MOD 30 RetroPAK Installation Guide · Installation, operation ... All software, including design, appearance, algorithms and source code, ... a Link firmware upgrade may be required

MOD30 RetroPAKTM Installation Retrofit for MOD 30 Instruments Product Description, Installation and Wiring for MOD 30 ML Controller and Associated Hardware with Model C RetroPAK Adaptor

MicroMod Automation & Controls Inc.

The Company MicroMod Automation & Controls Inc is dedicated to improving customer efficiency by providing the most cost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation. We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support. The quality, accuracy and performance of the Company's products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology.

Use of Instructions

Warning. An instruction that draws attention to the risk of injury or death.

Note. Clarification of an instruction or additional information.

i Information. Further reference for more detailedinformation or technical details.

Caution. An instruction that draws attention to the risk of the product, process or surroundings.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices. Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of MicroMod Automation, Inc.

Licensing, Trademarks and Copyrights MOD 30, MOD 30ML and RetroPAK are trademarks of MicroMod Automation & Controls Inc. MODBUS is a trademark of the Modbus Organization Inc.

Health and Safety To ensure that our products are safe and without risk to health, the following points must be noted: The relevant sections of these instructions must be read carefully before proceeding.

1. Warning Labels on containers and packages must be observed.

2. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given or injury or death could result.

3. Normal safety procedures must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and/or temperature.

4. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used.

5. When disposing of chemicals, ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual may be obtained from the Company address on the back cover, together with servicing and spares information.

All software, including design, appearance, algorithms and source code, is copyrighted by MicroMod Automation & Controls, Inc. and is

owned by MicroMod Automation or its suppliers.

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

SECTION 1 PRODUCT DESCRIPTION

1.1 OVERVIEW

The MOD 30 RetroPAK controller is designed to replace the MOD 30 1700 Series instruments formerly manufactured under the names Taylor Instrument, CE-Taylor, ABB Kent-Taylor and ABB. It can be used to directly replace most of the MOD 30 instruments or to expand an existing MOD 30 installation. The MOD 30 RetroPAK is a microprocessor-based controller which can be configured to perform all the PID, math, sequence and logic functions available in the MOD 30 instruments, and provides additional features not available in that family. The front display of the MOD 30 RetroPAK presents process variable, setpoint, output and other operational data in a format similar to the MOD 30 instrument displays, but is much easier to view and operate. This model of the MOD 30 RetroPAK utilizes an adapter cable, as opposed to the direct connection on previous models.

1.1.1 Features

RetroPAK Instrument

Can be installed in existing MOD 30 bezels or panel cutouts

Accepts MOD 30 plug-in cable connections from 1720N Standard Termination Panel

Can match all MOD 30 Controller, Controller XL and Indicator I/O, as well as some Math Unit* and SLU* configurations, with a combination of built-in I/O circuits and plug-in I/O modules

Communicates on the ICN with MOD 30 instruments, Local Control Panel and Links

Allows tuning from front panel; no handheld device required

Provides a brighter, easier-to-read display with larger characters

Uses Windows-based configuration software with online debug and tuning

Allows addition of Modbus communications via RS-232 or RS-485

Includes all the secure process features of MOD 30 instruments such as cut wire detection, failsafe/power restore settings for every parameter, per-point diagnostics and a portable memory module

Provides loop power for 2-wire transmitters

Portable Memory Module

Optional plug on module that provides redundant, removable non volatile RAM for database backup, portability and integrity (allows a data base to be ported from one instrument to another)

Updated every 50 ms

* The MOD 30 RetroPAK includes one adapter cable. When replacing a Math Unit or SLU, a second adapter cable may be required. Note that the MOD 30 RetroPAK I/O is limited to less than the full capability of a Math Unit or SLU.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

Back of Housing

Front Panel

Figure 1-1. Location of Controller Components

Modules shown are factory installed when ordering I/O Option 2.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.1.2 Related Documents General installation and hardware instructions for the MOD 30ML IB-1800R-INS Operations/Setup, MOD 30ML Instructions on the operation and setup activities performed at the front face of the MOD 30 RetroPAK instrument are found in the following document: IB-1800R-OPR Operations/Setup, MOD 30ML Reference information on the database structure and configuration parameters for the MOD 30 RetroPAK can be found in the following documents: IB-1800R-APP Database reference for MOD 30ML IB-23G600 Data Base Reference for System, Logic, I/O and Communication Functions IB-23G601 Data Base Reference for Advanced Control Functions IB-23G602 Data Base Reference for Algorithms, Tables and Sequence Logic Functions IB-VIZAPP-TUT Visual Application Designer Software Setup & Tutorial Reference information on ICN/Link Communications for the MOD 30 RetroPAK can be found in the following documents: IB-23A160 ICN Planning Guide IB-23C001 ICN Communication Link Instructions for 1720N IB-23C003 ICN MiniLink Board Instructions for 1731N, 1732N IB-23C004 ICN MiniLink External Instructions for 1733N, 1732N All the above manuals are available for download at www.micromod.com and on the Visual Application Designer installation CD.

1.2 EXPLANATION OF MODEL NUMBERS The product described in this manual has a model number structure that identifies specific features. The controller and modules are also assigned serial numbers which are used to track manufacturing data. The general format of the catalog number is shown below; specific product descriptions are provided in the following sections. The model number on the product label contains a series of single and multiple-character codes. These codes provide specific information concerning various electrical and/or structural options. Certain code combinations are not allowed, and options and combinations are subject to change.

Sample Catalog No. M30RETRO 10 2 C STD

Base Number Approvals I/O Options Design Model Programming

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http://www.micromod.com/

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.3 BASIC HARDWARE This section describes the basic controller, built-in and modular I/O, and optional memory module.

1.3.1 Base Controller The MOD 30 RetroPAK controller, Figure 1-1, is designed specifically for replacement of 1700 series MOD 30 instruments formerly manufactured under the names Taylor, CE Taylor, ABB Kent-Taylor and ABB, or for expansion of an existing MOD 30 installation. The RetroPAK controller mounts in a MOD 30 bezel or panel cutout using a mounting scheme identical to that of the MOD 30 instruments. A cable adapter to connect the existing MOD 30 cable to the terminal block of the MOD 30ML is included. When a MOD 30 Math Unit or SLU is being replaced, a second cable may be required, depending upon I/O usage. The adapter cable connector accepts the existing MOD 30 cable (1750F series). The MOD 30 complement of analog and digital inputs and outputs is supported by a combination of built-in and modular I/O in the RetroPAK. The built-in circuits provide two analog inputs and two analog outputs. Up to 11 additional modules can be installed on the carrier board to provide the digital inputs, digital outputs and additional analog inputs. A total of 15 I/O points (4 built-in and 11 modular) are available in the MOD 30 RetroPAK. The parameters of each I/O point can be configured to match the parameters of the corresponding MOD 30 point. The MOD 30 RetroPAK can be ordered with factory installed I/O modules to match the I/O complement of the MOD 30 Controller (1700R, 1702R) or Controller XL (1701R, 1703R). It can also be ordered with only the base analog inputs and outputs, and the user can select additional modules to match the application as needed. The RetroPAK also includes built-in ICN communications and can communicate on the ICN with any MOD 30 instrument. When using a MOD 30 Communications Link or Mini-Link to provide data to a personal computer, a Link firmware upgrade may be required (see Appendix C). The built-in communication channel can be used to support the RS-232 port through the front panel of the RetroPAK controller, instead of the ICN. This provides direct communication with a personal computer for database configuration. In this case, ICN communication can be provided by installing a 2030N ICN Communication module. An Identity Module provides the functionality that gives the instrument the capability to execute a user-configured database. The CPU includes nonvolatile RAM for database storage and a real-time clock. A high speed communication channel is used between the CPU and all I/O. The CPU board also provides for connection of a plug-in, removable memory module.

