MaxDna - Field Wiring

Model IOP
I/O Subsystem
Field Wiring
277562 Rev. B
Refer to this publication for complete and accurate information that helps you better operate and service Metso
Automation MAX Controls equipment. Your comments and suggestions are welcome.
Metso Automation MAX Controls, Inc.
1180 Church Road
Lansdale, PA 19446
Attention: Manager, Technical Publications
Copyright 1999-2001 by Metso Automation MAX Controls

Printed in the United States of America
All rights reserved
Metso Automation MAX Controls 277562
Contents
PREFACE ........................................................................................................................... III
Audience ............................................................................................................................................................. iii
CHAPTER 1 ...................................................................................................................... 1-1

Mounting and Removing I/O Modules...................................................................................................................... 1-1
Removing Plug-in Modules....................................................................................................................................... 1-1
Module Mounting.................................................................................................................................................. 1-1
CHAPTER 2 ...................................................................................................................... 2-1

Process Connections and Terminal Assignment ....................................................................................................... 2-1
Wiring and Terminations .......................................................................................................................................... 2-1
Field Wiring Practice ............................................................................................................................................ 2-1
Termination of Cable Shields................................................................................................................................ 2-2
Optional Terminal Lug Wiring.............................................................................................................................. 2-3
Module Configuration ........................................................................................................................................... 2-3
CHAPTER 3 ...................................................................................................................... 3-1

High Level Analog Inputs Module 081815/081824................................................................................................... 3-1
Introduction............................................................................................................................................................... 3-1
Individually Fused Current Inputs with External Drop Resistors.......................................................................... 3-1
Individually Fused Current Inputs with Internal Drop Resistors .......................................................................... 3-3
Inputs with External Loop Supply and External Drop Resistors .......................................................................... 3-5
Inputs with External Loop Supply and Internal Drop Resistors ............................................................................ 3-8
Isolated High Level Analog Input Module 081815 Terminal Connections........................................................ 3-10
Field Wiring ........................................................................................................................................................ 3-10
Voltage Inputs ..................................................................................................................................................... 3-10
CHAPTER 4 ...................................................................................................................... 4-1

Thermocouple/Millivolt Inputs Module 081803 ....................................................................................................... 4-1
Requirements............................................................................................................................................................. 4-1
CHAPTER 5 ...................................................................................................................... 5-1

Resistance Input Modules 081804 and 081814 ......................................................................................................... 5-1
Types......................................................................................................................................................................... 5-1
Three-Wire RTDs ................................................................................................................................................. 5-1
Model IOP I/O Subsystem Field Wiring

Four-Wire RTDs ................................................................................................................................................... 5-4
CHAPTER 6.......................................................................................................................6-1
Output Driver Modules CAT 064594, PAT 064314 ................................................................................................. 6-1
Terminal Connections ............................................................................................................................................... 6-1
Current Adjusting Type (CAT) ............................................................................................................................. 6-1
Position Adjusting Type (PAT)............................................................................................................................. 6-4
AC Drive Units.................................................................................................................................................. 6-4
DC Drive Units.................................................................................................................................................. 6-4
PAT Feedback................................................................................................................................................... 6-4
Two-Wire Rotary Sensor................................................................................................................................... 6-5
Four-Wire Rotary Sensor .................................................................................................................................. 6-5
Duration Adjusting Type (DAT) ......................................................................................................................... 6-10
Connecting Model MAS Auto/Manual Station ................................................................................................... 6-12
CHAPTER 7.......................................................................................................................7-1
Analog Output Module Terminal Connections ........................................................................................................ 7-1
Description ............................................................................................................................................................ 7-1
CHAPTER 8.......................................................................................................................8-1
Quad PAT Output Module Terminal Connections .................................................................................................. 8-1
CHAPTER 9.......................................................................................................................9-1
Digital Input/Output Module Terminal Connections............................................................................................... 9-1
Introduction ........................................................................................................................................................... 9-1
CHAPTER 10...................................................................................................................10-1
Counter/Timer Input Connections and Terminal Assignment............................................................................. 10-1
Preface
Audience
This publication provides the information required to complete field wiring
for the following MAXDNA Model IOP Series modules:
Digital Input Modules 081809, 081808, 081807, 081806, 056663,

056511, 056662, 056521, 056661,
Digital Output Modules 056513, 056693, 056512, 056692, 064319
Counter/Timer Module 056516
Analog Output Modules 056515, 080403, 080424, 064594, 080401
High Level Analog Input Modules 081815 and 081824
Thermocouple/Millivolt Input Module 081803
Resistance Input Modules, 081804 and 081814
Output Driver Modules CAT 064594, PAT 064314
Relay Digital Outputs 081820 and 081823
Individual terminal assignments are included for all channels on each

module. Information is provided on support frame mounting for the Model
IOP Input/Output System.
Chapter 2 also addresses the termination of cable shields and optional
terminal lug wiring.
For more information on the preparation and adjustment of individual modules, refer to the following Metso Automation MAX Controls publications.
Book No.
277566
Title
Analog Output Modules Preparation and Adjustment
277565
Counter/Timer Module Preparation and Adjustment
277564
Digital Input/Output Module
277563
Input/Output System Installation, Preparation, and

Adjustment
iv
277569
Output Driver
Adjustment
Field Wiring, Preparation and
277567
Analog Input Modules Preparation and Adjustment
277570
Heavy Duty Relay Panel
277571
Binary Control Module Preparation and Adjustment
Chapter 1
Mounting and Removing
I/O Modules
Removing Plug-in Modules

