acquisition board type and FPGA type to ensure correct matching. After Ethernet
initialization, the processor programs the on-board logic, runs the application, and
enables the acquisition board to begin operation.
The processor firmware contains all the logic necessary to allow the IO module to
operate from one or two Ethernet inputs. When operated from two Ethernet inputs, both
network paths are active all the time. A failure of either network will not result in an
interruption of the I/O module operation, and the failure will be indicated through the
working network connection. This arrangement is more tolerant of faults than a classic
hot-backup system where the second port is only used after a primary port failure is
detected. The Ethernet ports on the processor run at 100 MB/s speed and full-duplex
operation.

2.1.4.2 Analog input hardware
The MAI10 detects Amp or voltage signals from the BAI10 base for all 16 input channels.
The analog input section consists of an EMC interface, mA/V switch circuit, open/short
circuit detection, several gain and scaling selections, and a 24-bit analog-to-digital
converter (ADC).
MAI10 AI module
BAI10 AI base BAI10 AI base

board board
(Left) (Right)
220VAC protection
Open/short circuit
EMC interface/
mA/V switch
Analog to
Processor
isolation
detection
Digital Ethernet
1 of 16 mA/V Convertor communication
24 bit
DC/DC
24V Power
Supply
Figure 2.1-2 MAI10 analog input conditioning circuit diagram
The inputs can be individually configured as 5 V or 10 V scale signals, depending on

the software configuration. The acquisition board provides a 250 load resistor when
configured for current inputs yielding a 5 V signal at 20 mA.
Each one of the 16 mA/V channels has individual DC/DC converter that powers the
various components in the AI conditioning circuit. There is an EMC interface circuit for
each one of 16 mA/V channels. Any conductive interference from field mA/V signal
would be leaked to shield ground on the BAI10 AI base. The interference would then be
leaked to field ground. The 220VAC protection function can protect internal circuitry if a
220VAC signal is accidently applied to the AI signal terminal.
Through HMI interface, m Amp or Voltage settings can be configured for each one of the
16 channels. There is a detection of open and short circuits, in which case the MAI10 AI
module will report an alarm to the HMI via the controller.
2.1.4.3 ID line
During power initialization, the MAI10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BAI10. The processor then confirms
the correct matching of the IO module to base and reports board revision status to the
system level control.

2.1.4.4 Power management and monitor
The MAI10 includes power management in the 24V input circuit. The management
function provides soft starts to control current spikes during power application. After
applying power, the circuit provides a fast current limit function to prevent a module or
base failure from propagating back onto the 24V power system. When power is present
and working properly, the green PWR indicator will light. The MAI10 module includes
power monitoring for the dual 24V input. If either 24V power supply fails, the processor
can detect this, and will report an alarm to the HMI via the controller.
2.1.4.5 Module temperature monitor

There is a temperature sensor on each acquisition board and the processor reads
temperature data from each one. If two values are within 5 degree C of each other, the
processor uses the average value to estimate module inside temperature, and
determines whether it is normal or over limit. The processor reports an alarm to the HMI
via the controller when inside temperature exceeds the allowable temperature range.
2.1.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
A green LED labelled Power shows the presence of control power, which is always on
after power is supplied to the IO module.
A green LED labelled Run shows the firmware status. When firmware is in initialization
or Request IP address, the LED blinks slowly at 1s ON/ 1s OFF. When firmware is in
normal run after initialization, the LED blinks quickly at 0.125 ON / o.125 OFF. If the CPU
has stopped working, the LED will be steady or off.
A red LED labelled Internal Error shows the internal system status and alarm
information. The LED shines as below,
When firmware enters the QC mode, the LED blinks slowly with 0.5s ON, 0.5s OFF,
0.5s ON, 0.5s OFF, 2s OFF.
When some critical fault occurs that cant be recovered by reset, for example, RAM
self-diagnostic error, firmware in Flash memory CRC error, EEPROM self-diagnostic
error, RAM set value CRC error, EEPROM set value CRC error, board types do not
match each other or initialization fails, then the LED will be constant ON.
When a recoverable alarm activates, for example, temperature out of range, power
supply voltage is lower than 18V, configuration parameter cant be loaded or, if the
input or output exchange message goes into error, the LED will blink quickly with
0.125s ON and 0.125s OFF.
The LED should be off in normal state

A red LED labelled External Error shows IO Channel failure. When an IO channel fails,
the LED should blink at 0.125 ON and 0.125OFF. The LED will stay OFF when IO channel
is normal.
Two green LEDs labelled Tx/Rx A and Tx/Rx B show the status of Ethernet message.
The LED blinks as it receives input. When there is no Ethernet message, the LED will stay
OFF.
2.1.4.7 Connectors
MAI10 contains the following connectors.
A 64-pin connector on the underside of the MAI10 module connects directly to the
BAI10 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MAI10
module connects directly to the BAI10 base, which includes 16 mA/V signals and
dual 24VDC power supply
2.1.5 Specification
Table 2.1-1 MAI10 specification

Item Specification
Number of channel 16 channels per BAI10 base
Input span 0-5V/1-5V/5V/10V or 0-20mA/4-20mA per channel
Input resolution 15 bit
Scan time Normal 20 ms (50 Hz)
Measurement accuracy Better than 0.1% full scale range
Common Mode Rejection Ratio 120db at 250VAC common mode voltage
Normal Mode Rejection Ratio 60db at 50/60Hz with amplitude of half of full scale
Isolation between IO channels 500VAC at 50/60Hz
Isolation between input and ground 500VAC at 50/60Hz
IO Channel protection 220VAC
Power consumption 17.65W
Heat dissipation 4.47W
Physical Size (L*W*H) 152.6mm*70.7mm*131.9mm
Temperature -30 to 65C (-22 to +149 F)
2.1.6 Diagnostics
The IO module performs the following self-diagnostic tests:
A power-up self-test that includes check of RAM, EEPROM, flash memory, set value
in RAM and EEPROM and board type match. When a failure happens, the IO module
will stay in initialization phase, and doesn't advance. No alarm is sent to the
controller. The internal Error LED stays solid on

When downloaded Configuration parameters dont exist, the IO Module will send an
alarm to the controller and the Internal Error LED blinks quickly with 0.125ON and
0.125 OFF. IO Module stops sending and receiving IONET exchange data when no
configuration parameters exist.
There is continuous monitoring of the internal power supply. When a failure
happens, the IO module will send an alarm to the controller and the Internal Error
LED blinks fast with 0.125ON and 0.125 OFF.
There is continuous monitoring of temperature. When temperature goes out of
range or the deviation between two IO acquisition boards is over 5C, the IO module
will send an alarm to the controller and the Internal Error LED will blink fast with
0.125ON and 0.125 OFF.
There is continuous monitoring of proper function of RAM, EEPROM, Flash, set value
in RAM and EEPROM. When a failure happens, the IO module will send an alarm to
the controller and will stop sending and receiving IONET exchange data. Internal
LED will be Solid on.
There is continuous monitoring of Ethernet communication. When connection with
Ethernet is lost, the corresponding Tx/Rx LED will turn off and stay in OFF status.
When recovery occurs, Tx/Rx LED should shine normally
Each input has range checking for input signal based on configurable high and low
levels. This checking can be used to generate alarms. When a failure happens, the
IO module will send an alarm to the controller and deliver AI value to controller.
The analog input hardware includes precision reference voltages in each scan.
Measured values are compared against expected values and are used to confirm
proper function of the analog to digital converter circuits. When a failure happens,
the IO module will send an alarm to the controller along with the last AI value prior
to failure.
The analog input hardware also includes a function to detect an open circuit in each
scan. When a failure happens, the IO module will send an alarm to the controller
along with the last AI value prior to failure.
Details of the individual diagnostics are available from the HMI. The diagnostic signals
can be individually latched, and then reset manually if they are restored to proper
function.
2.1.7 Configuration
Table 2.1-2 MAI10 configuration parameters
Parameter Description Choice
-10V~10V, mA_No_Power_out,
Input Type Select input type for every AI channel
mA_Power_Out, Unused
Value of current/voltage at the low end of
Low_Value -10 to 20
scale per AI channel
Value of input in engineering units at low end
Low_Eng_Value -3.4082 e + 038 to 3.4028 e + 038
of scale per AI channel
Value of current/voltage at the high end of
High_Value -10 to 20
Value of input in engineering units at high
High_Eng_Value -3.4082 e + 038 to 3.4028 e + 038
end of scale per AI channel

InputFilter Bandwidth of input signal filter 50/60Hz, 50Hz, 60Hz, Unused
2.1.8 Alarms
Table 2.1-3 MAI10 specific alarms

Fault Fault Description Possible Cause
32~47 Analog Input [ ] Unhealthy Short-circuit of Analog Input []
48~63 Analog Input [ ] Unhealthy Open-circuit of Analog Input []
64~79 Analog Input [ ] Unhealthy Analog Input [] overflow
80~95 Analog Input [ ] Unhealthy Analog Input [] underflow
96~111 Low power supply per channel Power supply failure
112~127 SPI communication failure Analog Input hardware failure
Table 2.1-4 IO module common alarms

Alarm Id Fault Description Possible cause
0 Diagnostic Alarm Reset Received Alarm Reset Command from controller

2 Flash Memory CRC Failure Flash check failure
6 Special User Mode active. Entered QC Mode
7 IoPack - The I/O card has gone to the Off- Cant receive output exchange from controller
Line state
24 Firmware Hardware incompatible Baseboard type mismatch.
224 Two input temperature differ over 5C Temperature from 2 condition board not equal
225 RAM selftest Error hardware failure
227 EEPROM selfttest Error hardware failure
228 RAM Const selftest Error hardware failure or program failure
229 Ethernet A has gone to the offline state Ethernet A lost Egd communication with
controller(If it is Configured to Use)
230 Ethernet B has gone to the offline state Ethernet B lost communication with controller(If it
is Configured to Use)
231 IO Board Type mismatch IO Condition Board Type mismatch
232 IO Board Ver mismatched IO condition board Version mismatched
233 Input ExchangeVar Size mismatched XML config files mismatch
234 Output Exchange Var size mismatched XML config files mismatch
235 SOE lost SOE buffer full and lost

236 Eeprom Rectification Param Error Eeprom Size or content not matched

237 BootLoader Flash CRC failure hardware failure
238 External Firmware flash failure hardware failure
239 External FPGA logic Flash failure
hardware failure
240 Cfg Files HostName Mismatch Cfg file error,redownload
241 Baseboard EEPROM err Baseboard Eeprom failure
257 IOPack 18V Power Supply Is low Voltage Lower than 18V
258 IOPack Temperature out of range Temperature went outside -20 to +85 C
259 Output exchange frame overruns Output exchange sequence number out of order.
263 Config - Bad name Detected Pcode iopack name mismatch
264 Config - Bad config compatiblity code Pcode compatible code mismatch
265 Mapper - Egd input header size mismatch XML input cfg file's input header size mismatch
266 Config - Config size mismatch Pcode config file data array size mismatch.
267 FPGA - Name mismatch detected FPGA logici name mismatch
268 FPGA - Incompatible Revision FPGA logic version mismatch
273 onet-egd Message - Illegal Version EGD exchange header version mismatch
281 FPGA not programmed due to platform FPGA logic can't be loaded
errors
282 Unable to initialize application Fatal Initialize failure

independent processes
293 Waiting on IP addr from DHCP No Ip address on at least one port

301 XML files are missing XML files are missing
315 Controller output exchange received too Output exchange from controller too short
short
316 Controller output exchange major sig Output exchange from controller major signature
mismatch mismatch
318 Controller output exchange cfg timestamp Output exchange from controller signature time
mismatch mismatch
338 SSI signals are not being updated SSI signals not updated
342 IoPack App Io Compat does not match Input xml cfg file compatible code mismatch
firmware

2.2 MAI20 Analog Input with 16 channels of RTD/TC

The MAI20 module is capable of handling up to 16 RTD/TC analog inputs, each one of
which can be configured as RTD or TC input. The module contains a processor board,
two acquisition boards specific to the RTD/TC analog input function, which are mounted
on a base specific to the analog input function. The current source located on the
acquisition board provides an output of 0.2mA current to the RTD and voltage is sensed
across the RTD when the module is configured as an RTD input. The module provides
the electrical interface between one or two I/O Ethernet networks called IONET and field
analog input signals.
The module connects directly with the associated base through a 64-pin connector and
two 48-pin connectors. The 64-pin connector is used to connect the processor board.
The 48-pin connector is used to connect the acquisition board.
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

BAI20 AI base board
8 analog input
with RTD/TC
Dual 24VDC
power supply
100M
with RTD/TC
100M
Ethernet B
Figure 2.2-1 16 Analog Input with RTD/TC schematic diagram

The MAI20 AI module is compatible with the analog input baseboard BAI20 AI
baseboard.
2.2.3 Installation
accomodates a specific IO module type and another key accomodates a different

2.2.4 Operation
operation.

The MAI20 accepts RTD or TC signals from the BAI20 base for all 16 input channels. The
analog input section consists of an EMC interface, RTD/TC switch circuit, current source
circuit, open/short circuit detection, several gain and scaling selections, and a 24-bit
analog-to-digital converter (ADC).
MAI20 AI module

board Current board
(Left) source (Right)
220VAC protection
Open/short circuit
EMC interface/
RTD/TC switch
Analog to
Processor
isolation
detection
Digital Ethernet
1 of 16 Convertor communication
RTD/TC 24 bit
DC/DC
24V Power
Supply
Figure 2.2-2 MAI20 RTD/TC conditioning circuit diagram
The inputs can be individually configured as either RTD signal or TC signal, depending on
the software configuration. The acquisition board provides a 0.2mA current output
when configured for RTD inputs.
Each one of 16 RTD/TC channels has individual DC/DC convertor that powers the
various components in the AI conditioning circuit. There is an EMC interface circuit for
each one of 16 RTD/TC channels, then conductive interference from field RTD/TC signal
would be leaked to shield ground on BAI20 AI base, in addition, the interference would
be leaked to field ground. The 220VAC protection function can protect internal circuitry if
a 220VAC signal is accidently applied to the AI signal terminal.
Through the HMI interface, RTD input or TC input can be configured for each one of 16
channels. Otherwise, there is function circuitry to detect open and short circuit. The
MAI20 AI module will generate an alarm report to the HMI via the controller.
2.2.4.3 RTD Type and range
Table 2.2-1 MAI20 RTD types and temperature range

RTD Type Range of degree C Range of resistance ohm Name/Standards
100 ohm Platinum -200 to 850 18.52 to 390.48 ITS-90
100 ohm Copper -50 to 150 78.48 to 164.27 ITS-90

2.2.4.4 TC Type and range
Table 2.2-2 MAI20 TC types and temperature range

TC Type Range degree C Range Voltage mV Name/Standards
T -200 to 350 -5.603 to 17.818 ITS-90
J -200 to 1200 -7.890 to 69.553 ITS-90
E -200 to 1000 -8.825 to 76.373 ITS-90
K -200 to 1300 -5.891 to 52.410 ITS-90
N -200 to 1300 -3.990 to 47.513 ITS-90
B 400 to 1600 0.787 to 11.263 ITS-90
R 0 to 1600 0 to 18.884 ITS-90
S 0 to 1700 0 to 17.947 ITS-90
2.2.4.5 ID line

function provides soft start to control current spikes during power application. After

2.2.4.8 Temperature compensation for TC type

Any input can be configured as RTD types to connect a RTD in cabinet for measuring the
temperature inside cabinet, which can be utilized as cold junction compensation. The
measured temperature inside the cabinet is delivered to the controller, and the
controller can broadcast it to all TC modules installed in the cabinet to complete
temperature compensation.

2.2.4.9 Status LED
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
normal run after initialization, the LED blinks quickly at 0.125 ON / o.125 OFF. When CPU
is non-functional, the LED will be steady or off.
When some critical fault that cant be recovered by reset happens, for example,
RAM self-diagnostic error, firmware in Flash memory CRC error, EEPROM self-
diagnostic error, RAM set value CRC error, EEPROM set value CRC error, board types
do not match each other or initialization fails, then the LED will be constant ON.
is normal.
OFF.
2.2.4.10 Connectors
MAI20 contains the following connectors.
BAI20 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
module connects directly to the BAI20 base, which includes 16 RTD/TC signals and

2.2.5 Specification

Item Specification
Number of channel 16 channels
Input span RTD of Pt100/Cu50 or TC of T,J,E,K,N,B,R,S per channel
Input resolution 13 bits for TC, 15 bits for RTD
Scan time Normal scan 20 ms (50 Hz).
Physical Size(L*W*H) 152.6mm*70.7mm*131.9mm
2.2.6 Diagnostics
controller. The internal Error LED is solid on.
range or the difference between two IO acquisition boards is over 5C, the IO module
0.125ON and 0.125 OFF.
LED is Solid on.

levels. This checking can be used to generate alarms. When a failure happens, the
The analog input hardware includes precision reference voltages in each scan.
Measured values are compared against expected values and are used to confirm
proper function of the analog to digital converter circuits. When a failure happens,
the IO module will send an alarm to the controller along with the last AI value prior
to failure.
The analog input hardware includes a function to detect open circuit in each scan.
When a failure happens, the IO module will send an alarm to the controller along
with the last AI value prior to failure.
can be individually confirmed, and then reset manually if they are restored to proper
function.
2.2.7 Configuration

-60mV~60mV, Cu100, Cu50, Pt10, Pt100, TC-B,
InputType Select input type for every AI channel
TC-E, TC-J, TC-K, TC-N, TC-R, TC-S, TC-T, Unused
Value of RTD/TC at the low end per AI
Low_Eng_Value -3.4082 e + 038 to 3.4028 e + 038
channel
Value of RTD/TC at the high end per
High_Eng_Value -3.4082 e + 038 to 3.4028 e + 038
AI channel
InputFilter Bandwidth of input signal filter 50/60Hz, 50Hz, 60Hz, Unused
2.2.8 Alarms

IO module common alarms refer to Table 2.1-4 IO module common alarms.

2.3 MAO10 Analog Output with 8 channels

The MAO10 module is capable of providing up to 8 analog output of 0~20mA/0~10V
and includes an analog to digital converter to monitor open and short circuit for every
AO channel. The module contains a processor board, two acquisition boards specific to
the analog output function, which is mounted on a base specific to the analog output
function. The module provides the electrical interface between one or two I/O Ethernet
networks called IONET and field analog output signals.
Through a 64-pin connector and two 48-pin connectors, the module connects directly
with the associated base, where the 64-pin connector is used to connect the processor
board and the 48-pin connector is used to connect the acquisition board. On the base,
signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors and 4-pin power
supply wires are connected directly to the 64-pin connector, and 4 analog output
signals are connected directly to the terminal from the 48-pin connector. Visual
diagnostics are provided through indicator LEDs, which are shown as follows.
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

BAO10 AO base board
MAO10 AO module pin connector
Dual 24VDC
power supply
8 analog output
100M
Ethernet A
100M
Ethernet B
AO acquisition board
Figure 2.3-1 8 Analog Output schematic diagram

The MAO10 AO module is compatible with the analog output IO board BAO10 AO base.
2.3.3 Installation
Securely mount the desired base BAO10.
Directly plug one MAO10 AO module into the BAO10 base. On both the BAO10 base
and the AO module, there are keyed connectors to avoid incorrect assembly. One
key accomodates the IO module type and another key accomodates a different IO
module. If an attempt is made to plug the MAO10 AO module into the wrong base,
Plug in one or two Ethernet cables depending on the system configuration. The AO
Apply power to the pack by plugging in the connector on the side of the AO module.
Configure AO module as necessary.

2.3.4 Operation
board with a 64-pin connector. When power is applied, the soft-start circuit ramps up
the voltage available on the processor board. The local power supplies are sequenced
on, and the processor reset is removed. The firmware reads board ID information
through the FPGA. The processor attempts to establish Ethernet communications,
starting with a request for network address. The address request uses the industry
standard dynamic host configuration protocol (DHCP). If the processor board was
installed without firmware and FPGA logic, you will need to download correct firmware
and FPGA logic through the Ethernet. If there is FPGA logic and firmware, then the
firmware reads FPGA logic specific to the IO module from flash memory and writes it to
the FPGA. After initializing the FPGA clock and completing self-diagnostics of RAM, Flash,
EEPROM and set point in RAM and EEPROM, then the firmware checks the firmware type,
base board type, IO acquisition board type and FPGA type to ensure correct matching.
After Ethernet initialization, the processor programs the on-board logic, runs the
application, and enables the acquisition board to begin operation.
operation.

2.3.4.2 Analog output hardware
The MAO10 outputs mA or V signals to the BAO10 base for all 8 output channels. The
analog output section consists of an EMC interface, current/voltage output switch
circuit, open/short circuit detection, and a 12-bit digital-to-analog converter (DAC).
MAO10 AO module
BAO10 AO base BAO10 AO base

board board
Open/short circuit
(Left) (Right)
detection
220VAC protection
EMC interface/
isolation
mA/V switch
Digital to
Processor
Analog Ethernet
1 of 8 AO Converter communication
12 bit
DC/DC
24V Power
Supply
Figure 2.3-2 MAO10 analog output conditioning circuit diagram

The output can be individually configured as 0~20mA or 10 V signals, depending on
the software configuration. The load resistor is less than 750ohm when configured as
current source output.
Each one of 8 channels has individual DC/DC converters that power the various
components in the AO output circuit. There is an EMC interface circuit for each one of
the 8 channels, then conductive interference from field AO signal would be leaked to
shield ground on the BAO10 AO base, in addition, the interference would be leaked to
field ground. The 220VAC protection function can protect internal output circuitry if a
220VAC signal is accidently applied to the AO signal terminal.
Through HMI interface, current or Voltage output can be configured for each one of 8
channels.
Otherwise, there is the functionality to detect an open or short circuit, and the MAO10
AO module will generate an alarm report to the HMI via the controller. For each channel,
MAO10 AO module has an analog to digital converter to provide two feedback values.
When AO channel is configured as voltage source output, the short circuit detection is
available when load resistor is less than 60ohm. When AO channel is configured as
current source output, the detection of both open circuit and short circuit is available.
When open circuit happens, the value of one feedback channel is about 1.94V while the
value of the other feedback channel is 0V. When there is short circuit, the load resistor
should be lower than 50ohm.
When the module goes offline in normal operation, it will generate an alarm and switch
to predefined output mode at same time - hold the last value/drop to zero/output
predetermined value, according to the module configuration.