1.4 1800P IDENTITY MODULE The identity module (see Figure 1-1) contains the process and communication functionality. It is factory installed and provides the capability to execute a user-configured database consisting of built-in and modular I/O handling, signal conditioning, PID control, math, sequence and other control functions which are available in the MOD 30 instruments. The identity module can be upgraded in the field as necessary.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.5 2010P MEMORY MODULE

The optional memory module plugs directly into the CPU board (see Figure 1-1) and performs all the same functions as the 1710F or 1711F MOD 30 memory module including: Copy a configured database from one RetroPAK controller to another Write-protect setting to prevent accidental erasures Updated every 50ms with real-time changes when installed on an operating RetroPAK Checksum between instrument and memory module to prevent database corruption Data retention is more than 10 years without power applied. Note that although it performs the same functions for the RetroPAK controller as the 1710F/1711F perform for the MOD 30, they are not interchangeable.

1.6 MODEL NUMBER DESCRIPTION FOR MOD 30 RETROPAK Table 1-1. Model Numbers

____ __ __ __ __ __ __ MOD30 RETROPAK 08 09-10 11 12 13-15

Base Controller

Standard bezel, 24Vdc power supply M30RETRO

Approvals

General Purpose 10

CE (European Community destinations only) 12

I/O Options - see Note 1

Standard I/O only (2 universal analog inputs, 2 current outputs) 1

Pre-installed I/O modules (1 additional analog input, 2 digital inputs, 3 digital outputs) 2

Standard I/O only, NEMA 4 with conformal coating 5

Design Model

Design Model C

Programming / Special Features

None STD

Configured to customer's MOD 30 specifications - see Note 2 M30

ACCESSORIES

ICN Communication Module (optional) 2030NZ10000B

ICN Termination Assembly (optional - 1 termination needed per ICN network) 2030FZ00001A

RS-485 Communication Module (optional) 2034NZ10000A

Extra RetroPAK Adapter Cable (1 included with base instrument) 109S5004

Analog Input Module, 1-5Vdc 2001AZ10101B

Digital Input Module, Non-isolated 2.2-24Vdc 2006AZ10100A

Digital Output Module, Non-isolated 25Vdc/50mA TTL 2007AZ10100A Note 1: Pre-installed modules match MOD 30 1701R I/O. Other I/O combinations may be ordered by using Standard I/O option and selecting additional modules from S-MOD-MODULES. Modules listed in Accessories match signal types compatible with the 1722F Field Input Board. Note 2: Customer must provide current database files and documentation. Controller will be configured as per documentation supplied. Excludes 1710R/1711R Sequence and Logic Unit.

1.7 I/O

The descriptions included in this section give a brief overview of the functions and features of the I/O available for the MOD 30 RetroPAK.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.7.1 Built-In Analog Inputs

The MOD 30 instruments accepted 4-20mA signals via the 1722F or 1723F field input board; mV or thermocouple signals via the 1734F field input board; or RTD inputs via the 1735F field input board. These input boards converted the field signal to 1-5Vdc for use by the MOD 30 instrument. The two built-in analog inputs on the RetroPAK controller can be configured by the user to accept milliamp, volt dc, millivolt, thermocouple, RTD or resistance. The default configuration is 1-5V, which corresponds to the signal received form the field input board on the Standard Termination Panel. The built-in analog inputs use the Built-In Analog Input (AIN) Block in the Visual Application Designer software for configuration of input parameters.

1.7.2 Built-In Analog Outputs The MOD 30 Controller and Controller XL provide two 4-20mA analog output signals. The two built-in analog outputs on the RetroPAK controller can be configured by the user as either 0-20mA or 4-20mA signals; the default configuration is 4-20mA. The built-in analog outputs use the Built-In Analog Output (AOUT) Block in the Visual Application Designer software for configuration of input parameters.

1.7.3 2001A Voltage Input Module

The voltage input module provides dual ranges of ±10V dc and ±100 mV dc. The 10V dc range can be selected and scaled for 1 to 5 V dc by configuration to match the input of the MOD 30 instruments. Input to the module is scaled and then applied to an integrating analog to digital converter. Line cycle integration can be performed at either 50 or 60 Hz line frequencies to reject any line frequency noise. Transformer isolation from the +5 volt supply is used to derive all the internal voltages to run the isolated front end. Optical isolation is used to transfer the information from the A/D converter serially to the microprocessor. The microprocessor takes the raw A/D voltage, compares it to the reference, and then presents it to the host as requested over the serial communications bus. This module uses the Voltage/Current Input Module (VCIM) Block in the Visual Application Designer software for configuration of input parameters. If the RetroPAK I/O Option 2 is ordered, one 2001A module is factory installed. Catalog Number Description for 2001A

BASE NUMBER 2001A Voltage Input Module

UNUSED Z Unused Character

ELECTRICAL CODE 10 General Purpose

INPUT RANGE 10 ±100 mV or ±10 Vdc

ISOLATION 1 Isolated

MODEL B Design Level

Sample Number 2001AZ10101B

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.7.4 2006A Nonisolated Digital Input Module

The Nonisolated Digital Input Module is primarily intended for instrument-to-instrument signaling. The module interfaces 24-volt on/off signals with no isolation or accepts switch contact closures without external power requirements. This module uses the Digital Input Module (DIM) Block for configuration of input parameters. If the RetroPAK I/O Option 2 is ordered, two 2006A modules are factory installed. Catalog Number Description for 2006A BASE NUMBER 2006A Nonisolated Digital Input Module



INPUT RANGE 10 2.2V to 24V dc

UNUSED 0 Unused Character

MODEL A Design Level

Sample Number 2006AZ10100A

1.7.5 2007A Nonisolated Digital Output Module

The Nonisolated Digital Output Module is primarily intended for instrument-to-instrument signaling. The module interfaces 24-volt on/off signals with no isolation or works as an open collector switch that also supports 5V TTL. This module uses the Digital Output Module (DOM) Block for configuration of output parameters. If the RetroPAK I/O Option 2 is ordered, three 2007A modules are factory installed. Catalog Number Description for 2007A

BASE NUMBER 2007A Nonisolated Digital Output Module



INPUT RANGE 10 24 V, 50 mA TTL

UNUSED 0 Unused Character


Sample Number 2007AZ10100A

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.7.6 2030N ICN Communication Module