Before you wire I/O modules/chassis assemblies, you must remove them
from their support frames. Refer to Figure 1-1. I/O design allows you to
install and remove modules with the +24 V dc power supply applied.
Caution: While pulling and terminating field wiring, you may need to
remove printed circuit modules. Before mounting plug-in modules, read the
caution statement inside the front cover of this publication concerning
electrostatic discharge (ESD).
To remove module/chassis assemblies:
1.
Loosen the top and bottom lock-down screws that attach module to
chassis assembly; the lock-down screws are not removable from the
module assembly. Use the ejector to release module from the support
frame bus connector and the chassis assembly connector.
Place forefinger behind the upper tab of the ejector. Place thumb on
lower ejector tab.
Simultaneously pull with your forefinger and push with your thumb.
Lever action of the ejector simultaneously releases the module from the
I/O bus connector and the chassis assembly.
5.
Slide module forward and out of the top and bottom card guides of
chassis assembly. Temporarily store the module observing the handling
precautions described inside the front cover of this publication.
Module Mounting
Before installing any modules, refer to Publication 277563, Model IOP
Input/Output System Installation, Preparation, and Adjustment, and to the

appropriate preparation and adjustment publication to check for correct
module addressing and jumper selection.
To mount I/O modules:
1.
With chassis assembly in place and all wiring completed, position

module into top and bottom card guides of the chassis. Gently slide
module forward, verifying that the connector pins on the solder side of
the module engage the corresponding contact guides on the chassis
assembly.
2.
When the contacts are engaged and resistance is felt, firmly press on
the front panel of the module front plate to make the simultaneous
connections on the front and rear. Apply pressure to the left of the
LEDs to place the force directly in line with the printed circuit card of
the module.
3.
Secure module to chassis assembly with the top and bottom lock-down
screws on the front of the module.
Figure 1-1. Model IOP I/O Chassis Module Installation
1-2
Chapter 2
Process Connections and
Terminal Assignment
Wiring and Terminations
This section describes process input and output connections to the Model
IOP I/O. For easy access, wire termination is at the front of the cabinet. A
wire duct (4 in. x 6 in.), provided for wire routing, is located directly behind
the terminal strips on the chassis assembly.
Warning - shock hazard: Field wiring from end-element devices may be as
high as 240 V ac or 120 V ac/dc. Remove the voltage from the field wires
before making connections.
Field wiring should be done after chassis assembly mounting and before the
modules are installed. If modules are installed, remove them as described in
Chapter 1.
Because of the compact design of the Model IOP I/O, and the closeness of
adjacent modules, you should keep the field wiring from the wire duct to the
terminals short to avoid interference with adjacent modules (See Figure 2-1).
One or two 14 AWG wires may be used per terminal. Wire sizes ranging
from 10 to 18 AWG can be accommodated. The screw terminals also include
wire clamps, making lugs unnecessary.
The jumper strips provided, (part number 064362), should be used for
commoning instead of additional wiring, but it is not recommended that the
jumper strips be used for high current output loads. For example, if you were
using all 16 outputs of a 2 A per output module, the current could be as high
as 32 A (16 x 2 A).
Field Wiring Practice

Before connecting end element devices (process inputs and outputs) to the
Model IOP I/O chassis assembly, follow these general rules to maintain the
integrity of the signals. These rules apply to most field wiring applications,
not solely MAXDNA distributed control equipment.
All low-level signal wiring should always be physically separate from

all high-level power wiring.
Analog signal wiring should be made with shielded twisted-pairs and

should not be in the same vertical wire bundle with high level ac or dc
wiring.
Digital ac wiring should be in its own vertical wire path(s), separated

from digital dc vertical wiring path(s).
Try to keep high and low level ac and dc signals separate.
These specific rules are summarized as follows: Wherever possible, group

together wiring of the same type (ac or dc) and same level (voltage or
current), and separate each wire group from the other wire groups.
Termination of Cable Shields

Most low-level signals connected to the MAXDNA system are run in
shielded cables to keep the common mode voltage between the signal and
the ground reference for that signal as small as possible.
Shields are grounded at the point of usage. For example, analog input shields
should be grounded at the Remote Processing Unit (RPU) cabinet (see
below), and analog output shields should be grounded at the field device.
Note: a grounded thermocouple is an exception. In this case, the shield
should be grounded at the thermocouple junction, and not at the RPU
cabinet.
In many cases, terminals are provided for shield connection. In those cases
where no shield terminals exist, or if all available shield terminals are used,
an isolated bus bar can be installed in the bottom of the cabinet and can be
used for terminating the shields. This bus bar is often supplied with the
system, and should be connected (using an insulated conductor) directly to
the systems' central ground point.
Note: if a shield is connected to ground at the RPU cabinet, it must not be
grounded at any other point.
Also, from the point that the shield exits the cable to the point where it is
terminated, the shield should be insulated using some insulating tape or
sheath to prevent any electrical shorts.
2-2
Process Connections and Terminal Assignments
Optional Terminal Lug Wiring

The Output Driver Auto/Manual cable is terminated using terminal lugs on
the end of the leads. This technique can be used in other applications, such
as where small wires (under size 18 AWG) must be terminated. In these
applications, the following hardware can be used:
Terminal Lug - Amp #640903-1, 250 series, 22-18 AWG (No part
number)
45 Degree Tab - Augat/RDI Part QC8-45-4. Part Number 198947.
90 Degree Tab - Augat/RDI Part QC8-90-4. Part Number 198946.
3/8 x 8-32 Bindhd Screw - Part Number 304718
Note: the screw and plate provided with the terminal strip should be
discarded and replaced with the 3/8 x 8-32 screw listed above.
Module Configuration
Each Model IOP I/O chassis assembly contains 40 #8 screw terminals.
Depending on module type and the type of connections, you will not always
need to use all 40 terminals. For example, on the digital modules, 32
terminals are active and 8 are spares used for busing of loads and contacts,
or the spares may not be used at all. The screw terminals include wire
clamps, allowing for bare wires.
Jumper strips are provided for commoning. The screws are arranged in
staggered rows of 20 terminals each, protected by a cover plate removable
for wiring access. Cover plates are labeled to show module number and wire
identification. Label information is completed on site when wiring is
completed. Terminal assignments are the same regardless of which type of
digital I/O module is plugged into the chassis.
Caution: The Model APS1xx +24 V dc power supply used to power any
MAXDNA hardware should never be used for external relay contact wetting.
Use an isolated, separate supply for contact wetting to provide noise and
interference protection for the MAXDNA hardware.
Each type of digital Model IOP I/O Module, which plugs into the chassis
assembly containing the field connections, handles 16 inputs or outputs.
Inputs, outputs, input levels, and output levels are not mixed on the same
module. In other words, all points on the same module are identical.
However, the Relay Output Module 064319 can have any mix of normally
open or normally closed contacts, up to 16. On the chassis assembly, three
screw terminals are associated with each of the 16 inputs/outputs (commons
are shared by 2 points). The terminal arrangement is standard, with input and
output ranges determined by the module used.
2-3