2.3.4.3 ID line
During power initialization, the MAO10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BAO10. The processor then
confirms the correct matching of the IO module to base and reports board revision
status to the system level control.

The MAO10 includes power management in the 24V input circuit. The management
and working properly, the green PWR indicator will light. The MAO10 module includes

2.3.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

is normal.
OFF.
2.3.4.7 Connectors
MAO10 contains the following connectors.
A 64-pin connector on the underside of the MAO10 module connects directly to the
BAO10 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MAO10
module connects directly to the BAO10 base, which includes 8 Analog output
signals and dual 24VDC power supply
2.3.5 Specification
Table 2.3-1 MAO10 specification

Item Specification
Output type 0~5V/0~10V or 0-20mA/4-20mA(max load resistor 750ohm) per channel
DA converter resolution 12 bit digital to analog converter
Accuracy 0.2% full scale range
Frame rate 50Hz on all 8 channels

2.3.6 Diagnostics
controller. The internal Error LED stays solid on.
In initialization phase, there is check for each channel state, which includes SPI
interface state, AO configuration type, AO power, abnormal output in anyone of
channels; the AO output will be kept as zero if there is failure. The external Error LED
solid on.
range or difference between two IO acquisition boards is over 5C, the IO module will
send an alarm to the controller and the Internal Error LED will blink fast with
0.125ON and 0.125 OFF.
LED is Solid on.
Each output has range checking based on configurable high and low levels. These
ranges can be used to generate alarms. When a failure happens, the IO module will
send an alarm to the controller which output last AO value.
The analog output hardware also includes detection of open circuit or short circuit
during each scan. For each channels, MAO10 AO module has an analog to digital
converter to provide two feedback values. When AO channel is configured as
voltage source output, the short circuit detection is available when load resistor is
less than 60ohm, and when AO channel is configured as current source output, the
detection of both open circuit and short circuit is available. When open circuit
happens, the value of one feedback channel is about 1.94V while the value of
another feedback channel is 0V. When there is short circuit, the load resistor should
be lower than 50ohm.
When the module goes offline in normal operation, it will generate an alarm and
switch to predefined output mode at same time - hold the last value/drop to
zero/output predetermined value, according to the module configuration.
function.

2.3.7 Configuration
Table 2.3-2 MAO10 configuration parameters
Parameters Description Choice
OutputType Select output type for every AO channel 0-10V, 0-20mA, Unused
Value of current/voltage at the low end of scale
Low_Value per AO channel 0 to 20
Low_Eng_Value Output in engineering units at low value -3.4082e + 038 to 3.4028e + 038
Value of current/voltage at the high end of scale
High_Value per AO channel 0 to 20
High_Eng_Value Output in engineering units at high value -3.4082e + 038 to 3.4028e + 038
D/A_ErrLimit DA error threshold in percent 0~100%
Output_State State of the outputs when off-line HoldLastValue, Output_Value
Output_Value Pre-determined value for the outputs
2.3.8 Alarms
Table 2.3-3 MAO10 specific alarms

Fault Fault description Possible cause
32~39 Analog Output[] Unhealthy Short circuit - voltage source output
46~53 DA converter failure
62~69 Channel[] Initialization failure Actual output is zero, but feedback is not zero
78~85 Channel[] Voltage Lower
98~105 Analog Output[] Unhealthy Short circuit - current source output
106~113 Analog Output[] Unhealthy Open circuit - current source output
114~121 Analog Output[] Unhealthy SPI error
Error output type, e.g. current source output,
122~129 Analog Output[] Unhealthy output voltage value
160~167 Analog output [] is higher than high limitation

168~175 Analog output [] is lower than low limitation

2.4 MDI10 Configurable Digital input /Pulse input with
16 channels

The MDI10 module is capable of accepting up to 16 configurable PI/DI input channels.
When a channel is configured as DI type with 24V voltage level, all the 16 channels of
one module can be configured with the function of Sequence of event (SOE). The 16
channels are separated into two groups: Channel 1 to channel 8 are in group one;
Channel 9 to channel 16 are in group two. Each group can be configured as sink current
mode or source current mode. When channel is configured as sink current mode, the
MDI10 module can accept the dry contact input signal. When channel is configured as
PI type, the frequency of input signal should be in the range of 0~200Hz, and the width
of the pulse should also be no less than 2ms. For PI channel, SOE is not needed .The
module contains a processor board, two acquisition boards specific to the digital input
function, which is mounted on a base specific to the digital input function. The external
resistor is necessary if you need detection of open circuit for digital input. The module
provides the electrical interface between one or two I/O Ethernet networks called IONET
and field input signals.
two 48-pin connectors. The 64-pin connector is used to connect the processor board .
digital input signals are connected directly to the 48-pin connector. Visual diagnostics
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

BDI10 DI base board
MDI10 DI module pin connector
8 digital input &
pulse input
Dual 24VDC
power supply
100M
8 digital input Ethernet A
& pulse input
100M
Ethernet B
DI acquisition board
Figure 2.4-1 16 DI with 24VDC voltage level & PI schematic diagram

The MDI10 DI module is compatible with the DI/PI IO board BDI10 DI base.
2.4.3 Installation
Securely mount the desired base BDI10.
Directly plug one MDI10 DI/PI module into the BDI10 base. On both the BDI10 base
and the DI/PI module, there are keyed connectors to avoid incorrect assembly. One
module. If an attempt is made to plug the MDI10 DI/PI module into the wrong base,
Plug in one or two Ethernet cables depending on the system configuration. The DI/PI
Apply power to the pack by plugging in the connector on the side of the DI/PI
module.
Configure DI/PI module as necessary.

2.4.4 Operation
operation.

2.4.4.2 Digital input and pulse input hardware
The MDI10 accepts digital input signals with 24VDC voltage level and pulse input from
the BDI10 base for all 16 input channels. The input section consists of an EMC interface,
sink/source switch circuit, current limiter circuit and isolation opto-couple for both DI /PI
and open circuit detection.
The following are the explanations of DI/PI circuit.
MDI10 DI module
BDI10 DI base 24VDC BDI10 DI base

board board
(Left) (Right)
Current limiter DI Opto-

220VAC protection
couple
EMC interface/
Processor
Ethernet
1 of 16 DI communication
Open
detection
Opto-
couple
DC/DC
sink/source 24V Power
switch Supply
Figure 2.4-2 MDI10 digital input conditioning circuit diagram

All inputs can be configured as sink current mode or source current mode with different
wiring, depending on the software configuration.
The 16 DI channels are separated into two groups. Each group has eight channels
which have individual DC/DC convertors that power the various components in the DI
conditioning circuit. There is an EMC interface circuit for each one of 16 DI channels,
then conductive interference from field DI signal would be leaked to shield ground on
the BDI10 DI base, in addition, the interference would be leaked to field ground. The
220VAC protection function can protect internal circuitry if a 220VAC signal is accidently
applied to the DI signal terminal.
Through HMI interface, sink current mode or source current mode and SOE function per
channel can be configured for all of 16 channels. Otherwise, there is function circuitry to
detect open circuit if there is an external resistor, when an open circuit happens, the
opto-couple for detecting open circuit will trigger the MDI10 DI module to generate an
alarm report to the HMI via the controller.
The diode bridge circuit is used to form diversified DI path depending on both external
wiring and software configuration.
2.4.4.3 ID line
During power initialization, the MDI10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BDI10. The processor then confirms


The MDI10 includes power management in the 24V input circuit. The management
and working properly, the green PWR indicator will light. The MDI10 module includes

2.4.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

is normal.
OFF.
16 green LEDs labelled CH n indicate the state of DI channel, which can be on when DI
input opto-couple is on, otherwise will be off.
2.4.4.7 Connectors
MDI10 contains the following connectors.
A 64-pin connector on the underside of the MDI10 module connects directly to the
BDI10 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MDI10
module connects directly to the BDI10 base, which includes 16 digital input signals
and dual 24VDC power supply
2.4.5 Specification
Table 2.4-1 MDI10 specification

Item Specification
16 configurable PI/DI channels, DI configured with sink current mode
Number of channel or source current mode per BDI10 base;
DI: 0~30VDC, nominal 24VDC ;
Input signal PI: Signal frequency: 0200Hz The minimum pulse width: 2ms
AC test signal of 500V AC 50/60Hz for 1
Isolation of Input to ground minute while leak current is less than 10mA;
SOE 1ms (No SOE for PI)
2.4.6 Diagnostics

controller. The internal Error LED is solid on.
range or the difference between two IO acquisition boards is over 5C, the IO module
0.125ON and 0.125 OFF.
LED is Solid on.
The digital input hardware also detects open circuit in each scan when external
16~47K ohm resistor is available, which is installed at load end. When a failure
happens, the IO module will send an alarm to the controller which delivering last DI
value before failure to controller.
can be individually latched, and then reset manually after they are restored to proper
function.
2.4.7 Configuration
Table 2.4-2 MDI10 configuration parameters
InputType Select input type for every channel Normal_DI, Used_as _PI
ContactInput Set the channel used or not Unused, Used
SignalInvert Inversion makes signal true if contact is open Invert, Normal
SeqOfEvents Record contact transitions in sequence of events Disable, Enable
Open State Alarm Enabled Set the channel alarm when signal open Disable, Enable
InputType A/B Each board A or B work condition Sink, Source
SignalFilter ms 24~50

2.4.8 Alarms
Table 2.4-3 MDI10 specific alarms
32~47 Input channel[ ] open Open circuit when external resistor is available
48~49 DI acquisition board A,B cfg Type failure
50~51 DI acquisition board A,B voltage Low

2.5 MDO10 16 channels of Digital Output

The MDO10 module is capable of controlling up to 16 channels of digital output to drive
diversified DO base with different relays. In this manual, the BDO10 AC relay base is
used as an example to introduce the MDO10 module. The module contains a processor
board, two acquisition boards specific to the digital output function, which is mounted
on a base specific to the digital output function. The module provides the electrical
interface between one or two I/O Ethernet networks called IONET and field digital output
signals.
Through a 64-pin connector and two 48-pin connectors, modules connect directly with
the associated base, where the 64-pin connector is used to connect the processor
board and the 48-pin connector is used to connect the acquisition board.
On the board, signal wires of 2 Ethernet port from dual RJ45 Ethernet connectors and 4-
pin power supply wires are connected directly to the 64-pin connector, and 4 digital
output signals are connected directly to the terminal from the 48-pin connector. Visual
diagnostics are provided through indicator LED, which are shown as follows,
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

BDO10 DO base board
MDO10 DO module pin connector
4 DO output
Dual 24VDC
power supply
4 DO output
100M
Ethernet A
100M
Ethernet B
4 DO output
DO acquisition board
AC relay AC relay AC relay AC relay
4 DO output AC relay AC relay AC relay AC relay
Figure 2.5-1 16 Digital Output schematic diagram

The MDO10 DO module is compatible with the digital output base BDO10 DO base now.
2.5.3 Installation
Securely mount the desired base BDO10.

Directly plug one MDO10 DO module into the BDO10 base. On both the BDO10 base
and the DO module, there are keyed connectors to avoid incorrect assembly. One
module. If an attempt is made to plug the MDO10 DO module into the wrong base,
Plug in one or two Ethernet cables depending on the system configuration. The DO
Apply power to the pack by plugging in the connector on the side of the DO module.
Configure DO module as necessary.
If there is another type of DO base, the installation is the same as above.
2.5.4 Operation

operation.
2.5.4.2 Digital output hardware

The MDO10 outputs DO control signal to the BDO10 base for all 16 AC relay. The digital
output section consists of a DO output opto-couple, output driver circuit, and channel
state detection circuit and channel state indication.
MDO10 DO module
BDO10 DO base BDO10 DO base

board board
(Left) (Right)
Power DO Opto-
AC relay
driver couple
Processor
Ethernet
1 of 16 DO communication
state
detection Channel
Opto- State LED
couple
High voting 24V Power

Supply
Figure 2.5-2 MDO10 digital output conditioning circuit diagram

The DO output signal controls the power driver circuit through the DO output opto-
couple to drive the AC relay on the BDO10 base. There is a channel state detection
circuit to monitor the proper function of DO output circuit while visual indicator LED is
available.
2.5.4.3 ID line
During power initialization, the MDO10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BDO10. The processor then

The MDO10 includes power management in the 24V input circuit. The management

and working properly, the green PWR indicator will light. The MDO10 module includes

2.5.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

is normal.
OFF.
16 green LEDs labelled CH n indicate the state of DO channel, which can be on when
channel relay is close, else will be off.
2.5.4.7 Connectors
MDO10 contains the following connectors,
A 64-pin connector on the underside of the MDO10 module connects directly to the
BDO10 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MDO10
module connects directly to the BDO10 base, which includes 16 digital output
signals and dual 24VDC power supply
Another type of DO base has the same connectors and pin definition to MDO10.
2.5.5 Specification
Table 2.5-1 MDO10 specification

Item Specification
Number of channel 16 digital output channels
2.5.6 Diagnostics

0.125ON and 0.125 OFF.
LED is Solid on.
When recovery occurs, Tx/Rx LED should shine normally.
Continuous monitoring of proper function of DO channels. When a failure happens,
the IO module will send an alarm to the controller and sets the output to the
preconfigured default of Output-State.
function.
2.5.7 Configuration
Table 2.5-2 MDO10 configuration parameters

RelayOutput Set the channel used or not Unused, Used
SignalInvert Inversion makes relay closed if signal is false Normal, Invert
SeqOfEvents Record relay command transitions in sequence of events Disable, Enable
Output_State When offline with the controller, output the selected value HoldLastValue, Output_Value
Default Output value Default output value for DO is Output-State Off, On
2.5.8 Alarms
Table 2.5-3 MDO10 specific alarms

32~33 External power supply down External power supply down
34~49 DO[] Does Not Match Requested State The Digital Output[] has an error.
160~175 Command is not in use Firmware or communication error

2.6 MVP10 Valve Position Control Module

The MVP10 module is composed of a small servo current output board, an LVDT
feedback acquisition board and a CPU board. The small servo current output board
contains 2 channels of +/-40mA servo current output and 2 channels of 0~5V AO output
and one channel of 220VAC/1A DO output, and LVDT feedback acquisition board is
capable of handling 2 channels of general +/-5V AI input and 2 channels of LVDT input
with 3 wires/4 wires/5 wires/6 wires and 2 channel of dry contact DI input. All of these
three boards are in turn assembled on the special base that is for the valve position
control function.
There are 2 PI regulators running within the module. The servo output card can adjust
output current continuously in scope of 40mA~40mA and there are 2 LVDT processing
circuit within the LVDT acquisition card, then the module can handle two servo valve
position loops. The loop could be configured as two independent.
The module provides the electrical interface between one or two I/O Ethernet networks
called IONET and various kinds of valve position control signals.
Through a narrow 64-pin connector and two wide 64-pin connectors, the module is
connected directly with the associated base. The narrow 64-pin connector is used to
connect the processor board and the two wide 64-pin connectors are used to connect
the acquisition board.
On the base, the signal wire of 2 Ethernet ports comes from dual RJ45 Ethernet
connectors and 4-pin power supply wire are directly connected to 64-pin connector,
and various kinds of valve position control signals are directly connected to 2 wide
connectors with 64-pins. Visual diagnostics are provided through indicator LED, which
are shown as following:
Power
Run
Internal Error
External Error
Net A
Net B
LVDT 1
LVDT 2
Servo 1
Servo 2

BVP10 Valve Position Control Base
Processor board with 64s
2 lvdt input MVP10 VPC Module pin connector
2 AI
2 DI
Dual 24VDC
power supply
2 servo output 100M

2 AO output Ethernet A
1 DO output
100M
Ethernet B
LVDT /AI acquisition Board

with 64 pins connectors
Valve Control +/-40mA Output
Board with 64 pins connectors
Figure 2.6-1 MVP10 Valve Position Control Module with Small Servo Current Output

The MVP10 Valve Position Control module is compatible with BVP10 base.
2.6.3 Installation
Securely mount the desired base BVP10.
Directly plug one MVP10 module into the BVP10 base. On both the BVP10 base and
the MVP10 module, there are keyed connectors to avoid incorrect assembly. One
key accomodates a specific IO module type and another key accomodates a
different IO module. If an attempt is made to plug the MVP10 module into the wrong
base, the connector keys will not match up.
Plug in one or two Ethernet cables depending on the system configuration. The
MVP10 module will operate over either port.
Apply power to the pack by plugging in the connector on the side of the MVP10
module.
Configure MVP10 module as necessary.

2.6.4 Operation
operation.

2.6.4.2 Small current output board
The small servo current output board contains 2 channels of +/-40mA servo current
output and 2 channels of 0~5V AO output and one channel of 220VAC/1A DO output.
BVP10 Valve Valve Control +/-40mA Output Board BVP10 Valve
Position Control Position Control
Base Board Base Board
Short circuit detection
(Left) (Right)
isolation
EMC interface
Large Current
driver block
Processor
2 channels of Ethernet
16 bits
DAC
servo control communication
output
DC/DC
24V Power
Supply
EMC interface
isolation
16 bits
DAC
2 AO
DC/DC
24V Power
Supply
Photo MOS relay
isolation
output
1 DO
voting
High
24V Power
Supply
Figure 2.6-2 Valve Control +/-40mA Output Board
2.6.4.3 LVDT feedback acquisition board

LVDT feedback acquisition board is capable of handling 2 channels of general +/-5V AI
input and 2 channels of LVDT input with 3 wires/4 wires/5 wires/6 wires and 2 channels
of dry contact DI input.

BVP10 Valve LVDT /AI acquisition Board BVP10 Valve
(Left) (Right)
Zero and full scale

LVDT processer
Processor
calibration
2 lvdt Ethernet
isolation
16bits communication
ADC
DC/DC
24V Power
Supply
Open/short circuit
EMC interface
16 bits ADC
mA/V switch
isolation
detection
2 AI
DC/DC
Hysteresis
interface
isolation
Circuit
EMC
2 DI
DC/DC
Figure 2.6-3 LVDT /AI acquisition Board

The LVDT channel can accept 3/4/5/6 wires of LVDT and output DC signal that will be
proportional to the valve position. There is special function circuit for zero and full scale
calibration to calibrate the LVDT input signal in order to increase the resolution and be
compatible with different type/different scale of LVDT sensor.
The AI inputs can be individually configured as 5 V scale signals, depending on the
software configuration. The acquisition board provides a 250ohm burden resistor when
Each one of 2 mA/V channels has individual DC/DC convertor that powers the various
components in the AI conditioning circuit. Through HMI interface, milli Amp or Voltage
can be configured for each one of 2 channels. Otherwise, there is function circuit to
detect open circuit; The MVP10 module will generate an alarm report to the HMI via the
controller when failure happens.

2.6.4.4 ID line
During power initialization, the MVP10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BVP10. The processor then

The MVP10 includes power management in the 24V input circuit. The management
base board failure from propagating back onto the 24V power system. When power is
present and working properly, the green PWR indicator will light. The MVP10 module
includes power monitoring for the dual 24V input. If either 24V power supply fails, the
processor can detect this, and will report an alarm to the HMI via the controller.

2.6.4.7 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

is normal.
Two green LED labelled Tx/Rx A and Tx/Rx B show the status of Ethernet message.
OFF.
2.6.4.8 MVP Status LED

LVDT 1
LVDT 2
Servo 1
Servo 2
Two red LED labelled LVDT1 and LVDT2 show the LVDTs status. The LED shines as
below.
When LVDT open or short circuit, the LED is solid on.
When input voltage of LVDT is overflow or underflow, the LED is solid on.
When LVDT is ok and hasnt above failure, the LED is off.
Two red LED labelled Servo1 and Servo2 Show the status of servo control output
channels. The LED shines as below.
When servo channel is open or short circuit, the LED is solid on.
When servo channel is ok, the LED is off.
2.6.4.9 Connectors
MVP10 contains the following connectors.
A 64-pin connector on the underside of the MVP10 module connect directly to the
BVP10 base, which includes ID signals and dual 24VDC power supply
Two 64-pin connectors for either acquisition board on the underside of the MVP10
module connect directly to the BVP10 base, which includes 2 LVDT signals/2 mA/V
signals/2 DI signals and 2 AO signal/2 servo output signal/1 DO output signal and

2.6.5 Specification
Table 2.6-1 MVP10 specification
Item Specification
Servo control output
Output span Output capacity: +/-40mA
DAC resolution 16 bits DAC convertor
Deliver accuracy Better than 0.2% full scale over the temperature range
AO
Output span 0~5V
Normal scan 20 ms (50 Hz). Note that controller frame rate is
Scan time 50 Hz
Relay output
Number of channel 1 channel
Type NO
Contact capacity 220V/1A
AI signal
Number of channel 2 channels of AI signal
0-5V/1-5V/5V (input impedance 500K ohm)
Input span or 0-20mA/4-20mA per channel
Input converter resolution 16 bit analog to digital converter
Measurement accuracy Better than 0.1% full scale over the temperature range
DI signal
Number of channel 2 channels of DI signal
Input signal 0~30VDC, nominal 24VDC ;
On state Voltage: +15 to +30VDC, Current: 0 to 0.5mA
Off state Voltage: 0VDC to 5VDC, Current: 2.0 to 5.5mA
Frame rate Normal scan 20 ms (50 Hz).
LVDT signal
Number of channel 2 channel of LVDT signal
Input type 3/4/5/6 wires
Normal scan 20 ms (50 Hz).
Scan time Note that controller frame rate is 50 Hz
Power consumption
Heat dissipation
Physical
Size 152.6mm*70.7mm*131.9mm

2.6.6 Diagnostics
When downloaded Configuration parameters dont exist, or board types are
mismatched with each other, or board type is mismatched with firmware, the IO
Module will send an alarm to the controller and the Internal Error LED blinks quickly
with 0.125ON and 0.125 OFF. IO Module stops sending and receiving IONET
exchange data when no configuration parameters exist.
0.125ON and 0.125 OFF.
LED is Solid on.
Ethernet is lost. The corresponding Tx/Rx LED will turn off and stay in OFF status.
For each input of MVP10 module, there is a range checking based on configurable
high and low levels. When failure happens, IO module will send an alarm to
controller while delivers AI value to controller.
MVP10 module also has hardware configuration checking for AI and LVDT channels.
When the AI and LVDT configuration parameters are not same with the HMI, the
module will send an alarm to controller.
There are also detection of open and short circuit in each scan only for 3 wires type
of LVDT channel.
There is detection of open and short circuit in each scan for each servo output of
MVP10.
can be individually latched, and then reset manually if they go healthy.