The ICN Communication module provides Instrument Communication Network (ICN) communications capability for the MOD 30 RetroPAK when the built-in communication circuit is used to support the RS-232 communications port on the instrument front panel. The ICN is a proprietary network that allows peer-to-peer communications between the RetroPAK and the MOD 30 instruments. It also can use a communication link to a computer running the Visual Application Designer (ViZapp) or other compatible software. The ICN Baud rate is 31,250 bits per second, though the Communication Link settings specify the standard serial baud rate to a computer. The ICN requires an external terminator such as the 2030F ICN Terminator. If the RetroPAK is being installed with existing MOD 30 instruments, one of the existing Field Input Cards may already have the ICN termination resistors installed (see Figure 1-2). Only one terminator or set of resistors is required per ICN network. Installing a 2030F ICN Terminator if there are already ICN resistors on a field input card will cause ICN communication errors. The 2030N Communication Module is a double-wide module and occupies two slots on the carrier board. A rotating switch on the module is used to set the ICN address of the RetroPAK instrument. When used, the ICN Communication Module is installed in sockets S7 and S8 on the carrier board. This module is an option that must be ordered separately and installed by the user. Catalog Number Description for 2030N BASE NUMBER 2030N ICN Communication Module



UNUSED 000 Unused Characters

MODEL B Design Level

Sample Number 2030NZ10000B

Figure 1-2. 1722F Universal Input Board ICN Termination Resistors

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

1.7.7 2034N RS-485 Communication Module

The RS-485 module provides support for a single or multi-drop communication network. The module supports both Standard and Extended Modbus protocols. Its primary use is for connection to a host PC for configuration or data acquisition. The 2034N Communication Module is a 4-wire, double-wide module and occupies two slots on the carrier board. Rotating switches on the module are used to set the Modbus address of the RetroPAK instrument. A TERM switch provided bus stabilization (pull-up/pull-down) and a COMM DEFAULTS switch forces the module to 9600 baud, no parity and 8 databits on power-up. When used, the RS-485 Communication Module is installed in sockets S7 and S8 on the carrier board. This module is an option that must be ordered separately and installed by the user. Catalog Number Description for 2034N BASE NUMBER 2034N RS-485 Communication Module



UNUSED 000 Unused Characters


Sample Number 2034NZ10000A

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

SECTION 2 REPLACEMENT CONSIDERATIONS

2.1 GENERAL

This section provides information for planning the replacement of installed MOD 30 instruments using the MOD 30 RetroPAK. The principal factors to be considered when making a replacement are as follows:

The replacement applies to the instruments only. MOD 30 associated equipment such as termination panels, field input boards, power supplies, etc. are required for operation of the RetroPAK.

A single MOD 30 RetroPAK is used to replace any MOD 30 Controller, Controller XL, Indicator, or Math Unit. MOD 30 Sequence and Logic Units (SLU) often included remote I/O in excess of the capabilities of the MOD 30 RetroPAK controller. For SLU replacement contact MicroMod factory support.

Two I/O versions of the RetroPAK are available:

Model numbers M30RETRO__1C___ and M30RETRO__5C___ are supplied with only the base I/O. They provide only two built-in analog inputs and two built-in analog outputs. The user must specify any additional plug-in modules required for the specific application and install them as part of the replacement procedure.

Model number M30RETRO__2C___ is supplied with factory-installed I/O modules to match the I/O complement of 1700R and 1701R controllers (3 analog inputs, 2 analog outputs, 2 digital inputs and 3 digital outputs).

The maximum possible I/O count for a MOD 30 Math Unit 1700N is 22 points, using two cables. The maximum possible I/O count for the MOD 30 RetroPAK is 15 I/O points. It may be necessary to move I/O on the original MOD 30 units to multiple RetroPAK controllers. A second cable may be ordered separately if required.

Some I/O module locations on the RetroPAK controller can accept either an analog or a digital signal. When these locations are used for digital inputs, the corresponding analog input negative terminal must be grounded to the power supply negative at the termination panel (specific connection instructions are provided in Section 3).

The output holder 1725F/1726F used with the MOD 30 controllers is not supported by MOD 30 RetroPAK. For output holder capability contact MicroMod factory support.

The MOD 30 RetroPAK does not replace the MOD 30 Recorder 1700J.

If it is necessary to obtain both ICN communication and RS-232 communication for database configuration via the port in the front panel, a 2030N ICN Communication module must be installed.

If RS-485 communication is required, a plug-in RS-485 module must be specified. Special wiring is required for this option. Refer to the Communications section for details. The built-in communication port must be used for ICN, if required.

After completing installation of a MOD 30 RetroPAK, its database must be configured to match the functional requirements of the application. Configuration information is provided in other documents; see Section 1.1.2

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

2.2 COMMUNICATION AND I/O SIGNALS

2.2.1 Communications A built-in communications circuit supports either the RS-232 port in the front panel or communication over the ICN. If the built-in circuit is used for the RS-232 port, an ICN module must be installed to support ICN communication. The built-in port communication options are selected by positioning a jumper. Specific instructions for locating the jumper is provided in Section 3.4 Selection of the jumper positions is based on one of the following requirements:

Only ICN communication is required: Communication between the RetroPAK, a personal computer via a Communication Link, other MOD 30 or RetroPAK instruments is all done using ICN communications. The jumper is located to provide ICN communication via the built-in circuit. Installation of an ICN module is not required. The RS-232 port is not active.

ICN and RS-232 communications are required: This is typically used when the instruments are communicating to a personal computer via the Communication Link or Mini-Link and the user also desires the ability to plug into a single instrument using a laptop without a Link; or when the RetroPAK is only communicating with other MOD 30 instruments over the ICN (no host communication) and the database configuration will be done from a personal computer or laptop. The jumper is located to provide RS-232 communication via the built-in circuit. A 2030N ICN Communications module must be installed in module locations S7/S8 to support the ICN. Note that use of this module reduces the total number of I/O signals which can be accepted, as shown in Tables 2-2 and 2-3.

RS-485 and ICN communications are required: This is commonly used when all the MOD 30 instruments will be replaced, an RS-485 Modbus network will be substituted for the ICN Link communication to a PC, and peer-to-peer communication is required between instruments. The jumper is located to provide built-in ICN communication, and an RS-485 module 2034N is installed in locations S7 and S8. The RS-485 wiring must be made direct to the MOD 30 RetroPAK terminals. The MOD 30 cable does not support RS-485 communications.

Only RS-232 communication is required: No peer-to-peer communication with other MOD 30 or MOD 30 RetroPAK instruments. The built-in communication jumper is located to provide RS-232 communication via the built-in circuit.

2.2.2 I/O Signal Availability The I/O points available in the MOD 30 RetroPAK are distributed between built-in and modular circuits as follows:

Built-in circuits provide 4 points: 2 analog inputs and 2 analog outputs

I/O modules provide the following points:

3 module locations are dedicated to digital inputs 1, 2 and 3

4 module locations are dedicated to digital outputs 1, 2, 3 and 4

When only the built-in communication circuit is used, 4 remaining module locations can be used for analog inputs, digital inputs or digital outputs in any combination.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

When a communications module is used, 2 remaining module locations can be used for analog inputs, digital inputs or digital outputs in any combination.

The MOD 30 I/O signals which are assigned to a specific I/O module or built-in circuit are identified in Table 2-1. These are dedicated so as to match the termination positions on the MOD 30 instrument cables. The locations which are not dedicated and can be used for other MOD 30 analog and digital signals are identified in Tables 2-2 and 2-3. The user must select one location for each module depending on the requirements of the application. Table 2-3 shows a reduced number of locations available for additional I/O signals when a module is used for a second communication channel. Note that these module locations are selected to correspond to the wiring diagram in the appendix of this manual. Other layouts are possible. Refer to your company’s local signal wiring guidelines and the standard MOD 30ML Installation Manual for details.