The Model IOP I/O Module design provides isolation of each input and
output from the I/O bus and from the other inputs and outputs. When many
inputs or outputs on the same module are using the same field power source,
you can reduce wiring by using the jumper strips provided for each module.
Be careful when using the jumper strips on output modules because the
combined current load of several outputs can become excessive.
Figure 2-1 shows a top view of two adjacent Model IOP Modules. Take care
to position the field wiring so that there is no interference with adjacent
modules. This point can be easily overlooked since the modules will not be
installed during field wiring. Be careful not to make big loops in the wiring
between the duct and the terminal board that will obstruct module
installation.
Caution: You must remove plug-in modules before performing field wiring.
If modules are replaced in the wrong location, equipment damage can occur
due to possible field wiring voltage/current level differences between chassis
assemblies. Return plug-in modules to their original positions when field
wiring is completed. Use the labels provided on the screw terminal covers of
the chassis assemblies to record module number and wiring information.
To help prevent incorrect module replacement, a good practice is to group
the same voltage/current range modules together vertically as much as
possible. Keep the corresponding field wiring in the same vertical path
through the wire ducts on the chassis assemblies.
Figure 2-1. Model IOP I/O field wiring. Top view of adjacent modules
2-4
Chapter 3
High Level Analog Inputs
Module 081815/081824
Introduction
Input connections vary by input type and application. Refer to this chapter
for information about various connection options. Current inputs require
mounting of drop resistors. Module 081824 information is presented first.
Module 081815 information appears later in this chapter.
Individually Fused Current Inputs with External Drop Resistors

The 081824 module is manufactured with jumpers in position for
individually fused current inputs. Jumper positions do not have to be
changed. Figure 3-1 illustrates input connections for channels 1 and 2. Table
3-1 provides connections for additional channels.
The 081824 module is manufactured with a 0.4 Volt to 2.0 Volt span for
current input through a 100 Ohm resistor. These resistors can be mounted on
the terminal board (see Figure 3-1), or in a location external to the module.
A 24 Volt dc power supply is to be connected to terminals 38 and 39 as
shown in Figure 3-1. The power supply should be rated to provide 20 mA for
each transmitter loop.
Note: do not use the Model APS1xx +24 V system power supply for this
current source.
Figure 3-1. Current inputs, individually fused common loop supply,

external resistors, 081824
3-2
High Level Analog Inputs Module 081815/081824

Table 3-1. Current Input Connections; Individually Fused/Protected;
Common External Loop Supply External Resistor, 081824
Terminal No.
Channel
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1 and 2
1
1
2
2
3
3
4
4
3 and 4
5 and 6
5
5
6
6
7
7
8
8
7 and 8
9 and 10
9
9
10
10
11
11
12
12
11 and 12
13 and 14
13
13
14
14
15
15
15
Designation
Resistors 1 and 2
Transmitter 1 , resistor 1
Transmitter 1 +
Transmitter 2 +
Transmitter 3 +
Transmitter 4 +
Resistors 3 and 4
Resistors 5 and 6
Transmitter 5 +
Transmitter 6 +
Transmitter 7 +
Transmitter 8 +
Resistors 7 and 8
Resistors 9 and 10
Transmitter 9 +
Transmitter 10 +
Transmitter 11 +
Transmitter 12 +
Resistors 11 and 12
Resistors 13 and 14
Transmitter 13 +
Transmitter 14 +
Transmitter 15 +
Power Supply +
Power Supply
No Connection
Individually Fused Current Inputs with

Internal Drop Resistors
The module 081824 is manufactured with jumpers in position for
individually fused current inputs. Jumper positions do not have to be
3-3

changed. Figure 3-2 illustrates input connections for channels 1 and 2. Table
3-2 provides connections for additional channels. The 081824 module is
manufactured with a 0.4 Volt to 2.0 Volt span for current input through a
100 Ohm resistor. These resistors are to be mounted on the printed circuit
assembly in position shown in Figure 3-2. The 081824 module is
manufactured with component jacks for mounting these resistors.
A 24 Volt dc power supply is to be connected to terminals 38 and 39 as
shown in Figure 3-2. The power supply should be rated to provide 20 mA for
each transmitter loop.
current source.
Figure 3-2. Current inputs, individually fused common loop supply,

internal resistors, 081824.
Table 3-2. Current Input Connections, Individually Fused/Protected,
Common Loop Supply Internal Resistors
Terminal No.
1
2
3-4
Channel
Designation
No connection
Transmitter 1
3
4
5
6
7
8
9
10
1
2
2
3
3
4
4
Transmitter 1 +
Transmitter 2
Transmitter 2 +
Transmitter 3
Transmitter 3 +
Transmitter 4
Transmitter 4 +
No connection
11
12
13
14
15
16
17
18
19
20
5
5
6
6
7
7
8
8
no connection
Transmitter 5
Transmitter 5 +
Transmitter 6
Transmitter 6 +
Transmitter 7
Transmitter 7 +
Transmitter 8
Transmitter 8 +
No connection
21
22
23
24
25
26
27
28
29
30
9
9
10
10
11
11
12
12
No connection
Transmitter 9
Transmitter 9 +
Transmitter 10
Transmitter 10 +
Transmitter 11
Transmitter 11 +
Transmitter 12
Transmitter 12 +
No connection
31
32
33
34
35
36
37
38
39
13
13
14
14
15
15
No connection
Transmitter 13
Transmitter 13 +
Transmitter 14
Transmitter 14 +
Transmitter 15
Transmitter 15 +
Power Supply +
Power Supply
No connection
40
Inputs with External Loop Supply and