2.6.7 Configuration
2.6.7.1 Configuration parameters
Table 2.6-2 MVP10 configuration parameters
Parameters
InputFilter Center frequency of Band stop filter 50Hz,60Hz,Unused
Simulation Simulation or not No, Yes
DitherFrequency Dither frequency 2~200
1, 1/2, 1/4, 1/8, 1/16, 1/32,
DitherAmplitude Dither amplitude
1/64, 1/128
AO1_Source AO1 transmit selection LVDT1,LVDT2,AI1,AI2
DI_FilterTime DI debounce time(ms) 3~50
DI_Trip DI trip Enable/Disable Enable, Disable
PI_Redundancy PI redundant or single Redundancy, Single
Closed_Loop, Open_Loop,
Control_Mode PID Control mode
Calibration
High_Sel, Even_Sel,
Fdbk_Mode Feedback voting mode to PI
Single_Sel
Valve_FDBK1 Source choice for Valve1 feedback LVDT1, LVDT2, AI1, AI2
Kp PID proportional coefficient 0~32.768
Ti PID integral coefficient (s) 0~32.768
InputBias Input bias before pi (%) -100~100
I_Dead_Zone Integral Dead zone (%) 0~100
SetValue Set value (%) for Close valve -100~100
Control2_Mode PID Control mode
Calibration
High_Sel, Even_Sel,
Fdbk2_Mode Feedback voting mode to PI2
Single_Sel
Valve2_FDBK1 Source choice for Valve2 feedback LVDT1, LVDT2, AI1, AI2
Kp2 PID proportional coefficient 0~32.768
Ti2 PID integral coefficient (s) 0~32.768
InputBias2 Input bias before pi (%) -100~100
I_Dead_Zone2 Integral Dead zone (%) 0~100
SetValue2 Set value (%) for Close valve -100~100
AI1 Inputs
Unused,
Current_with_power,
InputType Input type
Current_no_power,
Voltage
Low_Value Low actual limit -5~20

Low_Eng_Value Low engineering limit
High_Value High actual limit -5~20
High_Eng_Value High engineering limit
Dead_Band Dead zone of over range
AI2 Inputs
Unused,
Current_with_power,
Current_no_power,
Voltage
LVDT1 Inputs
Three_wires,
Four_wires,
Input_Type Input type Five_wires,
Six_wires,
Unused
ExciteFreq Excite frequence type f, f+l, f+ll, f-l, f-ll
ExciteVoltage LVDT exciting voltage 20Vp,10Vp,5Vp
LVDTDac LVDT signal offset 0~2.5
LVDTAmp LVDT signal amplify 1X, 2X, 4X, 8X
Low_Value Low actual limit 0~2.5
High_Value High actual limit 0~2.5
LVDT2 Inputs
Three_wires,
Four_wires,
Six_wires,
Unused

DI1
InputType Digital Input used or unused Used
SignalInvert Invert signal value for Digital Input Normal, Invert
SeqOfEvents SOE enable or disable Enable, disable
DI2
ServoOutput1
Low_Value Low actual limit -40~40 mA
High_Value High actual limit -40~40 mA
Output_0,
Output_State Output state when offline or failure happens HoldLastValue,
Output_Value
Output_Value Output state when offline or failure happens
ServoOutput2
Output_0,
Output_Value
DO1
Relay_Output Relay output used or unused Used, Unused
SignalInvert Invert Digital output signal value Normal, Invert
Output_0,
Output_value
Output_Value Output state when offline or failure happens On, Off
2.6.7.2 Auto Calibration

Step 1: Configure Control Mode as calibration mode.
Step 2: Right click button on the MVP10 title, the MVP Calibration interface will pop up. In
this interface, engineer can set zero position and full position command to control servo
output for input calibration of AI and LVDT.
Step 3: Upload calibration parameter and apply them, then finish the auto calibration.
Step 4: Download all parameters into module.

2.6.8 Alarms
Table 2.6-3 MVP10 specific alarms

32-33 LVDT channel[] is failed LVDT is short or open circuit or set to be failed by engineer.
36-37 Servo channel[] is open Servo channel[] is open circuit
38-39 Servo channel[] is short Servo channel[] is short circuit
40-41 LVDT channel[] overflow LVDT signal overflow the input range
42-43 AI channel[] overflow AI signal overflow the input range
46-47 LVDT channel[] underflow LVDT signal underflow the input range
48-49 AI channel[] underflow AI signal underflow the input range
52 Configuration LVDT and AI failure Failed to configure type and setting of AI and LVDT.
53 SOE lost because of FIFO buffer full(Single Shot) Because of FIFO buffer full (Single Shot)
54 SOE initial failure Logic configuration fault in FPGA
70 DO channel[] failure Feedback is not same with DO or logic failed
80 No servo type MVPs servo type hasnt been wrote to EEPROM

2.7 MVP11 Valve Position Control Module
The MVP11 module is composed of a large servo current output board, LVDT feedback
acquisition board and CPU board. The large servo current output board contains 2
channels of +/-400mA servo current output and 2 channels of 0~5V AO output and one
channel of 220VAC/1A DO output, and LVDT feedback acquisition board is capable of
handling 2 channels of general +/-5V AI input and 2 channels of LVDT input with 3
wires/4 wires/5 wires/6 wires and 2 channels of dry contact DI input. All of these three
kinds of boards are in turn assembled on the base that is special for the valve position
control function.
There are 2 PI regulators running within the module. The servo output card can adjust
output current continuously in scope of 400mA~400mA and there are 2 LVDT
processing circuit within the LVDT acquisition card, then the module can handle two
servo valve position loops.
The module provides the electrical interface between one or two I/O Ethernet networks
called IONET and various kinds of valve position control signals.
Through a narrow 64-pin connector and two wide 64-pin connectors, module is
connected directly with the associated base. The narrow 64-pins connector is used to
connect the processor board and the two wide 64-pin connectors are used to connect
the acquisition board.
On the base, signal wire of 2 Ethernet port comes from dual RJ45 Ethernet connectors
and 4-pin power supply wire are directly connected to 64-pin connector, and various
kinds of valve position control signals are directly connected to 2 wide connectors with
64-pins. Visual diagnostics are provided through indicator LED, which are shown as
following:
Power
Run
Internal Error
External Failure
Net A
Net B
LVDT 1
LVDT 2
Servo 1
Servo 2

3A pin connector
1A
3B
1B
3C
1C
4A
2 LVDT input 1D
4B
2 AI 1E
4C
24vGnd
2 DI 1F
24VA Dual 24VDC
5A
2A
24VB
power supply
5B
2B
6A 24VGnd
2C
6B
2D
2E
2F
1 100M
9A Ethernet A
7A
9B
7B
10A
2 Servo output 7C
10B 100M
2 AO 7D
Ethernet B
1 DO 8A
8B
8C
8D
11A
11B
11C
11D
Figure 2.7-1 MVP11 Valve Position Control Module with Large Servo Current Output

The MVP11 Valve Position Control module is compatible with BVP10 base.
2.7.3 Installation
Securely mount the desired base BVP10.
Directly plug one MVP11 module into the BVP10 base. On both the BVP10 base and
the MVP11 module, there are keyed connectors to avoid incorrect assembly. One
key accomodates a specific IO module type and another key accomodates a
different IO module. If an attempt is made to plug the MVP11 module into the wrong
base, the connector keys will not match up.
MVP11 module will operate over either port.
Apply power to the pack by plugging in the connector on the side of the MVP11
module.
Configure MVP11 module as necessary.

2.7.4 Operation
operation.

2.7.4.2 Large current output board
The large servo current output board contains 2 channels of +/-400mA servo current
output and 2 channels of 0~5V AO output and one channel of 220VAC/1A DO output.
BVP10 Valve Valve Control +/-400mA Output BVP10 Valve

Position Control Board Position Control
Base Board Short/open circuit Base Board
(Left) detection (Right)
isolation
EMC interface
Large Current
driver block
Processor
2 channels of Ethernet
16 bits
DAC
servo control communication
output
DC/DC
24V Power 24V Power
PWM
Supply Supply
EMC interface
isolation
16 bits
DAC
2 AO
DC/DC
24V Power
Supply
Photo MOS relay
isolation
output
1 DO
voting
High
24V Power
Supply
Figure 2.7-2 Valve Control +/-400mA Output Board
2.7.4.3 Input (2LVDTs/2AI/2DI) board

LVDT feedback acquisition board is capable of handling 2 channels of general +/-5V AI
input and 2 channels of LVDT input with 3 wires/4 wires/5 wires/6 wires and 2 channels
of dry contact DI input.

BVP10 Valve LVDT /AI acquisition Board BVP10 Valve
(Left) (Right)
Zero and full scale

LVDT processer
Processor
calibration
2 lvdt Ethernet
isolation
16bits communication
ADC
DC/DC
24V Power
Supply
Open/short circuit
EMC interface
16 bits ADC
mA/V switch
isolation
detection
2 AI
DC/DC
Hysteresis
interface
isolation
Circuit
EMC
2 DI
DC/DC
Figure 2.7-3 LVDT /AI acquisition Board

The LVDT channel can accept 3/4/5/6 wires of LVDT and output DC signal that will be
proportional to the valve position. There is special function circuit for zero and full scale
calibration to calibrate the LVDT input signal in order to increase the resolution and be
compatible with different type/different scale of LVDT sensor.
The AI inputs can be individually configured as 5 V scale signals, depending on the
software configuration. The acquisition board provides a 250 burden resistor when
Each one of 2 mA/V channels has individual DC/DC convertor that powers the various
components in the AI conditioning circuit. Through HMI interface, milli Amp or Voltage
can be configured for each one of 2 channels. Otherwise, there is function circuit to
detect open circuit; MVP11 module will generate an alarm report to the HMI via the
controller when failure happens.

2.7.4.4 ID line
During power initialization, the MVP11 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BVP10. The processor then

The MVP11 includes power management in the 24V input circuit. The management
base board failure from propagating back onto the 24V power system. When power is
present and working properly, the green PWR indicator will light. The MVP11 module
includes power monitoring for the dual 24V input. If either 24V power supply fails, the
processor can detect this, and will report an alarm to the HMI via the controller.

2.7.4.7 Status LED

Power
Run
Internal Error
External Failure
Tx/Rx A
Tx/Rx B

is normal.
OFF.
2.7.4.8 MVP Status LED

LVDT 1
LVDT 2
Servo 1
Servo 2
Two red LED labelled LVDT1 and LVDT2 show the LVDTs status. The LED shine as below.
When LVDT open or short circuit, the LED is solid on.
When input voltage of LVDT is overflow or underflow, the LED will be lit
When LVDT is ok and hasnt above failure, the LED will be off.
Two red LED labelled Servo1 and Servo2 Show the status of servo control output
channels. The LED shines as below.
When servo channel is open or short circuit, the LED will be lit When servo channel
is ok, the LED will be off.
2.7.4.9 Connectors
MVP11 contains the following connectors,
A 64-pin connector on the underside of the MVP11 module connects directly to the
BVP10 base, which includes ID signals and dual 24VDC power supply
Two 64-pin connectors for either acquisition board on the underside of the MVP11
module connects directly to the BVP10 base, which includes 2 LVDT signals/2 mA/V
signals/2 DI signals and 2 AO signal/2 servo output signal/1 DO output signal and

2.7.5 Specification
Table 2.7-1 MVP11 specification
Item Specification
Output span Output capacity: +/-400mA
AO
Output span 0~5V
Relay output
Type NO
AI signal
Measurement accuracy Better than 0.1% full scale over the temperature range
DI signal
LVDT signal
Power consumption
Heat dissipation
Physical
Size 152.6mm*70.7mm*131.9mm

2.7.6 Diagnostics
When downloaded Configuration parameters dont exist, or board types are
mismatched with each other, or board type is mismatched with firmware, the IO
Module will send an alarm to the controller and the Internal Error LED blinks quickly
with 0.125ON and 0.125 OFF. IO Module stops sending and receiving IONET
exchange data when no configuration parameters exist.
0.125ON and 0.125 OFF.
LED is Solid on.
Ethernet is lost. The corresponding Tx/Rx LED will turn off and stay in OFF status.
For each input of MVP11 module, there is a range checking based on configurable
high and low levels. When failure happens, IO module will send an alarm to
controller while delivers AI value to controller.
MVP11 module also has hardware configuration checking for AI and LVDT channels.
When the AI and LVDT configuration parameters are not same with the HMI, the
module will send an alarm to controller.
There is also a function to detect open and short circuit in each scan only for a 3-
wire design LVDT channel.
There is a function to detect open and short circuit in each scan for each servo
output of MVP11.
can be individually latched, and then reset manually if they go healthy.

2.7.7 Configuration
Table 2.7-2 MVP11 configuration parameters
Parameters
InputFilter Center frequency of Band stop filter 50Hz,60Hz,Unused
Simulation Simulation or not No, Yes
DitherFrequency Dither frequency 2~200
1, 1/2, 1/4, 1/8, 1/16, 1/32,
DitherAmplitude Dither amplitude
1/64, 1/128
DI_FilterTime DI debounce time(ms) 3~50
DI_Trip DI trip Enable/Disable Enable, Disable
PI_Redundancy PI redundant or single Redundancy, Single
Control_Mode PID Control mode
Calibration
High_Sel, Even_Sel,
Fdbk_Mode Feedback voting mode to PI
Single_Sel
Kp PID proportional coefficient 0~32.768
Ti PID integral coefficient (s) 0~32.768
InputBias Input bias before pi (%) -100~100
I_Dead_Zone Integral Dead zone (%) 0~100
SetValue Set value (%) for Close valve -100~100
Control2_Mode PID Control mode
Calibration
High_Sel, Even_Sel,
Fdbk2_Mode Feedback voting mode to PI2
Single_Sel
Kp2 PID proportional coefficient 0~32.768
Ti2 PID integral coefficient (s) 0~32.768
InputBias2 Input bias before pi (%) -100~100
I_Dead_Zone2 Integral Dead zone (%) 0~100
SetValue2 Set value (%) for Close valve -100~100
AI1 Inputs
Unused,
Current_with_power,
Current_no_power,
Voltage

AI2 Inputs
Unused,
Current_with_power,
Current_no_power,
Voltage
LVDT1 Inputs
Three_wires,
Four_wires,
Six_wires,
Unused
LVDT2 Inputs
Three_wires,
Four_wires,
Six_wires,
Unused

DI1
DI2
ServoOutput1
Output_0,
Output_Value
ServoOutput2
Output_0,
Output_Value
DO1
Relay_Output Relay output used or unused Used, Unused
SignalInvert Invert Digital output signal value Normal, Invert
Output_0,
Output_value
Output_Value Output state when offline or failure happens On, Off
2.7.7.2 Auto Calibration

Step 1: Configure Control Mode as calibration mode.
Step 2: Right button on the MVP11 title, the MVP Calibration interface will pop up. In this
interface, engineer can set zero position and full position command to control servo
output for input calibration of AI and LVDT.
Step 3: Upload calibration parameter and apply them, then finish the auto calibration.
Step 4: Download all parameters into module.

2.7.8 Alarms
Table 2.7-3 MVP11 specific alarms

32-33 LVDT channel[] is failed LVDT is short or open circuit or set to be failed by
engineer.
36-37 Servo channel[] is open Servo channel[] is open circuit
38-39 Servo channel[] is short Servo channel[] is short circuit
40-41 LVDT channel[] overflow LVDT signal overflow the input range
42-43 AI channel[] overflow AI signal overflow the input range
46-47 LVDT channel[] underflow LVDT signal underflow the input range
48-49 AI channel[] underflow AI signal underflow the input range
52 Configuration LVDT and AI failure Failed to configure type and setting of AI and LVDT.
53 SOE lost because of FIFO buffer full(Single Shot) Because of FIFO buffer full (Single Shot)
54 SOE initial failure Logic configuration fault in FPGA
70 DO channel[] failure Feedback is not same with DO or logic failed
80 No servo type MVPs servo type hasnt been wrote to EEPROM

2.8 MSP10 Speed Measurement and Protection Module

The MSP10 I/O module is capable of handling the following channels:
2 channels of mA/V analog inputs, each one of which can be configured as 0~5 V
inputs, or 0~20 mA current loop inputs. They are used for analog signal acquisition
in Load Dump Protection (LDP) function.
1 speed (frequency) input that can accept various types of frequency signal
generated from different speed pickup sensors, for example sine or square wave
signal with voltage range from 40 mV up to 150V and frequency receivable range is
up to 20 kHz. Simultaneously, this signal is transferred as pulse output to supply
speed output for other system. This channel is also forwarded to 3rd monitor.
7 digital inputs with 24VDC operation voltage, some of them are utilized as turbine
critical digital input signals such as system latch -- ASL, and Breaker on status BR,
which is used in module logic.
4 digital outputs. They are drove by module on board logic and cant be controlled
by upper controller. In the logic, channel 1 and 3 are defined as the OPC output and
channel 2 and 4 are defined as the AST output. Two outputs (channel 3 and 4) of
which are for internal use that are usually connected to system simulator. Another
two channels (channel 1 and 2) are connected to relay expanding module through a
9-Pin D.
There is 1 normal closed relay contact output, which can be configured by upper
controller as OPC signal or AST signal.
There are two operation modes for MSP module - Normal and Simulation. In Normal
mode, the speed and analog signals come from terminal on base while in
Simulation mode these signals come from simulator interface - 50-Pin D-sub
connector on base.
The module contains a processor board and two acquisition boards. The I/O channels
stated above are located on two acquisition boards, which are mounted on a base
board (BSP10). The load terminal resistors for current loop inputs are located on the
acquisition board and voltage is sensed across these resistors.
On base board (BSP10), the signal wires of 2 Ethernet ports from dual RJ45 Ethernet
connectors and 4-pin power supply wires are connected directly to 64-pin connector,
and I/O input signals are connected directly to 64-pin I/O connector.

BSP10 SDP base board ETS relay module D-sub interface
2 digital Output
2 analog input with mA/V
1 wheel speed input/output MSP10 SDP Module
7 digital input
1 relay contact NC output
Dual 24VDC
power supply

pin connector
100M
Emulator D-sub Ethernet A
interface
100M
Ethernet B
I/O acquisition board

Figure 2.8-1 MSP10 Speed Measure and Protection Module schematic diagram
Visual diagnostics are provided through indicator LED, which are shown as follows.
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
LEDs labelled with 1~8 are corresponding to the following status,
1 - ASL
2 - BR
3 - OPC
4 - AST
5 - Relay output
6 - OPC readback
7 - AST readback
8 - Emulator actived

2.8.1.1 LDP function overview
Over speed is very harmful for rotation machinery. Load rejection is most common
cause of over speed for turbine-generator. Its important for a turbine control system to
predict the over speed and take action in advance. In general, when load rejection
occurs, Megawatt will go to zero immediately versus relatively slow decreasing for
turbine Intermediate exhaust pressure, so there will be a deviation between them, from
the deviation value, unbalance will be detected between turbine load and generator
load at the moment of load rejection. LDP function uses this principle to predict the
possible speed overshoot.
Load dump Protection (LDP), is one of the ways to restrain the possible speed overshoot
at the moment of load rejection, LDP function is integrated in MSP10 module, thus it can
be implemented within 20ms. Signals involving LDP consist of the following:
WS : Turbine wheel speed
MW : Megawatt , which reflect the generator load
IEP : Intermediate exhaust pressure
OPC : Over speed protection
WS, MW, IEP are input signals, and OPC is an output signal.
Each MSP10 acquires WS/MW/IEP signals and output one channel of OPC independently,
In DEH system, TMR configuration of MSP10 is used to complete the speed
measurement and protection, with each module independently outputting the OPC
signal, and three MSP10 modules outputting three OPC signals to the ETS relay module
for 2 of 3 voting, SDP frame is illustrated below.

24 Terminals
ASL1
BR1
9 Pin
WS1
D-SUB M MW1
S IEP1
AST1 / OPC1
P 5 x DI
25 Pin D-SUB
For Emulator
ASL2
BR2
9 Pin
WS2
D-SUB
M MW2
S IEP2
AST2 / OPC2
P 5 x DI
25 Pin D-SUB
1 OPC For Emulator
ASL3
1 AST 9 Pin BR3
D-SUB
M WS3
MW3
1 OPC S IEP3
AST3 / OPC3
1 AST P 5 x DI
1 OPC 25 Pin D-SUB
1 AST For Emulator
OPC1
OPC2
E OPC3
T
S AST1
25 Pin Relay AST2
D-SUB AST3
Figure 2.8-2 SDP system frame
2.8.1.2 The LDP function

The LDP function has three input channels, they are intermediate exhaust pressure (IEP),
megawatt (MW) and wheel speed (WS).
First, the input of IEP and MW are transformed to the range 0%-100% in full scale. The
formula is:
IEP = (IEP IEPz) / (IEPr - IEPz)
Where: IEPr - rated value, IEPz - zero value
And,
MW = (MW MWz) / (MWr - MWz)
Where: MWr - rated value, MWz - zero value
Second, the deviation value of (IEP-MW) is transformed to the range 0%-100%
according to below formula.
LDP = ((IEP-MW) LDP1) / (LDP1-LDP0)
Where: LDP0 and LDP1 can be configured by the engineer.
In the above figure, the result of LDP will contribution to the LDP generation.
The WS is transformed in the formula.

WS = (WS - 3000) / (OPCSP1 - 3000)
The default value of OPCSP1 is 105% of rated speed. Then, the result WS is added to the
LDP.
Finally, we can get a sum value (LDP+WS) and compare it with the over-limit value
presetted in FPGA. The high limitation is 100% and the returnable limitation is 99%.
When the sum exceeds the high level, a state 1 is output and when the sum is under the
low level, a state 0 appears.
LDP function can be configured as enable or disable. After you make sure there is no
interference with the analog inputs of MSP10 module, the LDP function can be enabled.
Load Dump Protection schematic is shown below.
Figure 2.8-3 Load Dump Protection schematic

The state of over-limit detection function is not changed until all three conditions are
met. The LDP function runs once per 3 ms. The whole function takes less than 10ms. The
transient deviation of analog value input is used as one part of the LDP function.