Table 2-1. Locations Dedicated to Assigned I/O Signals

Location Signal Module location S1* Digital Input 1 Module location S2* Digital Input 2 Module location S11 Digital Input 3 Module location S3* Digital Output 1 Module location S4* Digital Output 2 Module location S5* Digital Output 3 Module location S6 Digital Output 4 Built-in analog input 1 (voltage) Analog Input 1 Built-in analog input 2 (voltage) Analog Input 2 Built-in analog output 1 (milliamp) Analog Output 1 Built-in analog output 2 (milliamp) Analog Output 2

Table 2-2. Locations for Additional I/O Signals – No Communication Module Installed

Location May be used for one of the following: Module location S7 Analog Input 5 Digital Input 7 Module location S8 Analog Input 6 Digital Input 6 Digital Output 7 Module location S9 Analog Input 3* Digital input 5 Digital Output 6 Module location S10 Analog Input 4 Digital Input 4 Digital Output 5

Table 2-3. Locations for Additional I/O Signals – Communication Module Installed

Location May be used for one of the following: Module location S7 & S8 ICN Module RS-485 Module Module location S9 Analog Output 3 Digital Input 5 Digital Output 6 Module location S10 Analog Input 4 Digital Input 4 Digital Output 5

* Denotes module included with pre-installed I/O option

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

2.2.3 I/O Signal Specifications

In general, the specifications for the MOD 30 RetroPAK are compatible with the MOD 30 instrument specifications. The following differences should be noted: Specification MOD 30 Instrument MOD 30 RetroPAK Current Requirements

Controller/Controller XL 0.55A max 0.63A max Indicator 0.50A max 0.63A max Math Unit 0.58A max 0.63A max

Digital Input

High Level (Logic 1) 4.0V dc min 2.2V dc min Low Level (Logic 0) 1.5V dc max 0.65V dc max Current load 3mA 2.5mA max

Digital Output

Voltage 30V dc max 24V dc max Current 50mA max 100mA dc max

2.3 CONTROLLER 1700R / CONTROLLER XL 1701R The MOD 30 Controller (1700R) and Controller XL (1701R) require a single interconnecting cable to carry power, ICN communication and I/O signals between the instrument and the termination panel. The MOD 30 RetroPAK uses this same cable. The full complement of 10 I/O points and one communication network can be accommodated by the MOD 30 RetroPAK. The controller I/O signals are as follows:

3 analog inputs

2 analog outputs

2 digital inputs

3 digital outputs

If the full I/O complement is required, the MOD 30 RetroPAK with factory installed I/O modules (I/O Option 2) should be used. The locations of the factory installed modules, their model numbers and I/O signals are shown on the I/O Planning Form. This option simplifies the replacement procedure because the user does not need to plan for and specify the required modules, or install the modules prior to making the replacement. If the full I/O complement is not required, the MOD 30 RetroPAK with I/O option 1 should be ordered and the necessary signals selected from the list of available I/O modules. Use the controller I/O module planning form to record the selected modules and their locations. An example of the form for a controller having one digital input, two digital outputs, and both ICN and RS-232 communication is shown in Figure 2-1. See Appendix A for a blank copy of the planning form.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

I/O MODULE PLANNING FORM FOR MOD 30 CONTROLLER 1700R & CONTROLLER XL 1701R

MOD 30 RetroPAK Replacement for Controller No. _______FIC-102__________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations.

RetroPAK Location MOD 30 Signal

(Factory Installed I/O) MOD 30 Signal (Base I/O only) Allowed Signals

Built-in analog input 1 Analog Input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 Analog Input 2 AI2 only Built-in analog output 1 Analog Output 1 Analog Output 1 AO1 only Built-in analog output 2 Analog Output 2 Analog Output 2 AO2 only Built-in communication port

RS-232 ICN or RS-232

S1 Digital Input 1 DI 1 DI1 only (2006AZ10100A)

S2 Digital input 2 NOT USED DI2 only (2006AZ10100A)

S3 Digital Output 1 DO 1 DO1 only (2007AZ10100A)

S4 Digital Output 2 DO 2 DO2 only (2007AZ10100A)

S5 Digital Output 3 NOT USED DO3 only (2007AZ10100A)

S6 Not Used Not Used None S7 S8

ICN ICN module (2030NZ10000B)

S9 Analog Input 3 NOT USED AI3 only (2001AZ10101B)

S10 Not Used Not Used None S11 Not Used Not Used None

* ICN module is double-wide and requires two locations.

Figure 2-1. Example of an I/O Planning Form for a Controller Replacement

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

2.4 MATH UNIT 1700N The MOD 30 Math Unit requires two interconnecting cables to carry power, ICN communication, and support for all of its I/O signals between the instrument and the termination panel. The MOD 30 RetroPAK will need a second adapter cable if the Math Unit being replaced uses both of these cables. The full I/O complement for the Math Unit is as follows:

• 6 Analog Inputs

• 2 Analog Outputs

• 7 Digital Inputs

• 7 Digital Outputs

The 22 I/O points available in a Math Unit are not fully covered by the MOD 30 RetroPAK, which can accommodate only 15 I/O points. The combination of built-in and modular I/O in the MOD 30 RetroPAK does accommodate many Math Unit I/O combinations. For example, a possible arrangement using all 15 available points might be:

• 4 Analog Inputs

• 2 Analog Outputs

• 5 Digital Inputs

• 4 Digital Outputs

In this example, 2 analog inputs and 2 analog outputs are accommodated by the built-in I/O circuits. The remaining 11 points are handled by the modular I/O. Use the Math Unit I/O planning form to record the required modules and their locations for a specific application. An example of the form filled in to document the above example is shown in Figure 2-2. Note that the built-in circuit is specified for the ICN so that all module locations are available for I/O signals (see Section 2.2.1). See Appendix A for a blank copy of the planning form. This example requires two MOD 30 cables and two positions on the Standard Termination Panel. NOTE: Use of any I/O points beyond the standard Controller/Controller XL I/O may utilize a second MOD 30 cable from the Termination Panel connected to an optional second adapter cable on the rear of the MOD 30 RetroPAK. Connections may optionally be made direct to the MOD 30 RetroPAK terminals.

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MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

I/O MODULE PLANNING FORM FOR MOD 30 MATH UNIT 1700N

MOD 30 RetroPAK Replacement for Math Unit No. _________MA-101___________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations.

RetroPAK Location MOD 30 Signal Allowed Signals Built-in analog input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 AI2 only Built-in analog output 1 Analog Output 1 AO1 only Built-in analog output 2 Analog Output 2 AO2 only Built-in communication port

ICN ICN or RS-232

S1 DI1 DI1 only (2006AZ10100A)

S2 DI2 DI2 only (2006AZ10100A)

S3 DO1 DO1 only (2007AZ10100A)




S7 DI7 AI5* (2001AZ10101B) OR DI7* (2006AZ10100A) OR ICN Module (2030NZ10000B)

S8 DI6 AI6* (2001AZ10101B) OR DI6* (2006AZ10100A) OR DO7* (2007AZ10100A) OR ICN Module (2030NZ10000B)

S9 AI3 AI3 (2001AZ10101B) OR DI5* (2006AZ10100A)

S10 AI4 AI4 (2001AZ10101B) OR DI4 (2006AZ10100A) OR

DO5 (2007AZ10100A)

S11 DI3 DI3 only (2006AZ10100A)

*not allowed if ICN module selected. Communications modules require two locations.