External Drop Resistors
The modules are manufactured with jumpers in position for individually
fused current inputs. Jumper positions must be changed for external loop
supplies. Figure 3-3 illustrates the input connections for channels 1 and 2.
Table 3-3 provides input connections for additional channels. The 081824
module is manufactured with a 0.4 Volt to 2.0 Volt span for current input
through a 100 Ohm resistor. These resistors can be mounted on the terminal
3-5

board (see Figure 3-3), or in a location external to the module. A 24 Volt dc
power supply is to be connected in the loop as shown in Figure 3-3. The
power supply should be rated to provide 20 mA for each transmitter loop.
current source.
Figure 3-3. Current inputs, external loop supply, external resistors,

081824
Table 3-3. Current Input Connections, External Loop Supply External
Resistors, 081824
Terminal No.
1
2
3
4
5
6
7
8
3-6
Channel
1
1
2
2
3
3
4
Designation
No connection
Power Supply , resistor 1
9
10
11
12
13
14
15
16
17
18
19
20
5
5
6
6
7
7
8
8
21
22
23
24
25
26
27
28
29
30
9
9
10
10
11
11
12
12
31
32
33
34
35
36
37
38
39
40
13
13
14
14
15
15
No connection
No connection
No connection
No connection
No connection
No connection
No connection
No connection
No connection
3-7
Inputs with External Loop Supply and Internal Drop Resistors

The module 081824 is manufactured with jumpers in position for
individually fused current inputs. Jumper positions must be changed for
external loop supplies. Figure 3-4 illustrates the input connections for
channels 1 and 2. Table 3-4 provides input connections for additional
channels. The 081824 module is manufactured with a 0.4 Volt to 2.0 Volt
span for current input through a 100 Ohm resistor. These resistors are to be
mounted on the printed circuit assembly in position shown in Figure 3-4.
The 081824 module is manufactured with component jacks for installation
of these resistors. A 24 Volt dc power supply is to be connected in the loop
as shown in Figure 3-4. The power supply should be rated to provide 20 mA
for each transmitter loop.
current source.
CHASSIS
TERMINAL BOARD
return
T1
HIGH LEVEL ANALOG INPUT

MODULE
(+)
R2
100 ohm
ch #1
(-)
T2
W2
W3
(+)
R-C
NETWORK
W1
R6
100 ohm
ch #2
(-)
R-C
NETWORK
W4
W5
W6
+24V
38
PS -
-24V
39
Solid State
Self-Reset Fuse
40
Ch 1 - R2
Ch 5 - R18
Ch 9 - R67
Ch 13 - R75
Ch 2 - R6
Ch 3 - R10
Ch 4 - R14
Ch 6 - R22
Ch 10 - R38
Ch 11 - R42
Ch 12 - R46
Ch 14 - R79
Ch 15 - R83
Ch 7 - R55
Ch 8 - R71
Figure 3-4. Current inputs, external loop supply internal resistors
3-8
Table 3-4 - Current Input Connections - External Loop Supply Internal

Resistors
Terminal No.
1
2
3
4
5
6
7
8
9
10
Channel
1
1
2
2
3
3
4
4
11
12
13
14
15
16
17
18
19
20
5
5
6
6
7
7
8
8
21
22
23
24
25
26
27
28
29
30
9
9
10
10
11
11
12
12
31
32
33
34
35
36
37
38
39
40
13
13
14
14
15
15
Designation
No connection
Transmitter 1
Power Supply
Transmitter 2
Power Supply
Transmitter 3
Power Supply
Transmitter 4
Power Supply
No connection
No connection
Transmitter 5
Power Supply
Transmitter 6
Power Supply
Transmitter 7
Power Supply
Transmitter 8
Power Supply
No connection
No connection
Transmitter 9
Power Supply
Transmitter 10
Power Supply
Transmitter 11
Power Supply
Transmitter 12
Power Supply
No connection
No connection
Transmitter 13
Power Supply
Transmitter 14
Power Supply
Transmitter 15
Power Supply
No connection
No connection
No connection
3-9
Isolated High Level Analog Input

Module 081815 Terminal Connections
The 081815 isolated high level analog input module provides
voltage input channels. Each channel has a 0 to 2.4V span.
inputs, a 100 Ohm shunt resistor must be installed externally.
input spans other than 2.4V, voltage divider resistors must
externally.
15 isolated
For current
For voltage
be installed
Field Wiring
Input connections vary by type of input and application. Refer to the
following sections for information pertaining to three different kinds of
connections.
Voltage Inputs
The 081815 module is manufactured with an input span of 0 to 2.4 Volts.
Voltage above this will require a voltage divider. See Figure 3.5 and Table
3.5.
Note: do not use the Model APS +24 V system power supply for this current
source.
3-10
HIGH LEVEL ANALOG

INPUT TERMINATION
MODULE
CHASSIS
TERMINAL BOARD
1
return
-24V
R2
400K
2
(+)
+
ch #1
V1
R3
100K
W1D
R-C
NETWORK
W1A
W1B
R1
100 ohm
W1C
(-)
R5
400K
(+)
W2D
ch #2
V2
R6
100K
R-C
NETWORK
W2A
W2B
R4
100 ohm
W2C
(-)
+24V
38
39
-24V
40
Note: R1 and R4 are not installed.
Figure 3-5. Voltage Inputs, 081815
3-11
Table 3-5. Voltage Input Connections, 081815