MSP10 Module is compatible with the Speed Measure and Protection base (BSP10)
2.8.3 Installation
Securely mount the desired base BSP10.
Directly plug one MSP10 module into the BSP10 base. On both the BSP10 base and
the IO module, there are keyed connectors to avoid incorrect assembly. One key
accomodates the IO module type and another key accomodates a different IO
module. If an attempt is made to plug the MSP10 module into the wrong base, the
connector keys will not match up.

MSP10 module will operate over either port.
Apply power to the pack by plugging in the connector on the side of the MSP10
module.
Configure MSP10 module as necessary.
2.8.4 Operation

detected. The Ethernet ports on the processor run at 100 MB/s speed on full-duplex
operation mode.

The MSP10 accepts milli Amp or voltage signals from the BSP10 base for all 2 AI input
channels. The analog input section consists of an EMC interface, mA/V switch circuit,
open/short circuit detection, and an AD converter. The AI channel schematic is below:
MSP10 AI channel
BSP10 base
board
(Left) Emulator
interface
Open/short circuit
EMC protection
mA/V switch
Analog to
Processor
interface/
isolation
detection
Digital
1 of 2 mA/V Convertor
16 bit
DC/DC
Figure 2.8-4 MSP10 digital input conditioning circuit diagram

The inputs can be individually configured as 0~5 V or 0~20mA scale signals, depending
on the software configuration. The acquisition board provides a 250 burden resistor
when configured for current inputs yielding a 5 V signal at 20 mA.
Each channel has individual DC/DC convertor to power the various components in the AI
conditioning circuit. There is an EMC interface circuit for each AI channel, then
conductive interference from field would be leaked to shield ground on BSP10 base,
then the interference would be leaked to field ground.
Through HMI interface, milli Amp or Voltage can be configured for each one of 2
channels. Otherwise, there is function circuit to detect open or short circuit; MSP10
module will generate an alarm report to the HMI via the controller.
2.8.4.3 Wheel Speed channel

There are two main functions in the speed channel, one is speed measure, and another
one is Speed Sensor failure Detect.
There may be three types of speed signal input to the speed channel. The circuit will
convert them to TTL signal, and output to CPU card. FPGA on the CPU board will

calculate the frequency of the TTL signal to determine the rotation speed. Different
speed sensors will send different kinds of speed signals. The speed channel can accept
various kinds of speed pick up including magnetic, proximate or Hall speed pick up.
The speed channel can send an alarm to the CPU when there is something wrong with
the speed sensor. But you must set the speed sensor type first, and then acquire the
feedback voltage across the sensor resistance by AD convertor, or monitor the feedback
signal DC voltage via AD convertor. When the voltage is over limit, it indicates the speed
sensor is in failure.
There is also an internal transferred signal output from wheel speed channel to system
Simulator interface that is a 25 pin D sub connector.
The WS channel schematic as below:
Amplify
B uffed output
Rem ove
Amplify
DC from
ws
signal
FPG A Logic
R +/-15V DC
W heel speed
signal sensor O pen & Short
circuit ADC
detection
Figure 2.8-5 Wheel speed channel schematic
2.8.4.4 DI channel
The DI Channel has one TVS with Peak Power Dissipation up to 600W to eliminate the
surge pulse. The comparator, MOSFET and three resistors build up the hysteresis circuit.
The high and low hysteresis voltage is set at 15V and 5V. Photo-couple is applied for
isolation between DI channel & CPU card. DI is powered by a DC to DC converter. The
figure below shows the Digital Input Channel.
24V
FPGA Logic
Figure 2.8-6 Digital Input Channel schematic

Input voltage: 0 to +30VDC, +24VDC nominal, source current
On state voltage: +15 to +30VDC, current: 0 to 0.5mA
Off state voltage: 0VDC to 5VDC, current: 2.0 to 5.5mA
24VDC short circuit protection
2.8.4.5 DO channel
The DO circuit is shown below, The DO signal from the CPU board drives the photo-mos.
The Inverter provides enough power to drive the photo-mos.
Also the Cable Broken Detection Circuit is shown below. There is a diagnostic circuit to
detect 5V power supply for detection of broken cable, 5V power supply failure or the
Cable transpose. The diagnostic result will be feedback to CPU board and can be
indicated by a LED indicator.
The DO channel schematic is below:
24V
FPGA
Logic
readback
Figure 2.8-7 Digital output Channel schematic
2.8.4.6 Alarm output channel for losing system power supply

There are alarm output channels to indicate loss of system power supply. The output is
a normal closed signal. When system 24VDC power supply is lost, the output channels
contactor is closed. The schematic is below.
24V
FPGA
Logic
readback
Figure 2.8-8 Power fail alarm schematic

2.8.4.7 Switch for Simulation signal and field signal
The actual field signal and simulation signal can be switched internally for analog input
channel and wheel speed input channel. When MSP10 is in simulation model while
simulation connector is connected with Simulator, the simulation signal that includes
analog and wheel speed is routed to input channel.
2.8.4.8 ID line
During power initialization, the MSP10 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BSP10. The processor then confirms

The MSP10 includes power management in the 24V input circuit. The management
and working properly, the green PWR indicator will light. The MSP10 module includes

2.8.4.11 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B

information. The LED shines as below.
is normal.
Two green LED labelled Tx/Rx A and Tx/Rx B show the status of Ethernet messages.
OFF.
2.8.4.12 MSP Status LED

1 - ASL
2 - BR
3 - OPC
4 - AST
5 - Relay output
6 - OPC readback
7 - AST readback
8 - Emulator actived
A green LED labelled ASL shows the state of ASL signal, on state means there is ASL
signal, off state means there is no ASL signal.
A green LED labelled BR shows the state of BR signal, on state means there is BR signal,
off state means there is no BR signal.
A green LED labelled OPC shows the state of OPC output signal, on state means there
is OPC trip output, off state means there is no OPC trip output.
A green LED labelled AST shows the state of AST output signal, on state means there is
AST trip output, off state means there is no AST trip output.
A green LED labelled Relay shows the state of alarm output for loss of power supply,
on state means there is a power supply problem, off state means power supply is fine.
A red LED labelled OPC shows the state of cable connection for OPC channel; on state
means cable for OPC connection is broken, off state means it is good.

A red LED labelled AST shows the state of cable connection for AST channel; on state
means cable for AST connection is broken, off state means connection is good.
A red LED labelled simulator indicates the simulation mode, off state means the
module is in simulation mode and off state means the module is in normal mode.
2.8.4.13 Connectors
MSP10 contains following connectors,
A 64-pin connector on the underside of the MSP10 module connects directly to the
BSP10 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MSP10
module connect directly to the BSP10 base
2.8.5 Specification
Table 2.8-1 MSP10 specification

Item Specification
AI signal
Input span 0-5V(input impedance 500K ohm) or 0-20mA per channel
Measurement accuracy Better than 0.1% full scale over the temperature range -30 to 65C
WS signal
Number of channel 1 channel of WS signal
40mV~110V, sine wave/triangle wave/square wave, or TTL signal
Input span 0~20kHz
Measuring time Less than 10ms at 3kHz
Measurement accuracy 0.1rpm in 1000~8000rpm , 0.5rpm for in 0.5~20K rpm
DI signal
DO signal
Number of channel 4 DO channels , to simulator and relay expanding
Frame rate 20ms (50Hz)
optic-couple drive
passive output
Characteristics Channel 0 and 1 have output state detection
Relay output

Number of channel 1 channel for terminal block output
Type NC
Contact capacity AC250V 1.5A, DC 30V 1.5A
WS output signal
Number of channel 1 channel , to simulator
Type square wave, 24VDC, 0~20kHz

Physical
Size(L*W*H) 152.6mm*70.7mm*131.9mm
Technology Surface mount
2.8.6 Diagnostics
0.125ON and 0.125 OFF.
LED is Solid on.
There is continuous monitoring of connection cable status for external relay
extended module. When there is no cable or cable is broken, the IO module will send
an alarm to the controller which the red indicator OPC or AST is solid on.
When analog input is voltage signal and there is no cable or cable is broken, the IO
module will send an alarm to the controller.
When the speed sensor fails, the IO module will send an alarm to the controller.

can be individually latched, and then reset manually if they are rectified.
2.8.7 Configuration
Table 2.8-2 MSP10 configuration parameters

Parameter Description Default value
Parameters
IEPz Zero value of Intermediate Exhaust Pressure 1
IEPR Rated value of IEP 5
MWz Zero value of Megawatt (generator power) 1
MWR Rated value of Megawatt (generator power) 5
LDP_L Low limitation of set value for Load rejection protection 30
LDP_H High limitation of set value for Load rejection protection 60
OPCSP Set value (rpm) for OPC103% trip, is used before breaker on 3090
OPC_hysteresis Set value (rpm) for OPC103% hysteresis 5
OPC_LDP Set value (rpm) for LDA overspeed protection 3150
ASTSP Set value (rpm) for AST 110% trip 3300
MEHOSSP1 Set value 1 (rpm) for MEH overspeed protection 6300
MEHOSSP2 Set value 2 (rpm) for MEH overspeed protection 6600
LDA_DT Load dump protection holding time (s) 2
LDP_EN Load dump protection enable, 1=enable Enable
ACC_EN Enable for Acceleration protection Enable
WSF_EN Enable for Whirl speed failure protection Enable
OPC_REV Reverse the OPC output signal Normal
AST_REV Reverse the AST output signal Normal
MODE Configuration to choose DEH or MEH mode DEH
COMFAIL_EN Enable trip for Comm failure Enable
DO_MODE Configure the DO output mode of either OPC or AST OPC
DI_DT DI debounce time (ms) 3
ACCSP Set value (rpm/s) for Speed Acceleration protection 750
Configuration for choosing AI input filter frequency.50Hz,
InputFilter 50Hz
60Hz, Unused.
DI
DIREV Reverse DI signal or normal Normal
SeqOfEvents SOE enable or disable Enable
WS
Teeth Teeth number of turbine 60
Probe_DC Speed probe type, Mag or Prox mag

Enable alarm under low limitation for detection voltage of
DiagLowEn Disable
Speed probe loop
Enable alarm over high limitation for detection voltage of
DiagHighEn Disable
Speed probe loop
LLA Low limitation for detection voltage of Speed probe loop 0
HLA high limitation for detection voltage of Speed probe loop 0.6
DeadZone Dead zone for detection voltage of Speed probe loop 0.1
IEP/MW
(0-20mA)+pwr, 0-20mA,
InputType The type of AI signal
0-5V, Unused
Low_Value Low value for AI electric signal
High_Value high value for AI electric signal
Low_Eng_Value Low value for AI engineering signal
High_Eng_Value high value for AI engineering signal
2.8.7.2 OPC and AST trip conditions

Table 2.8-3 OPC and AST trip condition in DEH system
Condition Description OPC AST
WS sensor failure (Open/short circuit) Y Y
Zero speed detection (Set/Reset) Y Y
Acceleration and Deceleration Y Y
Two Network failure Configurable Configurable
CPU failure (Detected by FPGA) Include ROM/RAM/(100ms) Y Y
LDA (10ms) (BR, IMP>30%) Y N
LDP (50ms) (IMP-MW>30%) Y N
WS > 103% Y N
WS > 110% N Y
WS > 6300 Y N
WS > 6600 N Y
2.8.8 Alarms
Table 2.8-4 MSP10 specific alarms
48 AI0 (IEP) cable break Cable break
49 AI1 (MW) cable break Cable break
50 DO0 (OPC) cable break Cable break
50 DO1 (AST) cable break Cable break
53 Lost SOE record Because of fifo buffer full (Single Shot)
54 SOE init fault, Logic configuration fault in FPGA
60 hw configuration fault Logic configuration fault in FPGA
61 SDP logic configuration Logic configuration fault in FPGA
65 Write the over limit module fault Logic configuration fault in FPGA
66 Write the over speed module Logic configuration fault in FPGA
67 High level limit alarm of AI0 (IEP) Analog input is above the high level limit
68 low level limit alarm of AI0(IEP) Analog input is below the low level limit
69 High level limit alarm of AI1 (MW) Analog input is above the high level limit
70 low level limit alarm of AI1(MW) Analog input is below the low level limit
71 WS sensor fail WS sensor type is wrong or cable break


2.9 TMR 2oo3 Voting & Extension Relay Module

The TMR relay module (part number 178778) has the same mechanical structure as
other I/O modules; the difference is there is no CPU board in this module and no
communication to the controller. Refer to following figure 2.9-1. The yellow label just
indicates this module is usually used in safety related applications.
This module could be used in both turbine control system (DEH) and emergency trip
system (3701 ETS). It receives the contact outputs from the TMR 3701 ETS units or DEH
systems 3 independent speed measurement modules via the output-to-relay cable,
performs 2-out-of-3 voting, and provides the contacts to drive trip solenoids. The TMR
relay module provides six output contacts. These contacts are dry contacts, and the
system should supply an external voltage from the solenoids. The terminal blocks allow
the solenoids to receive their power directly through the contacts, or allow the contacts
to simply complete the circuit. Additionally, the TMR relay module provides alarm
contacts to indicate if its own +24V supply or the solenoid voltage has failed.
Figure 2.9-1 TMR Relay Module

The unit can individually operate the contacts for each channel in a de-energize to trip
mode or an energize to trip mode, which is controlled via DIP switches for each
channel. The system application engineer (the designer) must determine this operating
mode based on the safe working condition of the real system and make sure the DIP

switches are set correctly based on the designed operating mode before the system is
initiated.
2.9.2 Wiring Diagram

All solenoid connections are made at terminal blocks. The pins have been laid out in
such a fashion that the solenoid voltages may be brought into the module, or soldered
externally. Refer to figure 2.9-2 for outputs 1 through 4.
Figure 2.9-2 Relay Terminal Block

The six outputs are labelled OUT 1 to OUT 6, and each output has a + and a
connection for the contact. The terminal blocks also provide power inputs for the
solenoid power. If your installation will provide external power for the solenoids, simply
connect the PWR IN so that the relay module can monitor the voltage. If you will not
provide external power for the solenoids, then after connecting the PWR IN, simply
jumper it to the contact + and - pins. The two rows of terminal connections simplify
connections. For example, you can connect the power and contacts on the bottom row,
then on the top row, make the jumper connections between PWR IN and OUT N if
you will supply the solenoid power through the contacts.
Table 2.9-1 Summary of Relay Terminal Block Pins
Pin Description
High-Voltage or solenoid power is connected here. The polarity does not matter, the +/-
PWR IN designations can be used for consistency.
Max voltage: 220Vac, 125Vdc
These are the output contacts for the solenoids. The polarity does not matter, but if the
solenoid requires a certain polarity, the +/- designation can be used for consistency.
Furthermore, if PWR IN is jumpered to the contact output, this can be used for
OUT X
consistency here as well.
Maximum Voltage: 220Vac, 125Vdc
Maximum Current: 3 Amps
Two terminals for 24V alarm contact. Open circuit indicates alarm if either supply drops
below 18Vdc.
24V ALRM
Maximum Voltage: 30 Vac/dc
Maximum Current: 250 mAmps
Two terminals for high-voltage alarm. Open circuit indicates alarm.
ALRM Maximum Voltage: 30 Vac/dc
Maximum Current: 250 mAmps

Figure 2.9-3 shows the power and contacts for outputs 5 and 6, as well as the alarm
contacts. You can see there are two terminals for the 24V alarm, and two terminals for
the solenoid (high) voltage alarm. These alarm contacts are always de-energize to trip,
and are closed during normal operation. An open indicates an alarm.
Figure 2.9-3 Relay Terminal Block (continued)

A common configuration for trip applications is a two-out-of-three trip block, with
contacts on both sides of the solenoid. An example in figure 2.9-4 illustrates one of the
three solenoids. HV indicates high voltage, and is the voltage required to activate the
solenoid. Two contacts are placed in series for redundancy around the solenoid. In the
wiring diagram, you can see how the high voltage supply is connected to the PWR_IN-
terminal, which is jumped to OUT1-. OUT1+ is then connected to one side of the solenoid.
The other side of the solenoid is connected to OUT2-. Note that OUT2+ is jumped to the
PWR_IN+ terminal. This same wiring process would be repeated for solenoid 2 (using
OUT3 and OUT4) and solenoid 3 (using OUT5 and OUT6). You can see how the duplicate
terminal blocks (same connections on both upper and lower blocks) allow for simple
jumping, clean wiring and added reliability because only one wire per terminal is
required.

Figure 2.9-4 2oo3 Output Solenoid Wiring Example
2.9.3 DIP Switches

The TMR Relay module provides six DIP switches that are located next to the terminal
blocks. You use these switches to configure the function of each channel for energize
to trip or de-energize to trip. Figure 2.9-5 shows the DIP switches. The switch should
be in the OFF position for de-energize to trip mode, and in the ON position for
energize to trip mode.
Figure 2.9-5 DIP Switches
Table 2.9-2 TMR Relay Module DIP Switch Functions

Switch Position Channel Function
OFF De-energize to trip
ON Energize to trip

2.9.4 Specification
Table 2.9-3 TMR Relay Module specification

Item Specification
6 channels 2oo3 voting DO with 24 - 250VAC, 24 - 125VDC/3A
Number of channel 2 channels 24VDC 250mA alarm DO
Output Mode Energize or De-energize to trip configurable
24VDC Power supply 24VDC 5%
Physical Size(L*W*H) 351.9mm*127mm*60.9mm
Temperature 0 to 65C (+32 to +149 F)

2.10 MAI12 Analog Input with 16 channels of mA/V

The MAI12 module is capable of handling up to 16 mA/V analog inputs. Each one can be
configured as 10 V inputs, 0-20 mA current, or 0-20 mA current with power out inputs.
The module contains a processor board, two acquisition boards specific to the mA/V
analog input function, which are mounted on a base specific to the analog input
function. The load terminal resistors for current loop inputs are located on the
acquisition board and voltage is sensed across these resistors. The module provides the
electrical interface between one or two I/O Ethernet networks called IONET and field
are provided through indicator LED, as follows:
Power
Run
Internal Error
External Failure
Tx/Rx A
Tx/Rx B
BAI11 AI base board Processor board with 64
9A
pin connector
1A
9B
1B
9C
1C
8 analog input 10A
with m A/V 2A
10B
2B
10C
X 24V G ND Internal &
2C
11A X 24V External
3A
24V
24V DC
11B
3B
24V GN D
power supply
11C
3C
12A
4A
12B
4B
12C
4C
1 100M
13A Ethernet A
5A
13B
5B
13C
5C
14A 100M
8 analog input 6A
Ethernet B
14B
with m A/V 6B
14C
6C
15A
7A
15B
7B
15C AI acquisition board
7C
16A
8A
16B
8B
16C
8C
Figure 2.10-1 16 Analog Input with mA/V schematic diagram

The MAI12 AI module is compatible with the analog Input baseboard BAI11 AI
baseboard.
2.10.3 Installation
accommodates a specific IO module type and another key accomodates a different
2.10.4 Operation
Processor subsystem
Local power supply decoupled from dual power supplies in system, including
monitoring function
Independent system power supply and IO power supply
Ability to download the bootloader through RS232 ports
function, by the connector on the topside of processor board, and connects to the base

operation.
Analog input hardware
The MAI12 detects Amp or voltage signals from the BAI11 base for all 16 input channels.
The analog input section consists of an EMC interface, mA/V switch circuit, open/short
circuit detection, several gain and scaling selections, and a 16-bit analog-to-digital
converter (ADC).
MAI11 AI module

board board
(Left) (Right)
Open/short circuit
EMC interface
Analog
mA/V switch
Processor
isolation
detection
to Digital Ethernet
1 of 16 mA/V Converto communication
r
16 bit
DC/DC
24V Power
Supply
Figure 2.10-2 MAI12 mA/V conditioning circuit diagram
The inputs can be individually configured as 10 V scale signals, depending on the

software configuration. The acquisition board provides a 250 load resistor when
There are four groups of input channels. Each group shares individual ADC and DC/DC
convertors that power the various components in the AI conditioning circuit. There is an
EMC interface circuit for each one of 16 mA/V channels. Any conductive interference

from field mA/V signal would be leaked to shield ground on the BAI11 AI base. The
interference would then be leaked to field ground.
Through HMI interface, mAmp or Voltage settings can be configured for each one of the
16 channels. There is detection of open and short circuits, in which case the MAI12 AI
ID line
Power management and monitor
power monitoring for the single 24V input used in internal system. If the 24V power
supply fails, the processor can detect this, and will report an alarm to the HMI via the
controller.
Module temperature monitor
There is a temperature sensor on acquisition board A and the processor reads
temperature data. Processor reports an alarm to the HMI via the controller when inside
temperature exceeds the allowable temperature range.
2.10.4.1 Status LED

Power
Run
Internal Error
External Failure
Tx/Rx A
Tx/Rx B

is normal.
OFF.
2.10.4.2 Connectors
MAI12 contains the following connectors,
BAI11 base, which includes redundant Ethernet signals, ID signals and one 24VDC
power supply
module connects directly to the BAI11 base, which includes 16 mA/V signals and
dual 24VDC power supply.
2.10.5 Specification
Item Specification
Input span 10V, 0-20mA, or 0-20mA with power out per channel
Input resolution 14 bit
Scan time Normal 125 ms for all channels
Isolation between IO channels 400VDC at 50/60Hz

2.10.6 Diagnostics
range, the IO module will send an alarm to the controller and the Internal Error LED
will blink fast with 0.125ON and 0.125 OFF.
LED is Solid on.
levels. These checks can be used to generate alarms. When a failure happens, the
function.
2.10.7 Configuration
Configuration
System limits Enable or disable system limits Enable, Disable
Min Input Select minimum mA/V input for healthy 0~20mA/10V
Max Input Select maximum mA/V input for healthy 0~20mA/10V
Select input type for every AI channel, 0 for

Input Type
unused, 1 for 0~20mA, 5 for -10V~10V 0,1,2,3,4,5,6

Value of current/voltage at the low end of
Low Input -10 to 20
Low Value -3.4082 e + 038 to 3.4028 e + 038
Value of current/voltage at the high end of
High Input -10 to 20
High Value end of -3.4082 e + 038 to 3.4028 e + 038
Bandwidth of input signal filter, 0 for unused,
Input Filter 0,1,2,3
1 for 50Hz, 2 for 60Hz, 3 for 50/60Hz.
System Limit 1 Input limit in engineering units -3.4082 e + 038 to 3.4028 e + 038
System Limit 1
Input fault check Enable, disable
Enable
System Limit 1
Input fault latch Latch, unlatch
Latch
System Limit 1 Greater than or equal. Less than or
Input fault type
Type equal
System Limit 2
Enable
System Limit 2
Latch
Input fault type
Type equal
DiagHighEnab Enable high input limit Enable, disable
DiagLowEnab Enable low input limit Enable, disable
2.10.8 Alarms
2.10.8.1 MAI12 specific alarms