Figure 2-2. Example of an I/O Planning Form for a Math Unit Replacement

2-7

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

2.5 INDICATOR 1700K

The MOD 30 indicator 1700K requires a single interconnecting cable to carry power and I/O signals between the instrument and the Standard Termination Panel. The MOD 30 RetroPAK uses this same cable. The full complement of 5 I/O points can be accommodated by the MOD 30 RetroPAK. The I/O signals are as follows:

3 analog inputs

2 analog outputs The MOD 30 RetroPAK accepts analog inputs no.1 and no. 2 via built-in input circuits 1 and 2 as indicated in Table 2-1. An analog input module (model number 2006AZ10100A) must be installed in location S9 to provide the third analog input. Digital output modules (2007AZ10100A) must be installed in locations S3, S4 and S6 to provide digital outputs number 1, 2 and 3. Since the MOD 30 indicator does not communicate over the ICN, the MOD 30 RetroPAK may be configured via the RS-232 port in the front panel or over an RS-485 Modbus network if ICN is not desired. The MOD 30 RetroPAK with I/O option 1 should be ordered and the necessary signals selected to accommodate the third analog input and any required digital I/O. Use the Indicator I/O module planning form to record the selected modules and their locations. An example of the form for an indicator using all I/O and set up for built-in RS-232 communication is shown in Figure 2-2. See Appendix A for a blank copy of the planning form.

2-8

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

I/O MODULE PLANNING FORM FOR MOD 30 INDICATOR 1700K

MOD 30 RetroPAK Replacement for Indicator No. ______FI-103_____________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations. RetroPAK Location MOD 30 Signal Allowed Signals Built-in analog input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 AI2 only Built-in analog output 1 Not Used None Built-in analog output 2 Not Used None Built-in communication port RS-232

S1 Not Used None S2 Not Used None




S6 Not Used None

S7

S8 Not used ICN Module (2030NZ10000B)

S9 AI3 AI3 only (2001AZ10101B)

S10 Not Used None S11 Not Used None

The diagram below shows blank locations available for additional signals in accordance with Allowed Signals, above.

Figure 2-3. Example of an I/O Planning Form for an Indicator Replacement

2-9

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

2-10

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

SECTION 3 REPLACEMENT PROCEDURE

3.1 GENERAL

Read these instructions thoroughly before starting this procedure. Installation is to be performed by qualified technicians.

The replacement procedure involves:

Unpacking the MOD 30 RetroPAK (Section 3.2)

Installing I/O modules, if necessary, and the optional memory module (Section 3.3)

Setting up communications (Section 3.4)

Removing the old MOD 30 instrument (Section 3.5)

Installing the MOD 30 RetroPAK (Section 3.6)

3.1.1 Display

The display is protected by an overlay that can be removed after installation. The face of the display, while made of scratch-resistant plastic, can be abraded by harsh materials such as paper towels and industrial wipes. Lens cleaning tissues and soft cloths moistened with water are suitable for cleaning displays.

3.1.2 Storage

The ambient temperature for any equipment kept in storage must be between -40C and 75C (-40F and 167F).

3.2 UNPACKING THE MOD 30 RETROPAK Unpack and visually inspect the instrument housing, instrument, and associated modules for any damage. Save packing materials for any reshipment, or to support any claim of shipment damage. All damage claims are made against the carrier and are the responsibility of the customer. Included in the shipping container is a bag containing the following items:

Mounting brackets and retaining screws

RetroPAK adapter cable and jumpers

Installation manual Instructions for assembly of the mounting bracket, static drain clip, and cable connector mounting screws are provided in Section 3.6.1. The information package includes a card containing several copies of a writeable instrument identification tag. Write required data on the tag and insert it under the translucent strip at the bottom of the front panel after the MOD 30 RetroPAK is installed.

3-1

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.3 INSTALLING MODULES The I/O modules mount on the carrier board, and the optional memory module mounts on the CPU board as shown in Figure 1-1. If a MOD 30 controller is being replaced by the MOD 30 RetroPAK with factory installed I/O and no additional signals or communication network is required. Proceed to Section 3.4. If the factory installed I/O option was not selected and/or the user ordered additional I/O modules to fit the application, the I/O modules must be installed before placing the controller into operation. Each I/O module must be installed in a location which receives or transmits the appropriate MOD 30 signal. The following procedure is based on the assumption that the number of modules, the module types, and the location of each module has been determined as described in Section 2. Install the modules as follows:

1. Loosen the retaining screw(s) in the front panel, Figure 1-1, and pull the instrument out of its housing.

! CAUTION Support the instrument from the front and bottom whenever the instrument is outside its housing. Do not allow the full weight of the circuit boards to be suspended unsupported from the front display assembly as this may overstress the brackets at that end.

2. Place the instrument on a flat surface with the front panel overhanging the edge of the surface so that the carrier circuit board is firmly supported. This positioning assures that the instrument is not damaged by the force applied when inserting I/O modules.

3. Plug each I/O module into its required location on the carrier board and tighten the retaining screw.

4. If the optional memory module is being used and will be left installed during normal instrument operation, it can be plugged into the location provided on the CPU board.

5. If using a communication module, it must be plugged into sockets S7 and S8.

3-2

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.4 SETTING UP COMMUNICATIONS

3.4.1 ICN and/or RS-232 Either the built-in or plug-in ICN can be directed to the Standard Termination Panel via the MOD 30 Cable connection. The adapter wires are connected to different terminals to make this selection. The Port 1 Communication Jumper is used to determine the type for the built-in communication port. Figure 3-1 illustrates the jumper locations.

1. If the instrument is in its housing, loosen the retaining screw(s) in the front panel and pull the instrument out of the housing.

2. If a 2030N ICN Communications module is required, install the module in locations S7 and S8 using the procedure described in Section 3.3. Set the module address switch as required. This switch has setting in hexadecimal 0 through F, representing decimal 0 through 15. Note that each device on the ICN must have a unique address.

3. Position the communication jumper for the required communication.

4. Insert the instrument into its housing and tighten the screw(s) to draw the front panel tight against the housing.

Figure 3-1. Communication Port 1 Jumper Selection (RS-232 shown)

3-3

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.4.2 RS-485

It may be desirable to use Modbus RS-485 communication to a personal computer in place of ICN communications through a Link. This is done by installing an RS-485 module (2034N) in locations S7 and S8. If ICN peer-to-peer communication is also required, the built-in communication port is to be set to ICN. Because the MOD 30 instrument series does not support RS-485 communications, additional wiring connections must be made. See section 2.2.1 for details.

1. If the instrument is in its housing, loosen the retaining screw(s) in the front panel and pull the instrument out of the housing.

2. Install the RS-485 module in locations S7 and S8 using the procedure described in Section 3.3

3. Set the Modbus Address switches for the correct address on the Modbus network. The High switch sets the first hexadecimal digit of the address, and the Low switch sets the second. For example, a switch setting of 13 hex represents a decimal address of 19. For additional information on using Modbus, refer to IB-MODBUS-RTU.