Terminal No.
Channel
Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
No connection*
Input 1 +
Input 1
Input 2 +
Input 2
Input 3 +
Input 3
Input 4 +
Input 4
*
*
Input 5 +
Input 5
Input 6 +
Input 6
Input 7 +
Input 7
Input 8 +
Input 8
*
*
Input 9 +
Input 9
Input 10 +
Input 10
Input 11 +
Input 11
Input 12 +
Input 12
*
*
Input 13 +
Input 13
Input 14 +
Input 14
Input 15 +
Input 15
No connection
*
**
*These terminals are connected together and may be used for grounding inputs.
** Screw/pin 40 is connected internally and is not to be wired as a tie point.
3-12
Chapter 4
Thermocouple/Millivolt Inputs
Module 081803
Requirements
Thermocouple inputs require the use of extension leadwire; refer to Table 41. Thermocouples can be grounded or ungrounded. Type B thermocouples
and millivolt inputs use copper wire. Shields can be connected to terminals 5
and 7.
Four thermal sensors are mounted on the input terminal boards on the
terminals shown in Figure 4-1. These sensors are required for thermocouple
inputs. Figure 4-1 illustrates input connections for channels 1, 2, 3, 14 and
15. Table 4-2 provides connections for all other channels.
Table 4-1. Thermocouple/Millivolt Module Extension Leadwire Table
THERMOCOUPLE
COMBINATION
EXTERNAL TO INSTRUMENT
DUPLEX
SINGLE CONDUCTOR
Overall
Copper B Const. R
B
Copper B
Const. R-B
Copper Const
Type T
Iron Const
Iron W
Const R
Type J
*Nickel-Chromium
Ni-Cr
Const. R
Const
V
Type E
Nickel-Chromium
Ni-Cr
Ni-Al
Nickel-Aluminum
Y
R
Type K
Plat-Rhod Plat
Copper K Alloy R
Type S or R
Nicrosil Nisil
Nicrosil
Nisil
Type N
O
R
K - Black
G - Green
B - Blue
W - White
R - Red
N - Brown
* Thermocouple wire used as extension wire
Iron W
Const R-W
Ni-Cr
Y
Const R-B
Ni-Cr
Y
Ni-Al
R-Y
Copper K
Alloy R-K
Nicrosil O
Nisil R-O
O - Orange
Y - Yellow
T - Tan
Figure 4-1 - Thermocouple/Millivolt Module input connections
4-2
Thermocouple/Millivolt Inputs Module 081803
Table 4-2. Thermocouple/Millivolt Module - Input Connections

Designation
Thermal Sensor 2
Terminal Board
1
Designation
Thermal Sensor 1
Thermal Sensor 2
Thermal Sensor 1
Input 1 +
Thermocouple Shields
Input 1 -
Thermocouple Shields
Input 3 +
10
Input 2 +
Input 3 -
12
11
Input 2 -
Input 5 +
14
13
Input 4 +
Input 5 -
16
15
Input 4 -
Input 7 +
18
17
Input 6 +
Input 7 -
20
19
Input 6 -
Input 9 +
22
21
Input 8 +
Input 9
24
23
Input 8 -
Input 11 +
26
25
Input 10 +
Input 11 -
28
27
Input 10 -
Input 13 +
30
29
Input 12 +
Input 13 -
32
31
Input 12 -
Input 15 +
34
33
Input 14 +
Input 15 -
36
35
Input 14 -
Thermal Sensor 4
38
37
Thermal Sensor 3
Thermal Sensor 4
40
39
Thermal Sensor 3
4-3
Chapter 5
Resistance Input
Modules 081804 and 081814
Types
Inputs can be three-wire RTDs as shown in Figure 5-1, four-wire RTDs as
shown in Figure 5-2, or any combination of the two. The A, B and C lead
designations shown on the diagrams are for Thermohm Resistance
Thermometers and are presented for reference. The A and B leads are the
potential leads and the C leads are the current leads. RTDs manufactured by
other vendors may have different designations. Refer to manufacturersupplied specifications and make connections accordingly.
Three-Wire RTDs
Figure 5-1 provides an example of input connections for three-wire RTDs
for channels 1 and 7. Refer to Table 5-1 for input connections for channels 2
through 6. For three-wire RTDs, the resistance of the A and B leads must be
equal. Add jumpers to the terminal board as shown.
Note: Resistance of A and B leads must be equal

Table 5-1 - Input Connections for Three-Wire RTDs
Designation
Terminal Board
1
Shield
Shield
5-2
Designation
Shield
2
3
Shield
Shield
1 IN -
1 I2
11
2 I1
13
2 IN +
15
2 COM
17
3 IN -
19
3 I2
21
4 I1
23
4 IN +
25
4 COM
27
5 IN -
29
5 I2
31
6 I1
33
6 IN +
35
6 COM
37
7 IN -
39
7 I2
1 I1
1 IN +
1 COM
10
2 IN -
12
2 I2
14
3 I1
16
3 IN +
18
3 COM
20
4 IN -
22
4 I2
24
5 I1
26
5 IN +
28
5 COM
30
6 IN -
32
6 I2
34
7 I1
36
7 IN +
38
7 COM
40
Resistance Input Modules 081804 and 081814
Figure 5-1 - Input Connections for Three-Wire RTDs
5-3
Four-Wire RTDs
Figure 5-2 provides an example of input connections for four-wire RTDs for
channels 1 and 7. Refer to Table 5-2 for input connections for channels 2
through 6.
Figure 5-2 - Input connections for four-wire RTDs
5-4
Resistance Input Modules 081804 and 081814
Table 5-2 - Input Connections for Four-Wire RTDs

Designation
Terminal Board
1
Shield
Shield
Designation
Shield
2
3
Shield
Shield
1 IN -
1 I1
1 IN +
1 COM
10
2 IN -
12
9
11
2 I1
13
2 IN +
15
2 COM
17
3 IN -
14
3 I1
16
3 IN +
18
3 COM
20
4 IN -
22
19
21
4 I1
23
4 IN +
25
4 COM
27
5 IN -
24
5 I1
26
5 IN +
28
5 COM
30
6 IN -
32
29
31
6 I1
33
6 IN +
35
6 COM
37
7 IN -
34
7 I1
36
7 IN +
38
7 COM
40
39
5-5
Chapter 6
Output Driver Modules
CAT 064594, PAT 064314
Terminal Connections
Terminals 1 through 20 on the chassis assembly terminal board are used for
field wiring. Refer to Figure 6-1 for an illustrated view of individual terminal
connections. Terminals 21 through 40 are reserved for connections
Figure 6-1 - Modules CAT 064594, PAT 064314 terminal connections
Current Adjusting Type (CAT)