2.10.8.2 IO module common alarms


7 IoPack - The I/O card has gone to the Off-Line state Cann't receive output exchange from controller
24 Firmware Hardware incompatible BaseBoard type mismatch.
229 Ethernet A has gone to the offline state Ethernet A lost Egd communication with
controller(If it is Configured to Use)
230 Ethernet B has gone to the offline state Ethernet B lost communication with controller(If
it is Configured to Use)
239 External FPGA logic Flash failure
hardware failure
240 Cfg Files HostName Mismatch
Cfg file error,redownload
259 Output exchange frame overruns Output exchange sequence number out of
order.
264 Config - Bad config compatibility code Pcode compatible code mismatch
265 Mapper - GD input header size mismatch XML input cfg file's input header size mismatch
267 FPGA - Name mismatch detected FPGA logic name mismatch
273 onet-EGD Message - Illegal Version EGD exchange header version mismatch

281 FPGA not programmed due to platform errors FPGA logic can't be loaded
282 Unable to initialize application independent Fatal Initialize failure
processes
315 Controller output exchange received too short Output exchange from controller too short
316 Controller output exchange major sig mismatch Output exchange from controller major
signature mismatch
mismatch mismatch
342 IoPack App Io Compat does not match firmware Input xml cfg file compatible code mismatch

2.11 MAI22 Analog Input with 16 channels of RTD/TC

The MAI22 module is capable of handling up to 16 RTD/TC analog inputs, each one of
which can be configured as RTD or TC input. The module contains a processor board,
two acquisition boards specific to the RTD/TC analog input function, which are mounted
on a base specific to the analog input function. The current source located on the
acquisition board provides an output of 1mA current to the RTD and voltage is sensed
across the RTD when the module is configured as an RTD input. The module provides
the electrical interface between one or two I/O Ethernet networks called IONET and field
are provided through indicator LED, as follows:
Power
Run
Internal Error
External Failure
Tx/Rx A
Tx/Rx B
BAI21 AI base board
8 analog input
with RTD/TC
Internal
24VDC power
supply
100M
with RTD/TC
100M
Ethernet B
Figure 2.11-1 16 Analog Input with RTD/TC schematic diagram

The MAI22 AI module is compatible with the analog Input baseboard BAI21 AI
baseboard.
2.11.3 Installation
accomodates an IO module type and another key accomodates a different IO
module. If an attempt is made to plug the MAI22 AI module into the wrong base, the
connector keys will not match up.
2.11.4 Operation
Processor subsystem
Local power supply decouple from dual power supplies in system, including
monitoring function
Ability to download the bootloader through RS232 ports

operation.
Analog input hardware
The MAI22 accepts RTD or TC signals from the BAI21 base for all 16 input channels. The
analog input section consists of an EMC interface, RTD/TC switch circuit, current source
circuit, open/short circuit detection, several gain and scaling selections, and a 24-bit
analog-to-digital converter (ADC).
MAI22 AI module

board Current board
(Left) source (Right)
220VAC protection
Open/short circuit
EMC interface/
RTD/TC switch
Analog to
Processor
isolation
detection
Digital Ethernet
8 of 16 Convertor communication
RTD/TC 24 bit
DC/DC
24V Power
Supply
Figure 2.11-2 MAI22 RTD/TC conditioning circuit diagram
Each input can be individually configured as either RTD signal or TC signal, depending
on the software configuration. The acquisition board provides a 1mA current output
when configured for RTD inputs.
There are two groups of input channels. Group1 is from channel 1 to 8, and group2 is
from channel 9 to 16. Each group shares individual ADC and DC/DC convertors that

power the various components in the AI conditioning circuit. There is an EMC interface
circuit for each one of 16 RTD/TC channels, then conductive interference from field
RTD/TC signal would be leaked to shielding ground on BAI21 AI base, in addition, the
interference would be leaked to shielding ground. The 220VAC protection function can
protect internal circuitry if a 220VAC signal is accidently applied to the AI signal terminal.
Through HMI interface, RTD input or TC input can be configured for each one of 16
channels. Otherwise, there is function circuitry to detect open and short circuit. MAI22 AI
RTD Type and range
Table 2.11-1 MAI22 RTD types and temperature range
RTD Type Range of degree C Range of resistance ohm Name/Standards
TC Type and range

Table 2.11-2 MAI22 TC types and temperature range
TC Type Range degree C Range Voltage mV Name/Standards
T -200 to 350 -5.603 to 17.818 ITS-90
J -200 to 1200 -7.890 to 69.553 ITS-90
E -200 to 1000 -8.825 to 76.373 ITS-90
K -200 to 1300 -5.891 to 52.410 ITS-90
N -200 to 1300 -3.990 to 47.513 ITS-90
B 400 to 1600 0.787 to 11.263 ITS-90
R 0 to 1600 0 to 18.884 ITS-90
S 0 to 1700 0 to 17.947 ITS-90
ID line
Power management and monitor
power monitoring for the single 24V input used in internal system. If the 24V power
supply fails, the processor can detect this, and will report an alarm to the HMI via the
controller.
Module temperature monitor
There is a temperature sensor on acquisition board A and the processor reads
temperature data. Processor reports an alarm to the HMI via the controller when inside
temperature exceeds the allowable temperature range.

Temperature compensation for TC type
Any input can be configured as RTD types to connect a RTD in cabinet for measuring the
temperature inside cabinet, which can be utilized as cold junction compensation. The
measured temperature inside cabinet is delivered to controller, and controller can
broadcast it to all TC module installed in the cabinet to complete temperature
compensation.
2.11.4.1 Status LED

Power
Run
Internal Error
External Failure
Tx/Rx A
Tx/Rx B
is normal.
OFF.

2.11.4.2 Connectors
MAI22 contains the following connectors,
BAI21 base, which includes redundant Ethernet signals, ID signals and one 24VDC
power supply
module connects directly to the BAI21 base, which includes 16 RTD/TC signals and
one 24VDC power supply
Item Specification
Input span RTD of Pt100/Pt10/Cu100/Cu50 or TC of T/J/E/K/N/B/R/S per channel
Input resolution 13 bits for TC, 15 bits for RTD
Scan time Normal 500 ms for all channels
2.11.6 Diagnostics
range, the IO module will send an alarm to the controller and the Internal Error LED
will blink fast with 0.125ON and 0.125 OFF.

LED is Solid on.
levels. These checks can be used to generate alarms. When a failure happens, the
function.
Configuration
System limits Enable or disable system limits Enable, Disable
Min_Input Select minimum RTD/TC input for healthy 18.52~390.84 ohm /-8.825~76.373mV
Max_Input Select maximum RTD/TC input for healthy 18.52~390.84 ohm /-8.825~76.373mV
Select input type for every AI channel, 0 for

Input Type unused, 1 for Cu50 RTD, 2 for Cu100 RTD, 3
0,1,2,3,4,5
for PT10 RTD, 4 for PT100 RTD, 5 for TC.
Value of RTD/TC at the low end of scale per

Low Input -8.825~390.84
AI channel
Low Value -3.4082 e + 038 to 3.4028 e + 038
Value of RTD/TC at the high end of scale per
High Input -8.825~390.84
AI channel
High Value end of -3.4082 e + 038 to 3.4028 e + 038
Bandwidth of input signal filter, 0 for unused,
Input Filter 0,1,2,3
1 for 50Hz, 2 for 60Hz, 3 for 50/60Hz.
System Limit 1
Enable
System Limit 1
Latch
Input fault type
Type equal

System Limit 2
Enable
System Limit 2
Latch
Input fault type
Type equal
DiagHighEnab Enable high input limit Enable, disable
DiagLowEnab Enable low input limit Enable, disable
2.11.8 Alarms
2.11.8.1 MAI22 specific alarms
2.11.8.2 IO module common alarms


7 IoPack - The I/O card has gone to the Off-Line Cann't receive output exchange from controller
state
24 Firmware Hardware incompatible BaseBoard type mismatch.

229 Ethernet A has gone to the offline state Ethernet A lost Egd communication with controller(If
it is Configured to Use)
230 Ethernet B has gone to the offline state Ethernet B lost communication with controller(If it is
Configured to Use)

239 External FPGA logic Flash failure hardware failure
240 Cfg Files HostName Mismatch
Cfg file error,redownload
259 Output exchange frame overruns Output exchange sequence number out of order.
264 Config - Bad config compatibility code Pcode compatible code mismatch
265 Mapper - GD input header size mismatch XML input cfg file's input header size mismatch
267 FPGA - Name mismatch detected FPGA logic name mismatch
273 onet-EGD Message - Illegal Version EGD exchange header version mismatch
281 FPGA not programmed due to platform errors FPGA logic can't be loaded
282 Unable to initialize application independent Fatal Initialize failure

processes
315 Controller output exchange received too short Output exchange from controller too short
316 Controller output exchange major sig Output exchange from controller major signature
mismatch mismatch
mismatch mismatch
342 IoPack App Io Compat does not match Input xml cfg file compatible code mismatch
firmware

2.12 MDI12 Configurable Digital input /Pulse input with
24 channels

The MDI12 module is capable of accepting up to 24 configurable PI/DI input channels.
When channel is configured as DI type with 24V voltage level, all the 24 channels of one
module can be configured the function of Sequence of event (SOE). The 24 channels are
separated into two groups: Channel 1 to channel 12 are in group one; Channel 13 to
channel 24 are in group two. Each group can be configured as sink current mode or
source current mode. When channel is configured as sink current mode, the MDI12
module can accept the dry contact input signal. When channel is configured as PI type,
the frequency of input signal should be in the range of 0~5kHz, and the width of the
pulse should also be no less than 80us. For PI channel, SOE is not needed .The module
contains a processor board, two acquisition boards specific to the digital input function,
which is mounted on a base specific to the digital input function. The external resistor is
necessary if need the detection of open circuit for digital input. The module provides the
electrical interface between one or two I/O Ethernet networks called IONET and field
input signals.
two 48-pin connectors. The 64-pin connector is used to connect the processor board,
and the 4-pin power supply wire are connected directly to the 64-pin connector. Twelve
digital input signals are connected directly to the 48-pin connector. Visual diagnostics
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

BDI11 DI base board
MDI12 DI module pin connector
12 digital input &
pulse input
Internal &
External
24V DC
power supply
100M
12 digital input Ethernet A
& pulse input
100M
Ethernet B
DI acquisition board
Figure 2.12-1 24 DI with 24VDC voltage level & PI schematic diagram

The MDI12 DI module is compatible with the DI/PI IO board BDI11 DI base.
2.12.3 Installation
Securely mount the desired base BDI11.
Directly plug one MDI12 DI/PI module into the BDI11 base. On both the BDI11 base
and the DI/PI module, there are keyed connectors to avoid incorrect assembly. One
module. If an attempt is made to plug the MDI12 DI/PI module into the wrong base,
Plug in one or two Ethernet cables depending on the system configuration. The DI/PI
Apply power to the pack by plugging in the connector on the side of the DI/PI
module.
Configure DI/PI module as necessary.
2.12.4 Operation

operation.
2.12.4.2 Digital input and pulse input hardware

The MDI12 accepts digital input signals with 24VDC voltage level and pulse input from
the BDI11 base for all 24 input channels. The input section consists of an EMC interface,
sink/source switch circuit, current limiter circuit and isolation opto-couple for both DI/PI
and open circuit detection.
The following are the explanations of DI/PI circuit.

MDI12 Module
BDI11 Base BDI11 Base

Board Board
(Left side) (Right side)
Led
Indicator
220VAC Protection
Hysteresis Circuit
EMC Interface/
DSP Processor
Isolation
Dual 10/100M
Circuit
1 of 24 Digital Ethernet
Schmitt-
Input Channel
Trigger
Inverter
Power Dual 24V Power

Supply Supploy
Figure 2.12-2 MDI12 digital input conditioning circuit diagram

All inputs can be configured as sink current mode or source current mode with different
wiring, depending on the software configuration.
The 24 DI channels are separated into two groups. Each group has twelve channels
which have individual DC/DC convertors that power the various components in the DI
conditioning circuit. There is an EMC interface circuit for each one of 24 DI channels,
then conductive interference from field DI signal would be leaked to shield ground on
the BDI11 DI base. In addition, the interference would be leaked to field ground. The
220VAC protection function can protect internal circuitry if a 220VAC signal is accidently
applied to the DI signal terminal.
Through HMI interface, sink current mode or source current mode and SOE function per
channel can be configured for all of 24 channels. Otherwise, there is function circuitry to
detect open circuit if there is an external resistor, when an open circuit happens, the
opto-couple for detecting open circuit will trigger the MDI12 DI module to generate an
alarm report to the HMI via the controller.
The diode bridge circuit is used to form diversified DI path depending on both external
wiring and software configuration.
2.12.4.3 ID line
During power initialization, the MDI12 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BDI11. The processor then confirms

The MDI12 includes power management in the 24V input circuit. The management

and working properly, the green PWR indicator will light. The MDI12 module includes

2.12.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
1~24
is normal.

OFF.
24 green LEDs labelled 1~24 indicate the state of DI channel, which can be on when DI
input opto-couple is on, otherwise they will be off.
2.12.4.7 Connectors
MDI12 contains the following connectors.
A 64-pin connector on the underside of the MDI12 module connects directly to the
BDI11 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MDI12
module connect directly to the BDI11 base, which includes 24 digital input signals
Table 2.12-1 MDI12 specification
Item Specification
24 configurable PI/DI channels, DI configured with sink current mode
Number of channel or source current mode per BDI11 base;
Input signal PI: Signal frequency: 05kHz The minimum pulse width: 80us
AC test signal of 500V AC 50/60Hz for 1
Isolation of Input to ground minute while leak current is less than 10mA;
SOE 1ms (No SOE for PI)
2.12.6 Diagnostics
alarm to the controller and the Internal Error LED blinks quickly with 0.125s ON and
0.125s OFF. IO Module stops sending and receiving IONET exchange data when no
LED blinks fast with 0.125s ON and 0.125s OFF.

send an alarm to the controller and the Internal Error LED will blink fast with 0.125s
ON and 0.125s OFF.
the controller and will stop sending and receiving IONET exchange data. The
Internal Error LED is solid on.
The digital input hardware also includes a function to detect open circuit in each
scan when external 16~47K ohm resistor is available, which is installed at load end.
When a failure happens, the IO module will send an alarm to the controller which
delivers last DI value before failure to controller.
function.
Table 2.12-2 MDI12 configuration parameters
InputType Select input type for every channel Normal_DI, Used_as _PI
ContactInput Set the channel used or not Unused, Used
SignalInvert Inversion makes signal true if contact is open Invert, Normal
SeqOfEvents Record contact transitions in sequence of events Disable, Enable
SignalFilter ms 24~50
2.12.8 Alarms
Table 2.12-3 MDI12 specific alarms
50-51 DI Board[] voltage low
52 Digital Clock Manager init failure
53 Soe lost because of fifo buffer full(Single Shot)

2.13 MDO11 16 channels of Digital Output

The MDO11 module is capable of controlling up to 16 channels of digital output to drive
diversified DO base with different relay. In this manual, the BDO11 base connected with
BDO12 AC relay board or BDO20 DC relay board is used as an example to introduce the
MDO11 module. The module contains a processor board, one acquisition board specific
to the digital output function, which is mounted on a base specific to the digital output
function. The module provides the electrical interface between one or two I/O Ethernet
networks called IONET and field digital output signals.
Through a 64-pin connector and two 48-pin connectors, modules connect directly with
the associated base, where the 64-pin connector is used to connect the processor
board and the 48-pin connector is used to connect the acquisition board.
output signals are connected directly to the terminal from the 48-pin connector. Visual
diagnostics are provided through indicator LED, which are shown as follows,
Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
CH n

BDO11 DO base board
24vGnd 24V GND

24VA 24V A
24VB 24V B
24VGnd 24V GND
25-pin female D-sub

100M
Ethernet A
100M
Ethernet B
Figure 2.13-1 16 Digital Output schematic diagram

The MDO11 DO module is compatible with the digital output base BDO11 DO base.
With a 25-pin D-sub cable, BDO11 can be connected to either AC relay board or DC
relay board.
2.13.3 Installation
Securely mount the desired base BDO11.
Directly plug one MDO11 DO module into the BDO11 base. On both the BDO11 base
and the DO module, there are keyed connectors to avoid incorrect assembly. One
module. If an attempt is made to plug the MDO11 DO module into the wrong base,
Plug in one or two Ethernet cables depending on the system configuration. The DO
Connect BDO11 with BDO12 or BDO20 board by a 25-pin D-sub cable.
Apply power to the pack by plugging in the connector on the side of the DO module.
Configure DO module as necessary.
If there is another type of DO base, the installation is the same as above.

2.13.4 Operation
operation.

2.13.4.2 Digital output hardware
The MDO11 outputs DO control signal to the BDO11 base for all 16 AC relay. The digital
output section consists of a DO output opto-couple, output driver circuit, channel state
detection circuit and channel state indication.
MDO11 DO module
BDO20 DO relay BDO11

board DO base board
Power DO Opto-
DC relay
driver couple
Processor
Ethernet
1 of 16 DO communication
BDO12 DO relay
board
High voting 24 V Power

Supply
AC relay
1 of 16 DO
Figure 2.13-2 MDO11 digital output conditioning circuit diagram
The DO output signal controls the power driver circuit through the DO output opto-
couple to drive the relay on the BDO12 or BDO20. There is a channel state detection
circuit to monitor the proper function of DO output circuit while visual indicator LED is
available.
2.13.4.3 ID line
During power initialization, the MDO11 reads electric ID parts of processor board and
acquisition board, and reads the base type from the BDO11. The processor then

The MDO11 includes power management in the 24V input circuit. The management
and working properly, the green PWR indicator will light. The MDO11 module includes


2.13.4.6 Status LED

Power
Run
Internal Error
External Error
Tx/Rx A
Tx/Rx B
1~16
is normal.
OFF.
16 green LEDs labelled 1~16 indicate the state of DO channel, which can be on when
channel relay is closed, otherwise it will be off.

2.13.4.7 Connectors
MDO11 contains the following connectors,
A 64-pin connector on the underside of the MDO11 module connects directly to the
BDO11 base , which includes redundant Ethernet signals, ID signals and dual 24VDC
power supply
Two 48-pin connectors for two acquisition boards on the underside of the MDO11
module connect directly to the BDO11 base, which includes 16 digital output signals
Another type of DO base has the same connectors and pin definition as MDO11.
Table 2.13-1 MDO11 specification
Item Specification
Number of channel 16 digital output channels
2.13.6 Diagnostics
alarm to the controller and the Internal Error LED blinks quickly with 0.125s ON and
0.125s OFF. IO Module stops sending and receiving IONET exchange data when no
LED blinks fast with 0.125s ON and 0.125s OFF.
send an alarm to the controller and the Internal Error LED will blink fast with 0.125s
ON and 0.125s OFF.
the controller and will stop sending and receiving IONET exchange data. The
Internal Error LED is solid on.

Continuous monitoring of proper function of DO channels. When a failure happens,
the IO module will send an alarm to the controller and sets the output to the
preconfigured default of Output-State.
function.
Table 2.13-2 MDO11 configuration parameters
RelayOutput Set the channel used or not Unused, Used
SignalInvert Inversion makes relay closed if signal is false Normal, Invert
Record relay command transitions in sequence of
SeqOfEvents events Disable, Enable
When offline with the controller, output the selected
Output_State value HoldLastValue, Output_Value
Default Output value Default output value for DO is Output-State Off, On
2.13.8 Alarms
Table 2.13-3 MDO11 specific alarms
32 Conditioning board power failure. External Power Down
33 Baseboard and Relay board unconnected
34-49 DO Channel[] Does Not Match Requested State The Digital Output[ ] has an error.

Chapter 3 IO Base
3.1 BAI10 Analog Input base with 16 channels of mA/V

The Analog Input base supports 16 analog inputs. The 16 analog inputs accommodate
two-wire, three-wire, or externally powered transmitters. There is no noise suppression
circuitry in the board, which is in IO acquisition board of the MAI10 AI module.
There is a 64-pin connector and two 48-pin connectors provided on BAI10 for
connecting to the MAI10 AI module, where the 64-pin connector is used to connect the
processor board and the 48-pin connector is used to connect the acquisition board. On
the base, signal wire of 2 Ethernet port from dual RJ45 Ethernet connectors and 4-pin
power supply wire are connected directly to 64-pin connector, and 16 analog input
signals are connected directly to dual 48-pin connectors.

9A
pin connector
1A
9B
1B
9C
1C
8 analog input 10A
with mA/V 2A
10B
2B
24vGnd
10C
2C
11A
24VA Dual 24VDC
3A
24VB
power supply
11B
3B
11C 24VGnd
3C
12A
4A
12B
4B
12C
4C
1 100M
13A Ethernet A
5A
13B
5B
13C
5C
14A 100M
8 analog input 6A
Ethernet B
14B
with mA/V 6B
14C
6C
15A
7A
15B
7B
7C
16A
8A
16B
8B
16C
8C
Figure 3.1-1 BAI10 AI base

3.1.2 Installation
The 16 inputs are wired directly to four I/O terminal blocks mounted on the base. Each
block is held down with two screws and has 12 terminals accepting up to #12 AWG
wires.
The types of analog input that can be accommodated are as follows:
Analog input, two-wire transmitter
Analog input, three-wire transmitter
Analog input, externally powered transmitter
Analog input, voltage 5 V, 10 V dc
Wiring connection and cable connections appear on the baseboard wiring diagram.