4. If ICN Communications is required, set the Built-In Communication Port jumper to the ICN position.

5. Insert the instrument into its housing and tighten the screw(s) to draw the front panel tight against the housing.

Figure 3-2. ICN Selection for Port 1and RS-485 Module in Port 2

3-4

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.5 REMOVING OLD MOD 30 INSTRUMENT The MOD 30 RetroPAK makes use of the cables from the existing installation. If there is a MOD 30 instrument installed in the location planned for the replacement, remove the MOD 30 instrument and its housing as follows:

1. Ensure the process is in a safe condition before removing the instrument.

2. Press the release tab on the bottom of the bezel and pull the MOD 30 instrument out of its housing.

3. Remove the back cover, Figure 3-2, from the housing.

4. Disconnect the drain wire from the static drain clip. If the drain wire is connected to other MOD 30 instruments which are to remain installed, the wire must remain in place to connect each of these instruments together and to ground.

5. Remove the cable mounting screws to disconnect the cable(s) from the back cover.

6. Loosen the retaining screws and remove mounting brackets from the top and bottom of the housing.

7. From the front of the panel, remove the housing.

Figure 3-2. Removing MOD 30 Instrument Housing

3-5

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.6 INSTALLING MOD 30 RETROPAK After removing a MOD 30 instrument, the replacement instrument can be installed in the same panel or bezel opening and connected to the existing MOD 30 cables using the following procedures.

3.6.1 Mounting

1. Connect the adapter cable to the terminals at the rear MOD 30 RetroPAK housing. Refer to the diagram in appendix D for wiring instructions.

2. If the MOD 30 RetroPAK is not in its housing, insert the instrument and tighten the screw(s) to draw the front panel tight against the housing. It is recommended that the housing be mounted with the instrument installed. This improves the housing rigidity and helps prevent the possibility of distortion when the mounting screws are tightened.

3. From the front of the panel, insert the instrument into the panel or bezel opening.

4. From the back of the panel, insert mounting brackets into the slots in the top and bottom of the housing.

5. Tighten retaining screws to hold instrument in place. Use torque of 5 inch-pounds (0.6 Nm), or turn each screw 1-1/2 turns after contact is made with the back of the panel.

6. Press and hold the retaining clip on the RetroPAK adapter cable connecter. Connect the MOD 30 cable to the RetroPAK adapter cable and release the retaining clip. An optional second adapter may be required when replacing a Math Unit or SLU that uses two cables.

3-6

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3.6.2 Electrical Connections The required power, ICN communication, and I/O signal connections to the replacement instrument are made via the cables which are installed as part of the mounting procedure.

! CAUTION The RetroPAK is a 24V DC unit that is powered through the cable to the Standard Termination Panel. DO NOT connect a power source directly to its rear terminals!

If I/O module location S7, S8, S9, or S10 is used for a digital input or output, the negative terminal of the alternate analog signal which can use the location must be grounded to the negative power supply terminal at the termination panel, and the positive terminal of the analog signal must be open circuited.

The negative analog and power terminals are identified in Figure 3-5. The required connections are as follows:

To use module location S7 for a digital signal, ground Analog Input 5 negative.




NOTE: Before putting the MOD 30 RetroPAK into operation, it must be configured using either the front panel keys or the VIZAPP Visual Application Designer software. See Section 1.1.2 for related documents.

1720F Termination Panel Section Connected to Adapter1 on RetroPAK

1720F Termination Panel Section Connected to Adapter 2 on RetroPAK

Figure 3-5. Identification of Negative Terminals for Analog Input Numbers 3, 4, 5, 6 and Power

3-7

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

3-8

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

APPENDIX A PLANNING FORMS

A.1 GENERAL

The forms included in this appendix may be copied as necessary to record the /O module layout for MOD 30 RetroPAK used to replace MOD 30 Controller, Controller XL, Math Unit and Indicator.

A-1

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

I/O MODULE PLANNING FORM FOR MOD 30 CONTROLLER 1700R & CONTROLLER XL 1701R

MOD 30 RetroPAK Replacement for Controller No. _______________________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations.

RetroPAK Location MOD 30 Signal

(Factory Installed I/O) MOD 30 Signal (Base I/O only) Allowed Signals

Built-in analog input 1 Analog Input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 Analog Input 2 AI2 only Built-in analog output 1 Analog Output 1 Analog Output 1 AO1 only Built-in analog output 2 Analog Output 2 Analog Output 2 AO2 only Built-in communication port

ICN or RS-232

S1 Digital Input 1 DI1 only (2006AZ10100A) S2 Digital input 2 DI2 only (2006AZ10100A) S3 Digital Output 1 DO1 only (2007AZ10100A) S4 Digital Output 2 DO2 only (2007AZ10100A) S5 Digital Output 3 DO3 only (2007AZ10100A) S6 Not Used Not Used None S7 S8

ICN (2030NZ10000B) OR RS-485 (2034NZ10000A)

S9 Analog Input 3 AI3 only (2001AZ10101B) S10 Not Used Not Used None S11 Not Used Not Used None

* ICN and RS-485 modules are double-wide and require two locations. The diagram below shows the locations of pre-installed modules when the Factory Installed I/O option is selected. Blank locations are available for additional signals in accordance with Allowed Signals, above.

Figure A-1. Controller Module Locations with Pre-installed I/O Option

A-2

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

I/O MODULE PLANNING FORM FOR MOD 30 MATH UNIT 1700N

MOD 30 RetroPAK Replacement for Math Unit No. _______________________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations.

RetroPAK Location MOD 30 Signal Allowed Signals Built-in analog input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 AI2 only Built-in analog output 1 Analog Output 1 AO1 only Built-in analog output 2 Analog Output 2 AO2 only Built-in communication port

ICN or RS-232

S1 DI1 only (2006AZ10100A) S2 DI2 only (2006AZ10100A) S3 DO1 only (2007AZ10100A) S4 DO2 only (2007AZ10100A) S5 DO3 only (2007AZ10100A) S6 DO4 only (2007AZ10100A)

S7 AI5* (2001AZ10101B) OR DI7* (2006AZ10100A) OR ICN (2030NZ10000B) OR RS-485 (2034NZ10000A)

S8 AI6* (2001AZ10101B) OR DI6* (2006AZ10100A) OR DO7* (2007AZ10100A) OR ICN (2030NZ10000B) OR RS-485 (2034NZ10000A)

S9 AI3 (2001AZ10101B) OR DI5* (2006AZ10100A) OR DO6 (2007AZ10100A)

S10 AI4 (2001AZ10101B) OR DI4 (2006AZ10100A) OR

DO5 (2007AZ10100A) S11 DI3 only (2006AZ10100A) *Not allowed if ICN or RS-485 module selected. Communications modules require two locations. The diagram below shows locations available for I/O modules in accordance with Allowed Signals, above.