The CAT Module 064594 is supplied with jumpers already positioned for
CAT operation for an output of 4 to 20 mA. Refer to Figures 6-2 and 6-3 for
illustrated views of the connections for a CAT controller. Terminals 16 and
17 are the source of the current output which can be jumper selected to
provide ranges of 4 to 20 mA, 0 to 16 mA, 0 to 20 mA, or 10 to 50 mA for

full scale. Terminals 11 and 13 are used for 24 V dc field backup. Block and
override contacts, if applied, can be powered from line voltage (refer to
Figure 6-3). Note that the CAT output is not isolated from ground. Block and
override contacts are wetted by the power connected to terminal 1 (refer to
Figure 6-3). Voltages 120 V ac or 125 V dc can be used.
Figure 6-2 - CAT output and 24 V dc field backup
6-2
Output Driver Modules CAT 064594 and PAT 064314
Figure 6-3 - CAT output and 24 V dc field backup with blocks and
overrides - 120 V ac wetting voltage
6-3
Position Adjusting Type (PAT)

The PAT Module 064314 is supplied with jumpers already positioned for
PAT operation with a 1,000 Ohm feedback slidewire, 120 V ac drive unit
and limit switches, and no-backup 24 V dc power supply. Select other
arrangements, as shown in the following diagrams, by repositioning jumpers.
There are two basic types of output. The first has 120 V ac raise-lower
outputs. This configuration uses 120 V ac interrogating voltage for limit
contacts and drives a single phase drive unit or a three phase power switch.
The second, for the dc power switch, uses 24 V dc open collector raise-lower
outputs. This configuration typically uses 24 V dc interrogation voltage for
limit inputs. See "DC Drive Units" below.
Block and override contacts are wetted by the power connected to terminal
1. This is normally the drive unit power voltage. Voltages 120 V ac or 125 V
dc can be used.
AC Drive Units
Figures 6-4, 6-5, and 6-6 illustrate the connections for a single phase drive
unit. Figure 6-7 shows a three phase power switch. Loss of drive unit power
will give simultaneous indication of the raise and lower limits and will be
interpreted as drive unit unavailable. Power to the Blocks and Overrides is
fused. Power to the limit switches and Increase/Decrease outputs is fused
and switched. A switch in the OFF position or a blown fuse will be
interpreted as drive unit unavailable. Figures 6-4 and 6-7 also show
connections for 24 V dc field backup.
DC Drive Units
Figure 6-8 illustrates the connections for the dc power switch. The increase
and decrease outputs are open collector transistor switches. High and low
limits are available from the dc power switch as open collector outputs
which will interface with 24 V logic on the output module. Fused 24 V dc
will supply logic power to the power switch. Loss of 24 V dc power to the
power switch will result in simultaneous high limit and low limit indications
which will be interpreted as drive unit unavailable. A field 125 dc voltage
can be connected to the drive unit power terminals to provide wetting
voltage to the Block and Override contacts.
PAT Feedback
Slidewire and rotary sensor feedback can be accommodated. Figure 6-4
shows the standard 1,000 Ohm slidewire feedback. The slidewire is powered
with fused 20 mA current shunted by a 316 Ohm resistor. The bottom of the
slidewire is grounded through 250 Ohms. This results in a slidewire voltage
of 1 to 5 Volts full scale. A reasonability check of the feedback input allows
detection of an open slidewire. A pull down resistor on the slidewire input
6-4

allows detection of an open wiper. Slidewires with resistance values greater
than 1,000 Ohms can be shunted to 1,000 Ohms by adding an external
resistor. Slidewires between 500 and 1,000 Ohms will produce a
nonstandard output with a consequent loss of resolution. The reference
supply is derived from the backed-up 24 V dc.
Two-Wire Rotary Sensor

Figure 6-5 illustrates the use of a two-wire rotary sensor feedback element.
This device is powered from the 24 Vdc system supply and results in an
input of 1 to 5 V dc developed across the internal 250 Ohm resistor. A
reasonability check of the input voltage will detect an open circuit.
Four-Wire Rotary Sensor

Figure 6-6 illustrates the use of the 0 to 16 Volt output rotary sensor. This
device is powered from the 24 V dc system supply. External resistors are
added to provide an input of 0 to 4 Volts. A reasonability check for an open
circuit can only be provided if the sensor has a live zero.
6-5
Figure 6-4 - PAT output, 120 V ac Drive Unit with 1,000 Ohm slidewire and 24 V dc field
backup
6-6
Figure 6-5 - PAT output, 120 V ac Drive Unit with Two-Wire Rotary
Sensor
6-7
Figure 6-6 - PAT output, 120 V ac Drive Unit 0-16 V Four-Wire Rotary
Sensor
6-8
Figure 6-7 - PAT output, three phase power with 1000 Ohm slidewire
and 24 V dc field backup
6-9
Figure 6-8 - PAT output, dc power switch with 1000 Ohm slidewire
Duration Adjusting Type (DAT)

Figure 6-9 provides connections for DAT output. Switches must be set on
the output driver printed circuit assembly for DAT output. When DAT
output is selected, the increase PAT output is energized with a duty cycle
equal to the OUTPUT percent. For example, if the output % is 43, the PAT
increase output would be on 43 percent of the time. The PAT decrease
output is off when the increase output is on and on when the increase output
is off.
6-10
Figure 6-9 - DAT output with 24 V dc field backup

Duration Impulse Adjusting Type (DIAT)
6-11

Figure 6-10 provides connections for DIAT output. Switches must be set on
the Output Driver printed circuit assembly for DIAT output.
Figure 6-10 - DIAT output with 24 V dc field backup
Connecting Model MAS Auto/Manual Station