BAI10 AI base board
9A Input 9 (24V)
Input 1 (24V) 1A
9B Input 9 (20mA/V)
Input 1 (20mA/V) 1B
9C Input 9 (Return)
Input 1 (Return) 1C
10A Input 10 (24V)
Input 2 (24V) 2A
10B Input 10 (20mA/V)
Input 2 (20mA/V) 2B
24vGnd 24V GND
10C Input 10 (Return)
Input 2 (Return) 2C
24VA 24V A
11A Input 11 (24V)
Input 3 (24V) 3A
24VB 24V B
Input 3 (20mA/V) 3B
11C Input 11 (Return) 24VGnd 24V GND
Input 3 (Return) 3C
12A Input 12 (24V)
Input 4 (24V) 4A
Input 4 (20mA/V) 4B
Input 4 (Return) 4C
1 100M
Ethernet A
13A Input 13 (24V)
Input 5 (24V) 5A
Input 5 (20mA/V) 5B
Input 5 (Return) 5C
14A Input 14 (24V) 100M
Input 6 (24V) 6A Ethernet B
Input 6 (20mA/V) 6B
Input 6 (Return) 6C
15A Input 15 (24V)
Input 7 (24V) 7A
Input 7 (20mA/V) 7B
Input 7 (Return) 7C
16A Input 16 (24V)
Input 8 (24V) 8A
Input 8 (20mA/V) 8B
Input 8 (Return) 8C
+24Vdc A +24Vdc A
T
Two-wire B Three-wire B
4~20mA 4~20mA
transmitter wiring transmitter wiring T
4~20mA 4~20mA
Return C Return C
+24Vdc A +24Vdc A
Externally powered
transmitter wiring
4~20mA
4~20mA B Voltage Input B
+
Power +
T -
supply
- Return C Return C
Figure 3.1-2 BAI10 base wiring

There is only a simple indication for IO acquisition in the above wiring diagram. The IO
acquisition circuit is on the IO acquisition board not on the base.
3.1.3 Operation
The 16 analog inputs can be individually configured as 0~20mA current loop inputs or
5 V/10 V inputs by operator with HMI. The following table shows the input capability
of BAI10 base.
Table 3.1-1 BAI10 input type

Quantity Analog Input Types
16 0-5V/1-5V/5V/10V or 0-20mA/4-20mA per channel
3.1.4 Specification
Table 3.1-2 BAI10 specification

Item Specification
Input span 0-5V/1-5V/5V/10V or 0-20mA/4-20mA per channel
External power supply in current mode Provide 21mA per channel
Ethernet port 2 Ethernet ports with 100M and full duplex
Physical Size(L*W*H) 175mm*127mm*63.4mm
3.1.5 Diagnostic
Diagnostic tests are made on the base as follows:
Each base has its own ID device that is interrogated by the MAI10 AI module. The ID
device is a writable/readable chip coded with the base type and serial number. When
the chip is read by MAI10 module and a mismatch is encountered, a hardware
incompatibility fault is created.

3.2 BAI20 Analog Input Base with 16 channels of
RTD/TC

The Analog Input base supports 16 analog inputs. The 16 analog inputs accommodate
RTD or TC. There is not noise suppression circuitry in the board, which is an IO
acquisition board of MAI20 AI module.

pin connector
9A
1A
9B
1B
9C
8 analog input 1C
10A
with RTD/TC 2A
10B
2B 24vGnd
10C
2C 24VA Dual 24VDC
3A
11A
24VB
power supply
11B
3B 24VGnd
11C
3C
12A
4A
12B
4B
12C
4C
1 100M
Ethernet A
13A
5A
13B
5B
13C
5C 100M
8 analog input 14A
Ethernet B
6A
with RTD/TC 14B
6B
14C
6C
15A
7A
15B
7B AI acquisition board
15C
7C with 48 pin connector
16A
8A
16B
8B
16C
8C

3.2.2 Installation
wires.
RTD input
TC input
Wiring connection and cable connections appear on the base wiring diagram.
BAI20 AI base board
9A Input 9 (Excit)
Input 1 (Excit) 1A
9B Input 9 (Sig)
Input 1 (Sig) 1B
9C Input 9 (Return)
Input 1 (Return) 1C
10A Input 10 (Excit)
Input 2 (Excit) 2A
10B Input 10 (Sig)
Input 2 (Sig) 2B
24vGnd 24V GND
Input 2 (Return) 2C
24VA 24V A
Input 3 (Excit) 3A
24VB 24V B
11B Input 11 (Sig)
Input 3 (Sig) 3B
Input 3 (Return) 3C
Input 4 (Excit) 4A
12B Input 12 (Sig)
Input 4 (Sig) 4B
Input 4 (Return) 4C
1 100M
Ethernet A
Input 5 (Excit) 5A
13B Input 13 (Sig)
Input 5 (Sig) 5B
Input 5 (Return) 5C
14A Input 14 (Excit) 100M
Input 6 (Excit) 6A Ethernet B
14B Input 14 (Sig)
Input 6 (Sig) 6B
Input 6 (Return) 6C
Input 7 (Excit) 7A
15B Input 15 (Sig)
Input 7 (Sig) 7B
Input 7 (Return) 7C
Input 8 (Excit) 8A
16B Input 16 (Sig)
Input 8 (Sig) 8B
Input 8 (Return) 8C
A
Excitation A
B
Signal B
+
TC -
C
Three-wire RTD
Return C

3.2.3 Operation
The 16 analog inputs can be individually configured as RTD inputs or TC inputs by HMI
operator. The following table shows the input capability of BAI20 base.

Quantity Analog Input Types
16 RTD of Pt100/Cu50 or TC of T,J,E,K,N,B,R,S per channel
In acquisition board of MAI20 AI module, there is a 200A excitation current to each RTD,
which is not available for TC mode. All RTD/TC signal has a high frequency decoupling to
ground at signal entry.
3.2.4 Specification

Item Specification
Input span RTD of Pt100/Cu50 or TC of T,J,E,K,N,B,R,S per channel
Fault detection Check connector ID chip for hardware incompatibility
3.2.5 Diagnostic

3.3 BAO10 Analog Output Base with 8 channels

The Analog Output base supports 8 analog outputs with current range of 0~20mA or
voltage range of 0~10V. The current output or voltage output is generated by MAO10
AO module. There is no circuit of both noise suppression and surge protection in the
board, which is an IO acquisition board of the MAO10 AO module.
There is a 64-pin connector and two 48-pin connectors provided on BAO10 for
connecting to the MAO10 AO module, where the 64-pin connector is used to connect
the processor board and the 48-pin connector is used to connect the acquisition board.
On the board, there are signal wires of 2 Ethernet port from dual RJ45 Ethernet
connectors and 4-pin power supply wire are connected directly to the 64-pin connector,
and 8 analog output signals from dual 48-pin connectors are connected directly to
terminal.
BAO10 AO base board Processor board with 64

pin connector
1A
1B
24vGnd
2A
24VA Dual 24VDC
2B
24VB
power supply
3A
8 analog output 24VGnd
3B
4A
4B
5A
1
5B
6A 100M
6B Ethernet A
7A
7B
8A 100M
8B Ethernet B
Figure 3.3-1 BAO10 AO base

3.3.2 Installation
The 8 analog outputs are wired directly to one I/O terminal blocks mounted on the left of
the board. The block is held down with two screws and has 16 terminals accepting up to
#12 AWG wires.
The types of analog output that can be accommodated are as follows:
Analog output, current source with range of 0~20mA/4~20mA
Analog output, voltage source with range of 0~10V
The following figure shows the details of BAO10 wiring and cabling.
BAO10 AO base board
Output 1 (Signal) 1A
Output 1 (Return) 1B
24vGnd 24V GND
24VA 24V A
24VB 24V B
24VGnd 24V GND
Output 5 (Signal) 5A 1
Output 6 (Signal) 6A 100M

Ethernet A

Ethernet B
Signal A Signal A
Current source Voltage source
output 0~20mA/ output 0~10V
4~20mA
Return B Return B
Figure 3.3-2 BAO10 base wiring

There is only a simple indication for the IO acquisition circuit in the above wiring
diagram. The IO acquisition circuit is on the IO acquisition board not on the base.

3.3.3 Operation
The 8 analog outputs can be individually configured as current source output with
range of 0~20mA or voltage source output with range of 0~10V by operator with HMI.
The following table shows the output capability of BAO10 base.
Table 3.3-1 BAO10 input type

Quantity Analog Output Types
8 0~10V or 0-20mA (max load resistor 750ohm) per channel
3.3.4 Specification
Table 3.3-2 BAO10 specification

Item Specification
Number of channel 8 channels per BAO10 base
3.3.5 Diagnostic
Each base has its own ID device that is interrogated by the MAO10 AO module. The ID
the chip is read by MAO10 module and a mismatch is encountered, a hardware

3.4 BDI10 Digital input /Pulse input Base with 16
channels

The Digital Input base supports 16 digital inputs and Pulse inputs. The 16 digital inputs
accommodate dry contact, source current mode and sink current mode. There is no
noise suppression circuitry in the board, which is an IO acquisition board of the MDI10 DI
module.
There is a 64-pin connector and two 48-pin connectors provided on BDI10 for
connecting to the MDI10 DI module, where the 64-pin connector is used to connect the
the board, there are signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors
and 4-pin power supply wires are connected directly to the 64-pin connector, and 16
digital input signals are connected directly to dual 48-pin connectors.
BDI10 DI base board Processor board with 64

9A
pin connector
1A
9B
1B
9C
1C
10A
8 digital input 2A
10B
2B
10C 24vGnd
2C
11A 24VA Dual 24VDC
3A
24VB
power supply
11B
3B
11C 24VGnd
3C
12A
4A
12B
4B
12C
4C
1 100M
13A Ethernet A
5A
13B
5B
13C
5C
14A 100M
6A
8 digital input 14B Ethernet B
6B
14C
6C
15A
7A
15B
7B
15C DI acquisition board
7C
16A
8A
16B
8B
16C
8C
Figure 3.4-1 BDI10 DI base

3.4.2 Installation
wires.
The types of digital input that can be accommodated are as follows:
Dry contact
Wet contact with 24VDC
Appoximator: Sink current mode (DC PNP)
Appoximator: Source current mode (DC NPN)

BDI10 DI base board
9A Input 9 (24V)
Input 1 (24V) 1A
9B Input 9 (Signal)
Input 1 (Signal) 1B
9C Input 9 (Return)
Input 1 (Return) 1C
10A Input 10 (24V)
Input 2 (24V) 2A
10B Input 10 (Signal)
Input 2 (Signal) 2B
24vGnd 24V GND
Input 2 (Return) 2C
24VA 24V A
11A Input 11 (24V)
Input 3 (24V) 3A
24VB 24V B
Input 3 (Signal) 3B
Input 3 (Return) 3C
12A Input 12 (24V)
Input 4 (24V) 4A
Input 4 (Signal) 4B
Input 4 (Return) 4C
1 100M
Ethernet A
13A Input 13 (24V)
Input 5 (24V) 5A
Input 5 (Signal) 5B
Input 5 (Return) 5C
14A Input 14 (24V) 100M
Input 6 (24V) 6A Ethernet B
Input 6 (Signal) 6B
Input 6 (Return) 6C
15A Input 15 (24V)
Input 7 (24V) 7A
Input 7 (Signal) 7B
Input 7 (Return) 7C
16A Input 16 (24V)
Input 8 (24V) 8A
Input 8 (Signal) 8B
Input 8 (Return) 8C
+24V A Approximator: +24V A

Source current
mode (DC NPN)
Dry contact
Signal B Signal B
Return C Return C
A Approximator: +24V A
Sink current mode
(DC PNP)
Signal B Signal B
+24V
Return C Return C
Figure 3.4-2 BDI10 base wiring

There is only a simple indication for IO acquisition circuit in above wiring diagram. The IO
Wiring connection and cable connections of PI is as follows

BDI10 DI base board
9A NC
NC 1A
9B Input 9 (Signal)
Input 1 (Signal) 1B
9C Input 9 (Return)
Input 1 (Return) 1C
10A NC
NC 2A
Input 2 (Signal) 2B
24vGnd 24V GND
Input 2 (Return) 2C
24VA 24V A
11A NC
NC 3A
24VB 24V B
Input 3 (Signal) 3B
Input 3 (Return) 3C
12A NC
NC 4A
Input 4 (Signal) 4B
Input 4 (Return) 4C
1 100M
Ethernet A
13A NC
NC 5A
Input 5 (Signal) 5B
Input 5 (Return) 5C
14A NC 100M
NC 6A Ethernet B
Input 6 (Signal) 6B
Input 6 (Return) 6C
15A NC
NC 7A
Input 7 (Signal) 7B
Input 7 (Return) 7C
16A NC
NC 8A
Input 8 (Signal) 8B
Input 8 (Return) 8C
Figure 3.4-3 BDI10 base PI wiring
3.4.3 Operation
All 16 digital inputs can be configured as sink current mode and source current mode by
operator with HMI. Meanwhile, each channel can be configured by HMI. The following
table shows the input capability of the BDI10 base.
Table 3.4-1 BDI10 input type
Quantity Types
Digital input 0~30VDC (rated 24VDC) per channel
16 Pulse input
3.4.4 Specification
Table 3.4-2 BDI10 specification
Item Specification
16 configurable PI/DI channels, DI configured with sink current mode or source
Number of channel current mode per BDI10 base;
Input signal
PI: Signal frequency: 0200Hz The minimum pulse width: 2ms

3.4.5 Diagnostic
Each base has its own ID device that is interrogated by the MDI10 DI module. The ID
the chip is read by the MDI10 module and a mismatch is encountered, a hardware

3.5 BDO10 Digital Output Base with AC relay

The Digital Output base provides 16 AC relay with rating of 250VAC/5A to accept the 16
control outputs from MDO10 DO module.
There is a 64-pin connector and two 48-pin connectors provided on BDO10 for
connecting to the MDO10 DO module, where the 64-pin connector is used to connect
output signals from dual 48-pin connectors are connected directly to the terminals.

BDO10 DO base board Processor board with 64
pin connector
1A
1B
1C
4 DO output 2A
2B
24vGnd
2C
24VA Dual 24VDC
3A
24VB
power supply
3B
24VGnd
3C
4A
4B
4C
5A
100M
5B
Ethernet A
5C
6A
4 DO output 100M
6B
6C
Ethernet B
7A
7B
7C
8A
DO acquisition board
8B
8C
9A
9B
9C
4 DO output 10A
10B
10C
11A
11B
11C
12A
12B AC relay AC relay AC relay AC relay

12C
13A AC relay AC relay AC relay AC relay

13B
13C
14A
4 DO output
14B
14C
15A
15B
15C
16A
16B
16C
Figure 3.5-1 BDO10 DO base

3.5.2 Installation
The 16 digital outputs are wired directly to four I/O terminal blocks mounted on the left
of the board. The block is held down with two screws and has 12 terminals accepting up
to #12 AWG wires.
The following figure shows the details of BDO10 wiring and cabling.

BDO10 DO base board
Output 1 (NO) 1A
Output 1 (COM) 1B
Output 1 (NC) 1C
Output 2 (NO) 2A
Output 2 (COM) 2B
24vGnd 24V GND
Output 2 (NC) 2C
24VA 24V A
Output 3 (NO) 3A
24VB 24V B
Output 3 (COM) 3B
24VGnd 24V GND
Output 3 (NC) 3C
Output 4 (NO) 4A
Output 4 (COM) 4B
Output 4 (NC) 4C
Output 5 (NO) 5A 100M

Ethernet A
Output 5 (COM) 5B
Output 5 (NC) 5C
Output 6 (NO) 6A
Output 6 (COM) 6B 100M

Ethernet B
Output 6 (NC) 6C
Output 7 (NO) 7A
Output 7 (COM) 7B
Output 7 (NC) 7C
Output 8 (NO) 8A
Output 8 (COM) 8B
Output 8 (NC) 8C
Output 9 (NO) 9A
Output 9 (COM) 9B
Output 9 (NC) 9C
Output 10 (NO) 10A
Output 10 (COM) 10B
Output 10 (NC) 10C
Output 11 (NO) 11A
Output 11 (COM) 11B
Output 11 (NC) 11C

Output 12 (NO) 12A
Output 12 (COM) 12B
Output 12 (NC) 12C

Output 13 (NO) 13A
Output 13 (COM) 13B AC relay AC relay AC relay AC relay

Output 13 (NC) 13C
Output 14 (NO) 14A

Output 14 (COM) 14B
Output 14 (NC) 14C
Output 15 (NO) 15A
Output 15 (COM) 15B
Output 15 (NC) 15C
Output 16 (NO) 16A
Output 16 (COM) 16B
Output 16 (NC) 16C
NO A
COM B
NC C
Figure 3.5-2 BDO10 base wiring

Only a simple indication for IO acquisition circuit is shown in above wiring diagram. The
IO acquisition circuit is on the IO acquisition board not on the main base.
3.5.3 Operation
Table 3.5-1 BDO10 output types

Quantity Digital Output Types
16 1 NO/1 NC with 250VAC/3A per channel
3.5.4 Specification
Table 3.5-2 BDO10 specification

Item Specification
Number of channel 16 channels 1 NO/1 NC with 250VAC/3A per BDO10 base
3.5.5 Diagnostic
Each base has its own ID device that is interrogated by the MDO10 DO module. The ID
the chip is read by the MDO10 module and a mismatch is encountered, a hardware

3.6 BVP10 Valve Position Control Base

The BVP10 base supports these signals of 2 LVDT inputs, 2 AI inputs, 2 DIs, 2 servo
current output, 2 AO output, and 1 DO. The LVDT inputs accommodate two-wire, three-
wire, four-wire, five-wire and six-wire. The AI is a general analog input. The servo current
control output can source/sink +/-40mA or +/-400mA current.
There is a narrow 64-pin connector and two wide 64-pin connectors provided on BVP10
for connecting to the MVP10/MVP11 module, where the narrow 64-pin connector is
used to connect processor board and two wide 64-pin connectors are used to connect
the acquisition board. On base, signal wire of 2 Ethernet port from dual RJ45 Ethernet
connectors and 4-pin power supply wire are connected directly to 64-pin connector,
and input and output IO signals are connected directly to dual 64-pin connectors.

3A pin connector
1A
3B
1B
3C
1C
4A
2 LVDT input 1D
4B
2 AI 1E
4C
24vGnd
2 DI 1F
24VA Dual 24VDC
5A
2A
24VB
power supply
5B
2B
6A 24VGnd
2C
6B
2D
2E
2F
1 100M
9A Ethernet A
7A
9B
7B
10A
2 Servo output 7C
10B 100M
2 AO 7D
Ethernet B
1 DO 8A
8B
8C
8D
11A
11B
11C
11D
Figure 3.6-1 BVP10 Valve Position Control Base

3.6.2 Installation
The input and output IO signals are wired directly to two I/O terminal blocks mounted on
the base. Each block is held down with two screws and has 24 terminals.
The types of LVDT input that can be accommodated are as follows:
BVP10 Valve Position Control Base Board
3A AI1_POWER
LV1_EXC_OUT+
1A
3B AI1_AIN+
LV1_EXC_OUT-
1B
3C AI1_AIN-
INLV1_SENSE_IN+
1C
4A AI2_POWER
INLV1_SENSE_IN-
1D
4B AI2_AIN+
LV1_COM
1E
24vGnd 24V GND
4C AI2_AIN-
LV1_AGND 1F
24VA 24V A
5A DI_DI1
LV2_EXC_OUT+
2A
DI_COM1 24VB 24V B
5B
LV2_EXC_OUT-
2B
6A DI_DI2 24VGnd 24V GND
LV2_SENSE_IN+
2C
6B DI_COM2
LV2_SENSE_IN-
2D
N/A
LV2_COM
2E
N/A
LV2_AGND 2F
1
100M
Ethernet A
9A AO1_AO
7A
N/A
9B AO1_AGND
N/A 7B
10A AO2_AO
SERVO1_OUTPUT+ 7C
10B AO2_AGND
100M
SERVO1_OUTPUT- 7D Ethernet B
N/A
8A
N/A
N/A
N/A 8B
N/A
SERVO2_OUTPUT+ 8C
N/A
8D
SERVO2_OUTPUT-
11A
N-
N/A
11B
L+/OUT
N/A
11C
L+/IN
N/A
11D N-
N/A
Figure 3.6-2 3-wire LVDT

3A AI1_POWER
LV1_EXC_OUT+
1A
3B AI1_AIN+
LV1_EXC_OUT-
1B
3C AI1_AIN-
INLV1_SENSE_IN+
1C
4A AI2_POWER
INLV1_SENSE_IN-
1D
4B AI2_AIN+
LV1_COM
1E
24V GND
4C AI2_AIN-
LV1_AGND 24vGnd
1F
24V A
5A DI_DI1
LV2_EXC_OUT+ 24VA
2A
DI_COM1 24V B
5B
LV2_EXC_OUT- 24VB
2B
6A DI_DI2 24V GND
LV2_SENSE_IN+ 24VGnd
2C
6B DI_COM2
LV2_SENSE_IN-
2D
N/A
LV2_COM
2E
N/A
LV2_AGND
2F
1
100M
Ethernet A
9A AO1_AO
7A
N/A
9B AO1_AGND
N/A 7B
10A AO2_AO
SERVO1_OUTPUT+ 7C
10B AO2_AGND
100M
N/A
8A
N/A
N/A
N/A 8B
N/A
SERVO2_OUTPUT+ 8C
N/A
8D
SERVO2_OUTPUT-
11A
N-
N/A
11B
L+/OUT
N/A
11C
L+/IN
N/A
11D N-
N/A
Figure 3.6-3 4/6-wire LVDT

3A AI1_POWER
LV1_EXC_OUT+
1A
3B AI1_AIN+
1B
3C AI1_AIN-
1C
4A AI2_POWER
1D
4B AI2_AIN+
LV1_COM
1E
4C
24vGnd 24V GND
AI2_AIN-
LV1_AGND
1F
24VA 24V A
5A
DI_DI1
LV2_EXC_OUT+
2A
5B DI_COM1 24VB 24V B

LV2_EXC_OUT-
2B
LV2_SENSE_IN+
2C
6B
DI_COM2
LV2_SENSE_IN- 2D
N/A
LV2_COM
2E
N/A
LV2_AGND
2F
1
100M
Ethernet A
9A
AO1_AO
7A
N/A
9B
AO1_AGND
7B
N/A
10A
AO2_AO
SERVO1_OUTPUT+ 7C
10B
AO2_AGND
100M
N/A
8A
N/A
N/A
8B
N/A
N/A
8C
SERVO2_OUTPUT+
N/A
8D
SERVO2_OUTPUT-
11A
N-
N/A
11B
L+/OUT
N/A
11C
L+/IN
N/A
11D N-
N/A
Figure 3.6-4 5-wire LVDT