Figure A-2. Math Unit Module Locations

A-3

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

A-4

I/O MODULE PLANNING FORM FOR MOD 30 INDICATOR 1700K MOD 30 RetroPAK Replacement for Indicator No. _______________________ The table below shows the RetroPAK locations that are dedicated to specific MOD 30 signals (shaded in gray), and those that are available for user selection (blank). See the Allowed Signals column for MOD 30 signals that can be assigned to blank locations. RetroPAK Location MOD 30 Signal Allowed Signals Built-in analog input 1 Analog Input 1 AI1 only Built-in analog input 2 Analog Input 2 AI2 only Built-in analog output 1 Not Used None Built-in analog output 2 Not Used None Built-in communication port RS-232 See Section 2.4

S1 Not Used None S2 Not Used None S3 DO1 only (2007AZ10100A) S4 DO2 only (2007AZ10100A) S5 DO3 only (2007AZ10100A) S6 Not Used None S7 S8

ICN (2030NZ10000B) OR RS-485 (2034NZ10000A)

S9 AI3 only (2001AZ10101B) S10 Not Used None S11 Not Used None

The diagram below shows blank locations available for additional signals in accordance with Allowed Signals, above.

Figure A-3. Indicator Module Locations

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

APPENDIX B USING THE RETROPAK MEMORY MODULE

The portable memory module is an optional device which plugs directly into the CPU board. It can be used to maintain a mirror image of a controller database, reload a database into a controller after replacement, or transfer a copy of a database from one instrument to another. A small part of the database image is reserved for shutdown and diagnostic information and serves as a valuable troubleshooting and diagnostic tool. Refer to IB-23M601 for more information.

A controller database can be copied into the Memory Module and the module removed for safekeeping. Data retention, when the module is not installed on a working instrument, is typically 10 years. A module installed on a working controller will retain its data much longer. This provides a known good configuration as a backup. When a memory module is installed in a working instrument in Read/Write mode and software write protection off, the operating software keeps the module up-to-date with all real time changes in the instrument, including: tuning parameter changes; output values and states; changes made by operators; calculation results; sequence steps; alarm trip points and values; etc. These changes are written to the module every 50 milliseconds. Checksums protect the data in the module from being overwritten by bad data in the event of an instrument failure. Should a controller need to be replaced, the Memory Module containing the database for that controller can be plugged into a new controller and the database will be instantly transferred to the new controller when it is plugged into the housing (with power applied). This allows rapid replacement of controllers without programming. If the memory module was being updated by the old controller, the last good values of all parameters will also be loaded into the new controllers. The controller provides the option to automatically download from an installed Memory Module after a loss of power. This option must be selected during initial configuration of the controller.

B-1

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

MODULE SWITCHES There are two switches on the memory module, which control the flow of data between the module and the controller: the READ/WRITE switch and NORMAL/LOAD switch. Read / Write Switch

This switch has two positions: READ/WRITE and READ ONLY.

Read / Write Position With the switch in the READ/WRITE position, data can be written to the memory module by the controller.

Read Only Position With the switch in the READ ONLY position, the database in the memory module cannot be updated or overwritten by the controller. If a module is installed on a controller with the switch in this position, the controller generates a diagnostic indicating the Memory Module is write-protected.

Allows updates to memory module, from the controller

Database in memory module cannot be updated or overwritten.

Normal / Module Load Switch

This switch has two positions: NORMAL and MODULE LOAD.

Copies image of controller database into memory module on power up.

Normal Position With this switch in the NORMAL position, data is automatically transferred from the Memory Module to the instrument, on power up only. This is also referred to as downloading a database from the Memory Module. CAUTION: There are no partial downloads. The existing database in the controller will be overwritten. If the module is left on the controller during normal operation, it allows the module to accept updates to current process parameters. Data does not pass from the Module to the Controller during normal operation.

Module Load Position With this switch in MODULE LOAD position, the database resident in the controller is transferred to the memory module on power up. This action will overwrite any data currently residing in the memory module, if the Read/Write switch is set to READ/WRITE and the Memory Module is not write protected.

Loads Memory Module database into controller on power up. Allows updates to Memory Module during operation.

The following table shows the data flow for each combination of switch positions:

B-2

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

SWITCH POSITION SWITCH 1 SWITCH 2

READ/WRITE READ ONLY

NORMAL MODULE

LOAD

X X

Database transfer from memory module to controller on power up. Memory module updated every 50ms by controller during operation.

X X Complete contents of controller memory transferred to memory module (UPLOAD). Existing program is overwritten.

X X Instrument and/or PC cannot write to memory module. Contents remain unchanged.

X X

Invalid combination. Instrument display will indicate MEM MOD WRTPROT, UPL ERR (memory module write protected, upload error)

Memory Module Upload/Download

The term “upload” means transferring a database image from a controller to a Memory Module. The term “download” means transferring a database image from a Memory Module to a controller.

Uploading to a Memory Module

Place the Read/Write switch in READ/WRITE position Place the Normal/Module Load switch in MODULE LOAD position

Install the Memory Module on the controller. Power up the controller. The instrument attempts to transfer the database image to the Memory Module during the power up sequence. It then runs the default database with the instrument state equal to UPLOAD. Diagnostics and system events may be read from the instrument, but the instrument state cannot be changed to RUN until power is removed and either the memory module is removed from the instrument, or the Normal/Module Load switch is placed in the NORMAL position.

UPLOAD? appears on the front panel

UPLOAD?

NO

UPLOAD?

NO

UPLOAD?

NO

UPLOAD?

NO

B-3

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

Press the UP or DOWN arrow key to select YES. A flashing ENT appears next to the Scroll key.

Press the Scroll key to accept the upload.

The UPLOAD DONE / SET WP display appears.

Unless you intend to keep this memory module as a known good copy of this controller’s database, DO NOT answer YES to SET WP? on this display. If you wish to be able to use the memory module for other applications or controllers, REMOVE POWER FROM THE INSTRUMENT AT THIS TIME. Answering YES to SET WP? Write protects the Memory Module in software and overrides all module switch positions. Once set, the Write Protect can ONLY be removed using ViZapp Configuration Software. Contact MicroMod for instructions on removing the Write Protect.

YES

ENT

UPLOAD?

/

flashing

YES

ENT

UPLOAD?

//

flashing

UPL DONESET WP?

NO

UPL DONESET WP?

NO

UPL DONESET WP?

NO

UPL DONESET WP?

NO

B-4

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

Downloading from a Memory Module

Place the Read/Write switch in either READ/WRITE or READ position Place the Normal/Module Load switch in NORMAL position

Install the Memory Module on the controller.

Power up the controller. The controller verifies that the database image in the module has valid checksums, the configuration matches the controller firmware version, and the configured communication ports match those on the controller. If these parameters are good the database image is automatically transferred to the controller on power up. IMPORTANT: View all diagnostic alarms after power up. If the download from the memory module failed, the controller will display one or more diagnostic alarms and either the previous database will remain installed, or the controller will run the Default database.