A Model MAS Auto/Manual Station can be connected to terminals 21
through 40 on the Output Driver terminal board. The distance between the
Output Driver and the Auto/Manual Station can be up to 1000 ft. Twentyconductor interconnecting cable is supplied with the auto/manual station.
Refer to Publication 277577, Model MAS Auto/Manual Station Installation,
for installation and wiring procedures for the Auto/Manual Station.
The cable end that connects to the Output Driver contains terminal lugs on
the ends of the leads. Terminals 21 through 40 on the Output Driver have
mating lugs. Press the lugs on the end of the cable onto the lugs on the
Output Driver terminal board according to Figure 6-11. The shield does not
have a lug. Connect the shield lead under the clamp on terminal 18.
6-12
Figure 6-11 - Model MAS Auto/Manual Station connections
6-13
Chapter 7
Analog Output Module
Description
The Analog Output Module has 8 output channels each of which uses two
wiring modes, two wire and three wire. Two-wire mode is only used for 4 to
20 milliamps, and three-wire mode for other ranges (e.g. 0 to 16 milliamps, 0
to 20 milliamps or 4 to 20 milliamps). The modules are supplied for threewire mode operation on all channels. To select two-wire or three-wire modes
for an individual channel, you must change jumpers on the printed circuit
assembly.
Three-wire mode is the only way to get a true zero based signal, e.g. 0-16
mA. Two-wire mode, which has simpler wire connections, is used to
simulate a two-wire transmitter. Refer to Tables 7-1 and 7-2 for jumper
positions for either two-wire or three-wire output.
Outputs are connected to the terminal board as shown in Figures 7-1 and 7-2,
which illustrate connections for one channel each.
Figure 7-1. Two-Wire Output Connections, Analog Output Module

080403
7-2
Analog Output ModuleTerminal Connections

Table 7-1. Model IOP I/O Chassis Assembly Analog Output Module
Two-Wire Terminal Assignment
Terminal Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Channel
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
Designation
No connection
Supply
Load - Return
No connection
No connection
Supply
Load Return
No connection
No connection
No connection
No connection
Supply
Load - Return
No Connection
No Connection
Supply
Load - Return
No connection
No connection
No connection
No connection
Supply
Load - Return
No connection
No connection
Supply
Load - Return
No connection
No connection
No connection
No connection
Supply
Load - Return
No connection
No connection
Supply
Load - Return
No connection
No connection
No connection
7-3

Table 7-2. Model IOP I/O Chassis Assembly Analog Output Module
Three-Wire Terminal Assignment
Terminal Number
1
2
3
4
5
7-4
Channel
1
1
1
Designation
Return
Supply
Load
No connection
No connection
6
7
8
9
10
2
2
Supply
Load
No connection
No connection
Return
11
12
13
14
15
3
3
3
Return
Supply
Load
No Connection
No Connection
16
17
18
19
20
4
4
Supply
Load
No connection
No connection
Return
21
22
23
24
25
5
5
5
Return
Supply
Load
No connection
No connection
26
27
28
29
30
6
6
Supply
Load
No connection
No connection
Return
31
32
33
34
35
7
7
7
Return
Supply
Load
No connection
No connection
36
37
38
39
40
8
8
Supply
Load
No connection
No connection
Return
Analog Output ModuleTerminal Connections
Figure 7-2 Three-Wire Output Connections, Analog Output Module

080403
7-5
Chapter 8
Quad PAT Output Module
Introduction
The Quad Position Adjusting Type (PAT) Output Module consists of four channels, each
capable of producing PAT increase and decrease outputs (120 Vac or open collector) for
single-phase ac drive units or three-phase power switches. The module, which interfaces with
the Distributed Processing Unit (DPU), accommodates 1000 Ohm slidewire or two-wire rotary
position sensor feedbacks
Refer to the following table for a listing of the output terminal board connections for the Quad
PAT module.
Table 8-1. Quad PAT Output Module Terminal Board Connections
Terminal Description
Terminal
Description
1
120 Vac #1
2
Line ac Neutral #1
3
Drive Unit ac Neutral #1
4
Drive Unit Increase Output
#1
5
Drive Unit Decrease Output #1
6
120 Vac #2
7
Line ac Neutral #2
8
9
Drive Unit Increase Output #2
10
Drive Unit Decrease
Output #2
11
120 Vac #3
12
Line ac Neutral #3
13
14
Drive Unit Increase Output
#3
15
Drive Unit Decrease output #3
16
120 Vac #4
17
Line ac Neutral #4
18
19
Drive Unit Increase Output #4
20
Drive Unit Decrease
Output #4
21
Voltage Reference #1

Table 8-1. Quad PAT Output Module Terminal Board Connections (Continued)
22
Position Feedback #1
Terminal Description
Terminal
Description
23
Return #1
24
Signal GRD
25
Frame GRD
26
27
28
Return #2
29
Signal GRD
30
31
32
Return #3
33
Signal GRD
34
Frame GRD
35
36
37
Return #4
38
Signal GRD
39
Control Fail Sense 1
40
Control Fail Sense 2
8-2
Chapter 9
Digital Input/Output Module
Introduction
Figures 9-1 and 9-2, respectively, illustrate typical Digital Module input and
output field connections. The connections illustrated in these figures use
terminal numbers 1 to 10. The connection pattern formed by these 10
terminals is replicated three more times on the chassis assembly.
This is shown in Table 9-1, which provides the complete terminal
assignment for one chassis assembly, depicting the staggered mounting of
the two terminal strips. The jumper strips provided, (part number 064362),
are designed to fit into this repeating pattern of four bits (terminals 2 to 9),
sandwiched between a top and bottom common terminal (terminals 1 and
10). Also notice how all Hot (+) terminals are on the left terminal strip and
all Load terminals are on the right terminal strip, allowing for the use of the
jumper strips.
Refer to Figure 9-2 for Digital Output Relay Module (081820) terminal
connections. Note that the relay contact circuit is not fused. The relays
provide dry contacts, either normally open or normally closed. As supplied,
the module is set up for normally open contacts. Configure jumpers on the
module printed circuit assembly to select normally open or normally closed
contacts.
Refer to Table 9-2 for Form C Relay Module terminal assignments. Note that
the Form C module uses a terminal connection pattern that does not resemble
the patterns used on any other input module.
Note: Do not wire Model IOP outputs directly to Model IOP inputs without
an external load, or the input may not show the true state of the output. For
example, the snubber current of a triac output may be enough to turn ON an
input, even if the triac is OFF.
Figure 9-1. Model IOP digital input field connections
9-2
Digital Input/Output ModuleTerminal Connections
Figure 9-2. Model IOP digital output field connections
9-3