Analog input, voltage 5 V dc

3A AL1_POWER
LV1_EXC_OUT+ 1A
3B AL1_AIN+
LV1_EXC_OUT- 1B
3C AL1_AIN-
INLV1_SENSE_IN+ 1C
4A AL2_POWER
INLV1_SENSE_IN- 1D
4B AL2_AIN+
LV1_COM 1E
24vGnd 24V GND
4C AL2_AIN-
LV1_AGND 1F
24VA 24V A
5A DI_DI1
LV2_EXC_OUT+ 2A
24VB 24V B
5B DI_COM1
LV2_EXC_OUT- 2B
LV2_SENSE_IN+ 2C
6B DI_COM2
LV2_SENSE_IN- 2D
N/A
LV2_COM 2E
N/A
LV2_AGND 2F
1 100M
Ethernet
9A OT1_AO
N/A 7A
9B OT1_AGND
N/A 7B
10A OT2_AO
OL1_IOUT_L+ 7C
10B OT2_AGND 100M
OL1_IOUT_L- 7D Ethernet
N/A
N/A 8A
N/A
N/A 8B
N/A
OL1_IOUT_L+ 8C
N/A
OL1_IOUT_L- 8D
11A N/A
N/A
11B DO_220V_IN
N/A
11C DO_220V_OUT
N/A
11D 220_IN-
N/A
+24V a AI signal +24Vdc a AI signal +24Vdc a
DI signal T
b Two-wire b Three-wire b
Signal 4~20mA 4~20mA
4~20mA 4~20mA
Return c Return c
AO signal Signal a +24Vdc a +24Vdc a

Externally powered
Voltage source transmitter wiring
output 0~5V 4~20mA
Return b 4~20mA b Voltage Input b
+
Power +
T -
supply
- Return c Return c
AI signal AI signal
Figure 3.6-5 BVP10 Valve Position Control Base wiring


3.6.3 Operation
The BVP10 base supports these signals of 2 LVDT inputs, 2 AI inputs, 2 DIs, 2 servo
current outputs, 2 AO output and 1 DO. The LVDT inputs accommodate two-wire, three-
wire, four-wire, five-wire and six-wire. The AI is a general analog input. The servo current
control output can source/sink +/-40mA or +/-400mA current.
Table 3.6-1 BVP10 IO types

Quantity Type Characteristics
2 Servo output Output capacity: +/-40mA or +/-40mA
2 AO 0~5V
1 Relay output Output capability: 220V/1A
2 AI or 0-20mA/4-20mA per channel
2 DI 0~30VDC, nominal 24VDC
2 LVDT signal 3/4/5/6 wires of LVDT
3.6.4 Specification
Table 3.6-2 BVP10 specification
Item Specification
Output span Output capacity: +/-40mA or +/-400mA
AO
Output span 0~5V
Relay output
Type NO
AI signal
DI signal
LVDT signal

Physical
Size(L*W*H) 175mm*127mm*63.4mm

3.6.5 Diagnostic
Each base has its own ID device that is interrogated by the MVP10/MVP11 module. The
ID device is a read-only chip coded with the base serial number. When the chip is read
by the MVP10/MVP11 module and a mismatch is encountered, a hardware

3.7 BSP10 Speed Measurement and Protection Base

The Speed Measurement and Protection Base supports MSP10 module. There are 2
channels of mA/V analog inputs, 1 channel of wheel speed input which can handle
various types of pulse signal, 7 channels of digital input with 24VDC operation voltage, 4
channels of digital output, and 1 relay normal closed contact output. On the base, there
is also 1 D-sub connector that is an emulator interface and is used when MSP module
works in simulation mode, and also 1 D-sub connector for ETS relay module interface to
make 2/3 voting output on OPC and AST protection.
There are 3 64-pin connectors provided on BSP10 for connecting to the MSP10 module,
where a 64-pin connector is used to connect processor board and other 2 64-pin I/O
connectors are used to connect 2 acquisition boards. On base board, signal wire of 2
Ethernet ports from dual RJ45 Ethernet connectors and 4-pin power supply wire are
connected directly to 64-pin connector, and all I/O signals are connected directly to dual
64-pin I/O connectors.
BSP10 SDP base board ETS relay module D-sub interface

2 digital Output
2 analog input with mA/V
1 wheel speed input/output
7 digital input
1 relay contact NC output
24vGnd
24VA Dual 24VDC

24VB power supply
24VGnd

pin connector
100M
Emulator D-sub Ethernet A
interface
100M
Ethernet B
I/O acquisition board

Figure 3.7-1 BSP10 Speed Measurement and Protection base board
3.7.2 Installation
The I/O inputs are wired directly to one I/O terminal block mounted on the base board.
The block is held down with two screws and has 24 terminals accepting up to #12 AWG

wires. Below is wiring connection and cable connections appear on the base board
wiring diagram.
BSP10 base board
7A DI6 (24VDC) OPC + 1

ASL+/DI0 (24VDC) 1A AST + 2
6 OPC -
7B DI6 com 3
7 AST -
8
ASL-/DI0 com 1B DO GND 4
9 DO GND
8A Relay output P 5
BR+/DI1 (24VDC) 2A
8B Relay output N
BR-/DI1 com 2B
9A WS+
DI2 (24VDC) 3A
24vGnd 24V GND
9B WS-
DI2 com 3B
24VA 24V A
10A MW (24V)
DI3 (24VDC) 4A
24VB 24V B
10B MW (20mA/V)
DI3 com 4B
10C MW (Return) 24VGnd 24V GND
DI4 (24VDC) 5A
11A IEP (24V)
DI4 com 5B
11B IEP (20mA/V)
DI5 (24VDC) 6A
11C IEP (Return) 1
DI5 com 6B
100M
Ethernet A
50 Sw1+_simu 17 ASL+_simu
33 ASL-simu
49 Sw1-_simu 16 BR+_simu
32 BR-_simu
48 MW+_simu 15 DI2+_simu
31 DI2-_simu
47 MW-_simu 14 DI3+_simu
30 DI3-_simu
46 IEP+_simu
29 DI4-_simu
13 DI4+_simu 100M
45 IEP-_simu 12 DI5+_simu
44 Sw2+_simu
28 DI5-_simu
11 WS+_simu
Ethernet B
27 WS-_simu
43 Sw2-_simu 10
26
42 9
25
41 8
24
40 7
23
39 6
22 WS+_inter
38 5 WS-_inter
21 ASL+_inter
37 MW+_inter 4 ASL-inter
20 BR+_inter
36 MW-_inter 3 BR-_inter
19 OPC+_inter
35 IEP+_inter 2 OPC-_inter
18 AST+_inter
34 IEP-_inter 1 OPC-_inter
+24V A MW, IEP signal +24Vdc A MW, IEP signal +24Vdc A
DI signal T
B Two-wire B Three-wire B
Signal 4~20mA 4~20mA
4~20mA 4~20mA
Return C Return C
WS+ A +24Vdc A +24Vdc A

Externally powered
transmitter wiring
WS signal S 4~20mA
WS- B 4~20mA B Voltage Input B
+
Power +
T -
supply
- Return C Return C
MW, IEP signal MW, IEP signal
Figure 3.7-2 BSP10 base board wiring
3.7.3 Operation
The following table shows the input capability of BSP10 base.

Table 3.7-1 BSP10 IO type
Item Specification
Number of channel 2 AI channel, 1 speed input, 7 DI, 4 DO, 1 Relay output
D-sub interface 1 emulator interface, 1 2/3 voting relay extend module interface
Power supply 2 channels of 24VDC power supply
3.7.4 Specification
Table 3.7-2 BSP10 specification

Item Specification
AI signal
Input span 0-5V/(input impedance 500K ohm) or 0-20mA per channel
WS signal
Number of channel 1 channel of WS signal
40mV~110V, sine wave, triangle wave or square wave or TTL
Input span signal with 0~20kHz
DI signal
DO signal
Number of channel 4 DO channels
Characteristics Optic-couple drive passive output
Relay output
Type NC
Contact capacity AC250V 1.5A, DC 30V 1.5A
WS output signal
Type Square wave, 24VDC, 0~20kHz
Physical
Size 175mm*127mm*63.4mm
3.7.5 Diagnostic
Each base has its own ID device that is interrogated by the MSP10 module. The ID
the chip is read by the MSP10 module and a mismatch is encountered, a hardware

3.8 BAI11 Analog Input Base with 16 channels of mA/V

The analog Input base supports 16 analog inputs. The 16 analog inputs accommodate
two-wire, three-wire, or externally powered transmitters. There is no noise suppression
circuitry in the board, which is in IO acquisition board of the MAI12 AI module.
The internal 24VDC provides power supply to CPU board of MAI12. The external 24VDC
provides power supply to IO boards of MAI12 and field current sensor under power out
current mode. Both internal and external power supply should be provided by diode
coupler and redundant 24VDC power supply.

9A
pin connector
1A
9B
1B
9C
1C
8 analog input 10A
with mA/V 2A
10B
2B External 24VDC
X24V GND
10C
2C
power supply
X 24V
11A
3A
11B 24V
Internal 24VDC
3B
11C 24VGN D power supply
3C
12A
4A
12B
4B
12C
4C
1 100M
13A Ethernet A
5A
13B
5B
13C
5C
14A 100M
8 analog input 6A
Ethernet B
14B
with mA/V 6B
14C
6C
15A
7A
15B
7B
7C
16A
8A
16B
8B
16C
8C

3.8.2 Installation
wires.
Analog input, voltage 10 V dc
Wiring connection and cable connections appear on the baseboard wiring diagram.
3.8.3 Operation
The 16 analog inputs can be individually configured as 0~20mA current loop inputs or
10 V inputs by operator with HMI. The following table shows the input capability of
BAI11 base.
Quatity Analog Input Types
16 10V, 0-20mA, or 0-20mA with power out per channel
3.8.4 Specification
Item Specification
Input span 10V, 0-20mA, or 0-20mA with power out per channel
Fault detection Provide 21mA per channel
3.8.5 Diagnostic

3.9 BAI21 Analog Input Base with 16 channels of
RTD/TC

The analog Input base supports 16 analog inputs. The 16 analog inputs accommodate
RTD or TC. There is no noise suppression circuitry in the board, which is an IO acquisition
board of MAI22 AI module.
The internal power supply should be provided by diode coupler and redundant 24V DC
power supply.

pin connector
9A
1A
9B
1B
9C
8 analog input 1C
10A
with RTD/TC 2A
10B
2B
10C Internal
2C
11A
24VDC power
3A
11B
24V
supply
3B 24VGnd
11C
3C
12A
4A
12B
4B
12C
4C
1 100M
Ethernet A
13A
5A
13B
5B
13C
5C 100M
8 analog input 14A
Ethernet B
6A
with RTD/TC 14B
6B
14C
6C
15A
7A
15B
7B AI acquisition board
15C
7C with 48 pin connector
16A
8A
16B
8B
16C
8C

3.9.2 Installation
wires.
RTD input
TC input
BAI21 AI base board
9A Input 9 (Excit)
Input 1 (Excit) 1A
9B Input 9 (Sig)
Input 1 (Sig) 1B
9C Input 9 (Return)
Input 1 (Return) 1C
Input 2 (Excit) 2A
10B Input 10 (Sig)
Input 2 (Sig) 2B
Input 2 (Return) 2C
Input 3 (Excit) 3A
24V 24V
11B Input 11 (Sig)
Input 3 (Sig) 3B
Input 3 (Return) 3C
Input 4 (Excit) 4A
12B Input 12 (Sig)
Input 4 (Sig) 4B
Input 4 (Return) 4C
1 100M
Ethernet A
Input 5 (Excit) 5A
13B Input 13 (Sig)
Input 5 (Sig) 5B
Input 5 (Return) 5C
14A Input 14 (Excit) 100M
Input 6 (Excit) 6A Ethernet B
14B Input 14 (Sig)
Input 6 (Sig) 6B
Input 6 (Return) 6C
Input 7 (Excit) 7A
15B Input 15 (Sig)
Input 7 (Sig) 7B
Input 7 (Return) 7C
Input 8 (Excit) 8A
16B Input 16 (Sig)
Input 8 (Sig) 8B
Input 8 (Return) 8C
A
Excitation A
B
Signal B
+
TC -
C
Three-wire RTD
Return C

3.9.3 Operation
The 16 analog inputs can be individually configured as RTD inputs or TC inputs by
operator with HMI. The following table shows the input capability of BAI21 base.
Channels Analog Input Types
16 RTD of Pt100/Pt10/Cu100/Cu50 or TC of T/J/E/K/N/B/R/S per channel
In acquisition board of MAI22 AI module, there is a 1mA excitation current to each RTD,
which is not available for TC mode. All RTD/TC signal has a high frequency decoupling to
ground at signal entry.
3.9.4 Specification
Item Specification
Input span RTD of Pt100/Pt10/Cu100/Cu50 or TC of T/J/E/K/N/B/R/S per channel
3.9.5 Diagnostic

3.10 BAO21 Analog Output Base with 8 channels

The Analog Output base supports 8 analog outputs with current range of 0~20mA or
voltage range of 0~10V. The current output or voltage output is generated by MAO10
AO module. There is no circuit of both noise suppression and surge protection in the
board, which is an IO acquisition board of the MAO10 AO module.
There is a 64-pin connector and two 48-pin connectors provided on BAO21 for
connecting to the MAO10 AO module, where the 64-pin connector is used to connect
On the board, there are signal wires of 2 Ethernet port from dual RJ45 Ethernet
connectors and 4-pin power supply wire are connected directly to 64-pin connector,
and 8 analog output signals from dual 48-pin connectors are connected directly to
terminal.
The only difference between BAO21 and BAO10 is that BAO10 has redundant 24VDC
power supply input, but BAO21 only has one 24V power supply input. The 24VDC power
supply of BAO21 should be provided by diode coupler and redundant 24VDC power
supply.
BAO21 AO base board Processor board with 64

pin connector
1A
1B
2A
Internal
2B
24VDC power
24V
8 analog output 3A supply
24VGND
3B
4A
4B
5A
1
5B
6A 100M
6B Ethernet A
7A
7B
8A 100M
8B Ethernet B
Figure 3.10-1 BAO21 AO base

3.10.2 Installation
The 8 analog outputs are wired directly to one I/O terminal block mounted on the left of
the board. The block is held down with two screws and has 16 terminals accepting up to
#12 AWG wires.
Analog output, current source with range of 0~20mA/4~20mA
The following figure shows the details of BAO21 wiring and cabling.
BAO21 AO base board
24V 24V
24VGND 24V GND
Output 5 (Signal) 5A 1

Ethernet A

Ethernet B
Signal A Signal A
Current source Voltage source
output 0~20mA/ output 0~10V
4~20mA
Return B Return B
Figure 3.10-2 BAO21 base wiring

3.10.3 Operation
The 8 analog outputs can be individually configured as current source output with
range of 0~20mA or voltage source output with range of 0~10V by operator with HMI.
The following table shows the output capability of BAO21 base.

Table 3.10-1 BAO21 input type
Quantity Analog Output Types
8 0~10V or 0-20mA (max load resistor 750ohm) per channel
Table 3.10-2 BAO21 specification

Item Specification
Number of channel 8 channels per BAO21 base
3.10.5 Diagnostic
Each base has its own ID device that is interrogated by the MAO10 AO module. The ID
the chip is read by MAO10 module and a mismatch is encountered, a hardware

3.11 BDI11 Digital input /Pulse input Base with 24
channels

The Digital Input base supports 24 digital inputs and Pulse inputs. The 24 digital inputs
include dry contact, source current mode and sink current mode. There is no noise
suppression circuitry in the board, which is in IO acquisition board of the MDI12 DI
module.
There is a 64-pin connector and two 48-pin connectors provided on BDI11 for
connecting to the MDI12 DI module, where the 64-pin connector is used to connect the
the board, there are signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors
and 4-pin power supply wires are connected directly to the 64-pin connector, and 24
digital input signals are connected directly to dual 48-pin connectors.
The internal 24VDC provides power supply to CPU board of MDI12. The external 24VDC
provides power supply to IO boards of MDI12 and DI scan current. Both internal and
external power supply should be provided by diode coupler and redundant 24VDC
power supply.
BDI11 DI base board
13A Input 13 (Signal)

Input 1 (Signal) 1A
13B Input 13 (Return)
Input 1 (Return) 1B
Input 2 (Signal) 2A
Input 2 (Return) 2B
15A Input 15 (Signal) External
Input 3 (Signal) 3A X24VGND
15B Input 15 (Return) 24VDC power
Input 3 (Return) 3B
16A Input 16 (Signal) X24V
supply
Input 4 (Signal) 4A
16B Input 16 (Return) 24V
Internal 24VDC
Input 4 (Return) 24VGN
4B
17A Input 17 (Signal) D power supply
Input 5 (Signal) 5A
Input 5 (Return) 5B
Input 6 (Signal) 6A
Input 6 (Return) 6B
1 100M
Ethernet
19A Input 19 (Signal) A
Input 7 (Signal) 7A
Input 7 (Return) 7B
Input 8 (Signal) 8A 100M
Input 8 (Return) 8B
Ethernet
21A Input 21 (Signal) B
Input 9 (Signal) 9A
Input 9 (Return) 9B
Input 10 (Signal) 10A
Input 10 (Return) 10B
Figure 3.11-1 BDI11 DI base

3.11.2 Installation
wires.
The types of digital input that can be accommodated are as follows:
Dry contact
Wet contact with 24VDC
BDI11 DI base board

Input 1 (Signal) 1A
Input 1 (Return) 1B
Input 2 (Signal) 2A
Input 2 (Return) 2B
Input 3 (Return) 3B
supply
Input 4 (Signal) 4A
Internal 24VDC
4B
Input 5 (Signal) 5A
Input 5 (Return) 5B
Input 6 (Signal) 6A
Input 6 (Return) 6B
1 100M
Ethernet
Input 7 (Signal) 7A
Input 7 (Return) 7B
Input 8 (Return) 8B
Ethernet
Input 9 (Signal) 9A
Input 9 (Return) 9B
Figure 3.11-2 BDI11 base wiring

Wiring connection and cable connections of PI is as follows

BDI11 DI base board

Input 1 (Signal) 1A
Input 1 (Return) 1B
Input 2 (Signal) 2A
Input 2 (Return) 2B
Input 3 (Return) 3B
supply
Input 4 (Signal) 4A
Internal 24VDC
4B
Input 5 (Signal) 5A
Input 5 (Return) 5B
Input 6 (Signal) 6A
Input 6 (Return) 6B
1 100M
Ethernet
Input 7 (Signal) 7A
Input 7 (Return) 7B
Input 8 (Return) 8B
Ethernet
Input 9 (Signal) 9A
Input 9 (Return) 9B
Figure 3.11-3 BDI11 base PI wiring
3.11.3 Operation
Each channel can be configured by HMI. The following table shows the input capability
of the BDI11 base.
Table 3.11-1 BDI11 input type
Quantity Types
Digital input 0~30VDC (rated 24VDC) per channel
24 Pulse input
Table 3.11-2 BDI11 specification
Item Specification
Number of channel 24 configurable PI/DI channels,;
Input signal
PI: Signal frequency: 0200Hz The minimum pulse width: 2ms

3.11.5 Diagnostic
Each base has its own ID device that is interrogated by the MDI12 DI module. The ID
the chip is read by the MDI12 module and a mismatch is encountered, a hardware

3.12 BDO11 Digital Output Base
The Digital Output base accepts the 16 output control from MDO11 DO module and
provides interface to 16 AC relay/DC relay boards.
There is a 64-pin connector and one 48-pin connector to connect to the MDO11 DO
module. The 64-pin connector is used to connect the processor board and the 48-pin
connector is used to connect the IO conditioning board. On the board, signal wires of
two Ethernet ports from dual RJ45 Ethernet connectors and 4-pin power supply wires
are connected directly to the 64-pin connector, and 16 digital output signals from dual
48-pin connectors are connected directly to the terminals.
3.12.2 Installation
Connect the BDO11 with different relay modules by a 25-pin D-sub cable.
The internal 24VDC provides power supply to the CPU board of MDO11. The external
24VDC provides power to IO boards of MDO11 and driving current for the relay coil on
the relay boards. Both internal and external power supply should be provided by diode
coupler and redundant 24VDC power supply.
The following figure shows the details wiring and cabling of BDO11.
BDO11 DO base board
External
24VDC power
X24VGND
supply
X24V
24V
24VGN
Internal
D
24VDC power
supply
25-pin female D-sub
100M
Ethernet
A
100M
Ethernet
B
Figure 3.12-1 BDO11 Base

3.12.3 Operation
Table 3.12-1 BDO11 output types
Quantity Digital Output Types
16 1 NO/1 NC with 250VAC/10A per channel for BDO12
16 1 NO with 250VDC/10A per channel for BDO20
Item Specification
3.12.5 Diagnostic
Each base has its own ID device that is matched with the MDO11 DO module. The ID
the chip is read by the MDO11 module and a mismatch is encountered, a hardware
incompatibility error occurs.

3.13 BDO12 relay module with 16 DO 220VAC relays
3.13.1 Functional Description

This section describes the OC6 000e DO AC relay terminal board BDO12. BDO12 is an AC
relay terminal board which has 16 relay outputs. It is driven by BDO11 and connected to
output control module with a 25-pin D-sub cable.
NO0 NO8
COM0 COM8
NC0 NC8
NO1
COM1
NC1
......
NO7
COM7
......
NO15
COM15
NC7 NC15
Figure 3.13-1 BDO12 overview
3.13.2 Installation
The following steps describe how to install and uninstall the BDO12 module. The
following diagram shows the steps.
Align the four 4.0mm holes of the bottom plate with the four corresponding holes
of backplane plate, and then use four appropriate screws to fix it securely.
Remove the four screws. Then the module can be removed.