READ/WRITE

READ ONLY

NORMAL

MODULELOAD

READ/WRITE

READ ONLY

NORMAL

MODULELOAD

READ/WRITE

READ ONLY

NORMAL

MODULELOAD

READ/WRITE

READ ONLY

NORMAL

MODULELOAD

MEM MODDNLDFAIL

UAK

RET

47

IF 1

Failure indication

Diagnostic code

MEM MODDNLDFAIL

UAK

RET

47

IF 1

MEM MODDNLDFAIL

UAK

RET

47

IF 1

Failure indication

Diagnostic code

Diagnostic alarms The following diagnostic alarms are associated with memory module upload/download:

Code Failure indication Description 47 MEM MOD DNLDFAIL The database was not downloaded from the memory module 8 MEM MOD

CHKSMERR Checksum error found in memory module database

9 MEM MOD UNCONFIG

There is no valid database in the memory module

10 MEM MOD VERSERR The controller does not have the hardware and/or firmware to run the database in the memory module

11 MEM MOD WP The switch on the memory module is in the “READ ONLY” position

12 MEM MOD SWP The memory module has been write protected in software 16 COMM PORT

MISMATCH The database in the memory module does not match the communications ports on the controller

B-5

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

B-6

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

APPENDIX C ADAPTER CABLE

C.1 CONNECTIONS The diagram below shows typical connections that can be made using the MOD 30 RetroPAK conversion cable to a MOD 30ML with a Model C termination. The same connections are available on Models A and B, though their terminal style and numbering is different.

The connections shown are from the available signals in the J1 connector of the MOD 30. A second cable may be necessary when replacing MOD 30 instruments that could have two cables, such as the Math Unit or SLU. Note that not all connections may be necessary for your particular configuration and that this diagram is only a reference for commonly used configurations. Many connections have the letters “Com” shown by their negative terminal. This indicates that a connection to common must be made. Jumper wires of various lengths are included for this purpose. Refer to the notes, wiring examples, and the table on the following page for additional information.

Figure C-1. Sample Wiring for J1 Cable

Grn/Red ICN+

Red/Grn ICN-

Grn/Wht DI3+

Com (DI3-)

Wht/Grn DI4+

Com (DI4-)

Orn/Red AI3+

AI3- Red/Orn

Orn/Blk DO4

Com (DO4-)

Brn/Wht DI1+

Com (DI1-)

Wht/Brn DI2+

Com (DI2-)

Blk/Blu DO1

Com (DO1-)

Blu/Blk DO2

Com (DO2-)

Slate/Red DO3

Com (DO3-)

Slate/Wht AI1+ Blu/Red AI2+

AI1- Wht/Slate Red/Blu AI2- Brn/Red AO1+ Blk/Orn AO2+

Com (AO1- Com (AO2-

} 24Vdc+ Blu/Wht Orn/Wht Wht/Blu

} 24Vdc- Wht/Orn

C-1

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

Table C-1. RetroPAK Connections for J1 Cable

Controller RetroPAK Adapter MOD 30 Signal Terminal Wire Color Signal Terminal 24Vdc+ L1/+ BLU-WHT & ORN-WHT 24Vdc+ 1 & 2

Power Common L2/- WHT-BLU & WHT-ORN Common 3 & 4 AI1+ 23 SLATE-WHT AI1+ 5 AI1- 20 WHT-SLATE AI1- 6 AI2+ 44 BLU-RED AI2+ 8 AI2- 41 RED-BLU AI2- 9

AO1+ 19 BRN-RED AO1+ 14 AO1- 18 <Com> AO1- 15 AO2+ 40 BLK-ORN AO2+ 17 AO2- 39 <Com> AO2- 18 ICN+ 3 GRN-RED ICN+ 23,24 ICN- 2 RED-GRN ICN- 25,26

ICN Common 1 <Com> ICN Common Com RS-232 Tx 3 GRN-RED n/a 23,24 RS-232 Rx 2 RED-GRN n/a 25,26

RS-232 Common 1 <Com> n/a Com S1-1 38 BRN-WHT DI1+ 27 S1-2 37 <Com> DI1- 28 S2-1 36 WHT-BRN DI2+ 29 S2-2 35 <Com> DI2- 30 S3-1 34 BLK-BLU DO1+ 35 S3-2 33 <Com> DO1- 36 S4-1 32 BLU-BLK DO2+ 37 S4-2 31 <Com> DO2- 38 S5-1 30 SLATE-RED DO3+ 39 S5-2 29 <Com> DO3- 40 S6-1 17 ORN-BLK DO4+ 41 S6-2 16 <Com> DO4- 42 S7-1 15 S7-2 14 S8-1 13 S8-2 12 S9-1 11 ORN-RED AI3+ 11 S9-2 10 RED-ORN AI3- 12

S10-1 9 WHT-GRN DI4+ 33 S10-2 8 <Com> DI4- 34 S11-1 7 GRN-WHT DI3+ 31 S11-2 6 <Com> DI3- 32

not used RED-BRN OH Return - not used RED-SLATE OH Sense -

Notes:

1. Circuit common terminals 3,4,15,18,21,28,30,32,34,36,38,40,42 and 43 of the 1720F panel are internally tied together

2. Connections labeled <Com> must be jumpered to a circuit common terminal, such as 25, 18 or 39 on the RetroPAK termination

3. Earth ground and shield connections are to be made at the 1720F panel terminals 4. The color listed first for the RetroPAK Adapter wire colors is the predominant color and the second

color listed is the stripe 5. Use 24 AWG or heavier wires to wires to jumper the necessary terminals to ground

C-2

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

6. The table above shows possible connections that can be made to the MOD 30ML using the provided cable. Depending upon your configuration, not all connections may need to be made or connections may be different. Wires not being utilized should be folded back and shrink wrapped or taped, for possible future use.

7. Connection made to terminals for S01 through S11 must have a module installed in the associated sockets of the controller to be functional.

C-3

MOD 30 RetroPAKTM

PRODUCT DESCRIPTION

C-4

Assembly Instructions 1. Locate wire loop attached to the cable insulation. Tilt rear of controller down so that the washer rests

against the head of the screw. Slip wire loop around screw underneath the washer as shown by reference A. Squeeze wire loop together so that it is underneath the washer, using needle nose pliers if necessary. Use a Phillips head screwdriver to tighten the screw, securing the wire loop under the washer. Caution: Do not over-tighten the screw, as the plastic threads may become stripped.

2. Use the wiring table to determine which wires will be used for your configuration. Fold unused wires back over shrink wrap and fasten with shrink wrap or electrical tape to keep them out of the way.

3. Pull the pre-cut insulation from the ends of the wires to be used 4. Route the shrink wrapped bundles as shown by reference B between the terminal blocks. Use wiring

table to determine the direction each bundle should be routed. 5. Fasten each wire to its appropriate location in the terminal blocks. 6. Use jumper wires provided in the plastic bag to make any necessary common connections. Built-in

mA output commons are internally tied to Instrument Common. Instrument Common must be also to be connected to the negative of the 24Vdc power. The diagram on the first page shows this by installing a jumper from terminal 25 to the upper Chassis terminal, which leads back to the negative of the power supply through the connection at the lower Ground terminal.

7. Twist wires together where more than one will be inserted into a terminal 8. Push retaining clip at location C to release its lock when attaching conversion cable to existing cable.

Figure C-2. Assembly Diagram

The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice, or to make engineering refinements that may not be reflected in this bulletin. MicroMod assumes no responsibility for errors that may appear in this manual. © 2013 MicroMod Automation & Controls, Inc. Printed in USA

IB-M30RETRO-INS, Issue 3 11/2013

MicroMod Automation & Controls, Inc.75 Town Centre Drive

Rochester, NY USA 14623 Tel. 585-321 9200 Fax 585-321 9291

www.micromod.com