Table 9-1. Model IOP I/O Chassis Assembly DigitalI/O Module Terminal
Assignment Form A/B Relay
Terminal Number
1
2
3
4
5
9-4
Designation
Common (1 & 2)
Hot (+) 1
Load 1
Hot (+) 2
Load 2
6
7
8
9
10
Hot (+) 3
Load 3
Hot (+) 4
Load 4
Common (3 & 4)
11
12
13
14
15
Common (5 & 6)
Hot (+) 5
Load 5
Hot (+) 6
Load 6
16
17
18
19
20
Hot (+) 7
Load 7
Hot (+) 8
Load 8
Common (7 & 8)
21
22
23
24
25
Common (9 & 10)

Hot (+) 9
Load 9
Hot (+) 10
Load 10
26
27
28
29
30
Hot (+) 11
Load 11
Hot (+) 12
Load 12
Common (11 & 12)
31
32
33
34
35
Common (13 & 14)

Hot (+) 13
Load 13
Hot (+) 14
Load 14
36
37
38
39
40
Hot (+) 15
Load 15
Hot (+) 16
Load 16
Common (15 & 16)
Digital Input/Output ModuleTerminal Connections

Table 9-2. Form C Relay module 081823 field wiring terminal
assignment
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Form C
-------# 1 N.O.
# 1 Common
# 1 N.C.
#2 N.C.
# 2 N.O.
# 2 Common
# 3 N.O.
# 3 Common
# 3 N.C.
----------------------# 4 N.C.
# 4 N.O.
# 4 Common
# 5 N.O.
# 5 Common
# 5 N.C.
----------------------# 6 N.C.
# 6 N.O.
# 6 Common
# 7 N.O.
# 7 Common
# 7 N.C.
# 8 N.C.
# 8 N.O.
# 8 Common
----------------------# 9 N.O.
# 9 Common
# 9 N.C.
# 10 N.C.
# 10 N.O.
# 10 Common
-------------------------------------
9-5
Chapter 10
Counter/Timer Input
Connections and Terminal Assignment
Physical pulse-input connections are generally of a variety of types: 24 V dc
contact inputs, 120 V ac contact inputs, 5 V dc differential logic inputs via
RS422 communications port, variable reluctance pickups (magnetic pickup,
e.g., turbine speed, flowmeters, rotopulsers), etc. The Counter/Timer module
has optically isolated, high-speed differential inputs. Other inputs (e.g.,
contacts) can be accommodated by slaving an adjacent digital input module
or by using an input device with 5 Volt signals (common with tachometers
and flow signals). The 5 Volts itself must be externally supplied, which is
done with contact wetting supplies in general.
The Counter/Timer Module (056516) consists of eight channels with two
inputs per channel. As supplied, the module is set up for on-card inputs from
an external source via the input terminal board. Figure 10-1 illustrates input
connections for two channels. Table 10-1 provides input connections for all
eight channels.

Table 10-1. Model IOP I/O Chassis Assembly Counter/Timer Module
Terminal Assignment
Terminal Number
1
2
3
4
5
6
7
8
9
10
10-2
Channel
1
1
1
1
2
2
2
2
Designation
No connection
Input 1+
Input 1Input 2+
Input 2Input 1+
Input 1Input 2+
Input 2No connection
11
12
13
14
15
16
17
18
19
20
3
3
3
3
4
4
4
4
No connection
Input 1+
Input 1Input 2+
Input 2Input 1+
Input 1Input 2+
21
22
23
24
25
26
27
28
29
30
5
5
5
5
6
6
6
6
No connection
Input 1+
Input 1Input 2+
Input 2Input 1+
Input 1Input 2+
31
32
33
34
35
36
37
38
39
40
7
7
7
7
8
8
8
8
No connection
Input 1+
Input 1Input 2+
Input 2Input 1+
Input 1Input 2+
Counter/Timer Input Connections and Terminal Assignment
Figure 10-1. Model IOP Counter/Timer Module input connections
10-3

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Model IOP

Copyright 1999-2001 by Metso Automation MAX Controls

Metso Automation MAX Controls 277562

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

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

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

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

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

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

Metso Automation MAX Controls 277562

Digital Input Modules 081809, 081808, 081807, 081806, 056663,

Digital Output Modules 056513, 056693, 056512, 056692, 064319

Counter/Timer Module 056516

Analog Output Modules 056515, 080403, 080424, 064594, 080401

High Level Analog Input Modules 081815 and 081824

Thermocouple/Millivolt Input Module 081803

Resistance Input Modules, 081804 and 081814

Output Driver Modules CAT 064594, PAT 064314

Relay Digital Outputs 081820 and 081823

Individual terminal assignments are included for all channels on each

Counter/Timer Module Preparation and Adjustment

Digital Input/Output Module

Input/Output System Installation, Preparation, and

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

Field Wiring, Preparation and

Analog Input Modules Preparation and Adjustment

Heavy Duty Relay Panel

Binary Control Module Preparation and Adjustment

Metso Automation MAX Controls 277562

Removing Plug-in Modules

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

With chassis assembly in place and all wiring completed, position

Figure 1-1. Model IOP I/O Chassis Module Installation

Metso Automation MAX Controls 277562

Field Wiring Practice

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

All low-level signal wiring should always be physically separate from

Analog signal wiring should be made with shielded twisted-pairs and

Digital ac wiring should be in its own vertical wire path(s), separated

Try to keep high and low level ac and dc signals separate.

These specific rules are summarized as follows: Wherever possible, group

Termination of Cable Shields

Metso Automation MAX Controls 277562

Process Connections and Terminal Assignments

Optional Terminal Lug Wiring

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

Metso Automation MAX Controls 277562

Individually Fused Current Inputs with External Drop Resistors

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

Figure 3-1. Current inputs, individually fused common loop supply,

Metso Automation MAX Controls 277562

High Level Analog Inputs Module 081815/081824

Individually Fused Current Inputs with

Metso Automation MAX Controls 277562

Model IOP I/O Subsystem Field Wiring

Figure 3-2. Current inputs, individually fused common loop supply,

Metso Automation MAX Controls 277562