3.13.3 Terminals
Figure 3.13-2 the terminals of BDO12
Table 3.13-1 Terminal definition

terminal pin description
1 NO0
2 COM0
3 NC0
4 NO1
5 COM1
6 NC1
P2
7 NO2
8 COM2
9 NC2
10 NO3
11 COM3
12 NC3
13 NO4
14 COM4
15 NC4
P3 16 NO5
17 COM5
18 NC5
19 NO6

20 COM6
21 NC6
22 NO7
23 COM7
24 NC7
25 NO8
26 COM8
27 NC8
28 NO9
29 COM9
30 NC9
P4
31 NO10
32 COM10
33 NC10
34 NO11
35 COM11
36 NC11
37 NO12
38 COM12
39 NC12
40 NO13
41 COM13
42 NC13
P5
43 NO14
44 COM14
45 NC14
46 NO15
47 COM15
48 NC15
There is a 25-pin D-Sub P1 used to connect BDO12 and output control module.
The following diagram shows details of the D-Sub:
Figure 3.13-3 25-pin D-Sub

Table 3.13-2 PIN Assignment of D-Sub Connector
terminal pin signal name description
1 XDO_A0 Channel 0 Output Signal
P1 14 X24V_A 24V Power A
15 X24V_A 24V Power A
18 X24V_B 24V Power B
26 EARTH EARTH
27 EARTH EARTH
Item Specification
Number of channels 16
Output Contact
Resistor load capacity 10A/250VAC; 10A/30VDC
Inductor load capacity 7.5A/250VAC; 6A/30VDC
Power supply 24VDC10%
Power consumption 10W Maximum
Size (L x W x H) 174mm x 127mm x 46mm
Temperature -20C to 60C
Humidity 5~95% (without condensation)
3.13.5 Diagnostic
Diagnostic tests are made on BDO12 as follows:
1) Connect the cable to a digital output module. If HMI still shows low voltage alarm, the
cable is broken.
2) Connect the relay output to DI module. Make sure the DI and DO module is OK. In HMI
output all channels of DO to 1 and check if DI inputs are 1. Then output all channels of

DO to 0 and check if DI inputs are 0. If DI input is not the same as output, then the
relay is bad.

3.14 BDO20 relay terminal board with 16 DO 220VDC
relays
3.14.1 Functional Description

This section describes the OC 6000e DO DC relay terminal board BDO20. BDO20 is DC
relay terminal board which has 16 relay output. It is driven by BDO11 and connected to
output control module via 25-pin D-sub cable.
Figure 3.14-1 BDO20 overview
3.14.2 Installation
The following steps describe how to install and uninstall the BDO20 module. The
following diagram shows the steps.
Align the six 4.5mm holes of the bottom plate with the six corresponding holes of
backplane plate, and then use six appropriate screws to fix it securely.
Remove the six screws. Then the module can be removed.
3.14.3 Terminals
Figure 3.14-2 the terminals of BDO20

Table 3.14-1 Terminal definition
terminal pin description
1 COM0
P2
2 NO0
3 COM1
P3
4 NO1
5 COM2
P4
6 NO2
7 COM3
P5
8 NO3
9 COM4
P6
10 NO4
11 COM5
P7
12 NO5
13 COM6
P8
14 NO6
15 COM7
P9
16 NO7
17 COM8
P10
18 NO8
19 COM9
P11
20 NO9
21 COM10
P12
22 NO10
23 COM11
P13
24 NO11
25 COM12
P14
26 NO12
27 COM13
P15
28 NO13
29 COM14
P16
30 NO14
31 COM15
P17
32 NO15
There is a 25-pin D-Sub P1 used to connect BDO12 and output control module.
The following diagram shows details of the D-Sub:
Figure 3.14-3 25-pin D-Sub

Table3.14-2 PIN Assignment of D-Sub Connector
terminal pin signal name description
P1 14 X24V_A 24V Power A
26 EARTH EARTH
27 EARTH EARTH
Item Specification
Number of channels 16
Output Contact
Resistor load capacity 16A/500VAC; 10A/220VDC
Inductor load capacity 3.6A/110VDC; 2A/220VDC;
Power supply Dual 24VDC10%
Power consumption 0W typical, 22W Maximum
Size (L x W x H) 352mm x 127mm x 90mm
Temperature -20C to 60C
Humidity 5~95% (without condensation)
3.14.5 Diagnostic
Diagnostic tests are made on BDO20 as follows:
1) Connect the cable to a digital output module. If HMI still shows low voltage alarm, the
cable is broken.

2) Connect the relay output to DI module. Make sure the DI and DO module is OK. In HMI
output all channels of DO to 1 and check if DI inputs are 1. Then output all channels of
DO to 0 and check if DI inputs are 0. If DI input is not the same as output, then the
relay is bad.

Chapter 4 Communication Module
4.1 MCI10 Communication Module with 8 Channels of

RS-485

The MCI10 module provides the electrical interface between DCS system and other
systems. The module communicates with DCS system through one or two Ethernet, and
communicates with other systems through RS-422/485 networks under MODBUS
protocol. The MCI10 module is capable of handling up to 7 ports RS-485 and 1 port RS-
422/485 communication.
The module consists of a PC/104 motherboard and a PC/104 bus RS-422/485 expansion
board that are mounted on a terminal board. On the terminal board, the signal wires of
2 Ethernet ports from dual RJ45 Ethernet connectors and the 4-pin power supply wire
are connected to DCS system. Eight serial communication signals are used to connect
to other systems. Visual diagnosis is provided through indicator LED for power, Ethernet,
run, master and configuration. A diagnostic RS-232C port can provide information
during start-up.
Figure 4.1-1 MCI10 schematic diagram

4.1.2 Operation
The motherboard in the module contains the following:
PC/104 self-stacking bus
AMD low power LX800/500 MHz Processor
Onboard Flash (128 MB) and memory (256 MB)
AWARD 4 Mbit Flash BIOS
Lithium 3 V/196 mAH battery
Two fully independent 10M/100Mbps Ethernet ports
The motherboard connects to RS-422/485 expansion board with PC/104 connectors.
The module can operate from one or two Ethernet inputs. The IP address request uses
the industry standard dynamic host configuration protocol (DHCP). When operated from
two Ethernet inputs, both network paths are active all the time. A failure of either
network will not result in an interruption of the module operation, and the failure will be
indicated through the working network connection. This arrangement is more tolerant
of faults than a classic hot-backup system where the second port is only used after a
primary port failure is detected. The Ethernet ports on the processor run at 100 Mbps
speed and full-duplex operation.
4.1.2.2 Status LED

Power
Ethernet
Run
Master
Configuration
Two red LEDs labelled Power A B show the presence of dual redundancy 24V module
power supply input. Each LED indicates the status of one 24V power supply and is
always on after module powered on.
A green LED labelled RUN shows the firmware status. When firmware is in normal run,
the LED blinks ON and OFF. If the CPU has stopped working, the LED will be steady or off.
A green LED labelled MST shows the master status. When the module runs as a master
station, the LED is ON. When the module runs as a slave station, the LED is OFF.
A green LED labelled CFG shows the configuration status. When the module is
downloading configuration, the LED flashes, otherwise the LED is OFF.
Each Ethernet port has two LEDs with status as follows.
Table 4.1-1 Ethernet LED status
LED status
LED Function
On Off Blinking
Green Link indication Link No Link Activity
Yellow Activity indication No activity No activity Link

4.1.2.3 Connectors
MCI10 contains the following connectors:
The 4-pin connector on the top of the module is directly connected to dual 24VDC
power supply.
Figure 4.1-2 Power supply connector
The RJ45 Ethernet connector with LED named Net A is the primary system interface.
The RJ45 Ethernet connector with LED named Net B is the redundant or secondary
system interface.
The 29-pin connector on the bottom of the module is directly connected to the other
system and provides 1 port RS-232C, 7 port RS-485 and 1 port RS-422/485.
Table 4.1-2 Signal definition 29-pin connector

Pin No. Signal Comments
1 RXD
Only for
2 TXD RS-232C port
diagnosis
3 GND
4 A1+
5 B1- RS-485 port 1
6 GND1
7 A2+
8 B2- RS-485 port 2
9 GND2
10 A3+
11 B3- RS-485 port 3
12 GND3
13 A4+
14 B4- RS-485 port 4
15 GND4
16 A5+
17 B5- RS-485 port 5
18 GND5
19 A6+
20 B6- RS-485 port 6
21 GND6
22 A7+
23 B7- RS-485 port 7
24 GND7
25 A8/TX8+
26 B8/TX8- RS-485 port 8
27 GND8 RS-422 port 8
28 RX8+
29 RX8-
Note: There are no signal indicators on module case.

4.1.3 Specification
The following table gives an information spec for MCI10 serial communication module,
Table 4.1-3 MCI10 specification

Item Specification
Ethernet ports to DCS Dual 10M/100M Base-T Ethernet
COM ports to other system 7 RS-485 ports and 1 RS-485/422 port
9600bps, 19200bps at 3000 points
COM ports for diagnosis 1 port RS-232C
115200bps
Internal bus PC/104
Software system QNX
Protocol to other system MODBUS
Power supply Dual 24VDC
Power consumption 13W
Certification CE/FCC
Physical
Assembly 35mm DIN rail in communication cabinet
Size (L*W*H) 165mm*121mm*87mm
Weight 950g
Operating temperature 0 to 55C
Operating relative humidity 10-90%, non-condensing
4.1.4 Configuration
Refer to GEK-114905 OC 6000e Engineer Software Manual.
The chapter 2.9 Virtual Device shows how to configure the communication parameters
of 8 serial ports. Take care of the point that physical serial port 1~8 correspond to virtual
ports 5~12 in parameter setting.

isolated RS-485

The MCI11 module provides the electrical interface between the DCS system and other
systems, like PLC. The module communicates with DCS system through one or two
Ethernet, and communicates with other systems through isolated RS-422/485 networks
under MODBUS protocol. The MCI11 module is capable of handling up to 3 port isolated
RS-485 and 1 port isolated RS-422/485 communication.
The module consists of a PC/104 motherboard and a PC/104 bus RS-422/485 expansion
board that are mounted on a terminal board. On the terminal board, the signal wires of
2 Ethernet ports from dual RJ45 Ethernet connectors and the 4-pin power supply wire
are connected to DCS system. Eight serial communication signals are connected to the
other system. Visual diagnosis is provided through indicator LED for power, Ethernet, run,
master and configuration. A diagnostic RS-232C port can provide information during
start-up.
4.2.2 Operation
The mother board in the module contains the following:

The motherboard connects to the isolated RS-422/485 expansion board with PC/104
connectors. The module can operate from one or two Ethernet inputs. The IP address
request uses the industry standard dynamic host configuration protocol (DHCP). When
operated from two Ethernet inputs, both network paths are active all the time. A failure
of either network will not result in an interruption of the module operation, and the
failure will be indicated through the working network connection. This arrangement is
more tolerant of faults than a classic hot-backup system where the second port is only
used after a primary port failure is detected. The Ethernet ports on the processor run at
100 Mbps speed and full-duplex operation.
4.2.2.2 Status LED

Power
Ethernet
Run
Master
Configuration
Each Ethernet port has two LEDs with status as follows.

LED status
LED Function
On Off Blinking
4.2.2.3 Connectors

power supply.

system interface.
board and provides 1 port RS-232C, 3 port isolated RS-485 and 1 port isolated RS-
422/485.
1 RXD
Only for
2 TXD RS-232C port
diagnosis
3 GND
4 A1+
5 B1- N/A
6 GND1
7 A2+
8 B2- N/A
9 GND2
10 A3+
11 B3- N/A
12 GND3
13 A4+
14 B4- N/A
15 GND4
16 A5+
17 B5- RS-485 port 1
18 GND5
19 A6+
20 B6- RS-485 port 2
21 GND6
22 A7+
23 B7- RS-485 port 3
24 GND7
25 A8/TX8+
26 B8/TX8- RS-485 port 4
28 RX8+
29 RX8-
4.2.3 Specification

Item Specification
2000VDC isolation channel to channel
2000VDC isolation channel to system
115200bps
Internal bus PC/104
Software system QNX
Physical
Weight 1000g
4.2.4 Configuration
of 4 serial ports. Note that physical serial port 1~4 correspond to virtual ports 5~8 in
parameter setting.

isolated RS-485

The MCI12 module provides the electrical interface between the DCS system and other
systems. The module communicates with the DCS system through one or two Ethernet
networks, and communicates with other systems through isolated RS-422/485 networks
under MODBUS protocol. The MCI12 module is capable of handling up to 7 port isolated
RS-485 and 1 port isolated RS-422/485 communication.
The module consists of a PC/104 motherboard and two PC/104 bus RS-422/485
expansion boards that are mounted on a terminal board. On the terminal board, the
signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors and the 4-pin
power supply wire are connected to the DCS system. Eight serial communication signals
are connected with the other system. Visual diagnosis is provided through indicator LED
for power, Ethernet, run, master and configuration. A diagnostic RS-232C port can
provide information during start-up.
4.3.2 Operation

The motherboard connects to isolated RS-422/485 expansion board with PC/104
4.3.2.2 Status LED

Power
Ethernet
Run
Master
Configuration
Two red LED labelled Power A B show the presence of dual redundant 24V module
Each Ethernet port has two LED with status as follows.

LED status
LED Function
On Off Blinking
4.3.2.3 Connectors

power supply.

system interface.
system and provides 1 port RS-232C, 7 port isolated RS-485 and 1 port isolated RS-
422/485.
1 RXD
Only for
2 TXD RS-232C port
diagnosis
3 GND
4 A1+
5 B1- RS-485 port 1
6 GND1
7 A2+
8 B2- RS-485 port 2
9 GND2
10 A3+
11 B3- RS-485 port 3
12 GND3
13 A4+
14 B4- RS-485 port 4
15 GND4
16 A5+
17 B5- RS-485 port 5
18 GND5
19 A6+
20 B6- RS-485 port 6
21 GND6
22 A7+
23 B7- RS-485 port 7
24 GND7
25 A8/TX8+
26 B8/TX8- RS-485 port 8
28 RX8+
29 RX8-
4.3.3 Specification

Item Specification
2000VDC isolation channel to channel
2000VDC isolation channel to system
115200bps
Internal bus PC/104
Software system QNX
Physical
Weight 1100g
4.3.4 Configuration
of 8 serial ports. Note that physical serial port 1~8 correspond to virtual ports 5~12 in
parameter setting.

Ethernet

The MCI20 module provides the electrical interface between DCS system and other
systems, like PLC. The module communicates with DCS system through one or two
Ethernet, and communicates with other systems through Ethernet networks or RS-232C
networks under MODBUS protocol. The MCI20 module is capable of handling up to 2-
port Ethernet communication and 3-port RS-232C communication.
The module consists of a PC/104 plus motherboard and a PC/104 plus bus Ethernet
expansion board that are mounted on a terminal board. On the terminal board, the
signal wires of 2 Ethernet ports from dual RJ45 Ethernet connectors and the 4-pin
power supply wire are connected to DCS system. Two Ethernet ports from dual RJ45
Ethernet connectors and 3 RS-232C signals are connected to the other system. One RS-
232C offers diagnostic information for modules. Visual diagnosis is provided through
indicator LED for power, Ethernet, run, master and configuration. A diagnostic RS-232C
port can provide information during start up.
4.4.2 Operation

The motherboard connects to isolated RS-422/485 expansion board with PC/104
4.4.2.2 Status LED

Power
Ethernet
Run
Master
Configuration
Each Ethernet port has two LED with status as follows.

LED status
LED Function
On Off Blinking
4.4.2.3 Connectors

power supply.

system interface.
Two RJ45 Ethernet connectors (Net1 and Net2) on the middle of the module are
directly connected to the other system.
The 12-pin terminal on the bottom of the module provides 4-port RS-232C. Port 1
can only be used as diagnostic port and ports 2~4 are directly connected to the
other system.
1 RXD1
Only for
2 TXD1 RS-232C port 1
diagnostic
3 GND
4 RXD2
6 GND
7 RXD3
9 GND
10 RXD4
12 GND
4.4.3 Specification
The following table gives an information spec for MCI20 serial communication module.
Item Specification
Ethernet ports to other system Dual 10M/100M Base-T Ethernet
3 port RS-232C
COM ports to other system
1 port RS-232C
COM ports for diagnosis
115200bps
Internal bus PC/104 plus
Software system QNX
Protocol to other system MODBUS or IEC60870-5-104

Physical
Weight 950g
4.4.4 Configuration
of 2 Ethernet and 3 serial ports. Note that physical serial port 2~4 correspond to virtual
ports 2~4 in parameter setting. Physical Ethernet ports Net1~2 correspond to virtual
ports 192.168.1~2.xxx in parameter setting.

4.5 MDP Profibus-DP Communication Module
The MDP is a PROFIBUS-DP master communication module that provides the electrical
interface between OC DCS system and PROFIBUS-DP network, as well as controller
function. It maps I/O from PROFIBUS slave devices to DCS as virtual I/O modules.
Figure 4.5-1 MDP Profibus-DP Master Module
Two types of MDP module are available for PROFIBUS-DP communication, MDP10 &
MDP11. The former has 2 PROFIBUS-DP expansion boards, which means it can interface
with 2 PROFIBUS-DP networks, max 125 slave devices per network with repeater. And
MDP11 only has one PROFIBUS-DP expansion board.
For detail product information, please refer to GEK-118580 MDP Profibus-DP Master
Module Manual.

Chapter 5 OC 6000e input/output Module
Packages
5.1 Module Package overview

OC 6000e IO module comprises of module and base as follows,
Figure 5.1-1 OC600e IO module package overview
There are several features for the package,

Options of mounting module packages within cabinet with screw or 35mm DIN rail*.
Channel and CPU status indicated by LED.
Dust accumulation within module package is minimized.
Full metal enclosure grounding path and EMI shielding.
Non-interchangeable connection of incompatible module and base assemblies.
Notes: The mechanical parts are not the same for mounting with screw compared to
mounting with 35mm DIN rail.
5.2 Installation
The following steps describe how to install the IO module.
Align the four 5.3mm holes of the bottom plate assembly with the four
corresponding holes of backplane plate for mounting, then using four appropriate
screws to secure. Refer to "Figure 5.2-1" for illustration.

Tilt the left hand side of the bottom plate assembly downward appropriately toward
the left hand side rim of the 35mm DIN rail, then push the right hand side the
assembly upon the rail till snap. Refer to "Figure 5.2-2" for illustration.
Put the base assembly onto the bottom plate assembly and let the right hand side
of the base align with the groove on the right side of bottom plate, then slide the
base assembly to right until the two assemblies fit together. Refer to "Figure 5.2-3"
for illustration.
Align the bottom of the module assembly with the flange of base assembly, and
then push the module against base until the assemblies fit together. Refer to "Figure
5.2-4" for illustration.
Figure 5.2-1 Bottom plate installation
Figure 5.2-2 Bottom plate assembly

Figure 5.2-3 Base assembly
Figure 5.2-4 IO Module assembly

5.3 Disconnection
The following steps describe how to disconnect the IO module.
Push the two latched modules to the left side respectively, and then pull the module
assembly from base vertically toward operator, Refer to "Figure5.2-4" for illustration.
Pull out all connectors plugs, lift the base latch and then push the base assembly to
left. Refer to "Figure 5.2-3" for illustration.
Respectively loosen the four screws that fix the bottom plate assembly with
backplane plate. Refer to "Figure 5.2-1" for illustration.
Pull the rail latch outward then the right hand side of bottom plate assembly will tilt
upward. Pull the assembly to left side then the bottom plate assembly will be
disconnected from the rail. Refer to "Figure 5.2-2" for illustration.

GEK-114903 OC6000e Hardware Manual - V2.0

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Note Indicates an essential or important procedure or statement.

GEK-114903 OC 6000e Hardware Manual i

GEK-114903 OC 6000e Hardware Manual 1

Figure 1.3-1 Module Envelope and Mounting Dimensions

1.4 UCSA overview

2 GEK-114903 OC 6000e Hardware Manual

GEK-114903 OC 6000e Hardware Manual 3

1.6 UCSA Specifications

4 GEK-114903 OC 6000e Hardware Manual

2.1 MAI10 Analog Input with 16 channels of mA/V

2.1.1 Functional description

GEK-114903 OC 6000e Hardware Manual 5

Figure 2.1-1 16 Analog Input with mA/V schematic diagram

2.1.2 Groups & Compatibility

6 GEK-114903 OC 6000e Hardware Manual

GEK-114903 OC 6000e Hardware Manual 7

BAI10 AI base BAI10 AI base

Figure 2.1-2 MAI10 analog input conditioning circuit diagram

The inputs can be individually configured as 5 V or 10 V scale signals, depending on

8 GEK-114903 OC 6000e Hardware Manual

2.1.4.5 Module temperature monitor

2.1.4.6 Status LED

GEK-114903 OC 6000e Hardware Manual 9

Table 2.1-1 MAI10 specification

10 GEK-114903 OC 6000e Hardware Manual

GEK-114903 OC 6000e Hardware Manual 11

Table 2.1-3 MAI10 specific alarms

32~47 Analog Input [ ] Unhealthy Short-circuit of Analog Input []

48~63 Analog Input [ ] Unhealthy Open-circuit of Analog Input []

64~79 Analog Input [ ] Unhealthy Analog Input [] overflow

80~95 Analog Input [ ] Unhealthy Analog Input [] underflow

96~111 Low power supply per channel Power supply failure

112~127 SPI communication failure Analog Input hardware failure

Table 2.1-4 IO module common alarms

0 Diagnostic Alarm Reset Received Alarm Reset Command from controller

235 SOE lost SOE buffer full and lost

12 GEK-114903 OC 6000e Hardware Manual

282 Unable to initialize application Fatal Initialize failure

293 Waiting on IP addr from DHCP No Ip address on at least one port

GEK-114903 OC 6000e Hardware Manual 13

2.2.1 Functional description

14 GEK-114903 OC 6000e Hardware Manual

Figure 2.2-1 16 Analog Input with RTD/TC schematic diagram

2.2.2 Groups & Compatibility

GEK-114903 OC 6000e Hardware Manual 15

16 GEK-114903 OC 6000e Hardware Manual

BAI10 AI base BAI10 AI base

Figure 2.2-2 MAI20 RTD/TC conditioning circuit diagram

2.2.4.3 RTD Type and range

Table 2.2-1 MAI20 RTD types and temperature range

GEK-114903 OC 6000e Hardware Manual 17

Table 2.2-2 MAI20 TC types and temperature range

2.2.4.6 Power management and monitor

2.2.4.7 Module temperature monitor

2.2.4.8 Temperature compensation for TC type

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GEK-114903 OC 6000e Hardware Manual 19

Table 2.2-3 MAI20 specification

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