PanelMate Power Series Installation Guide PanelMate Power Series
Contents
1. 20 GE Fanuc Genius I O CommunicationsS 21 Modicon Modbus Plus Communications 22 DeviceNet Communications i 23 Profibus DP Communications iii 24 Profibus DP Shielding Recommendations ss 24 Using PanelMate on a Profibus DP network 24 Chapter 4 Cable Segregation amp Placement 25 Cable Segresationi c roca dl anda caga 26 Cable Placement urigrinicn anal alla atea 26 Chapter 5 Replacing an Existing PanelMate Power Series Unit 27 Replacing a 120V AC PMPS unit with another 120VAC PMPS unit 28 Replacing a 120VAC PMPS unit with a 24VDC PMPS unit 28 Upgrading a PMPS Model 1500 unit with a PMPS Model 1700 unit 29 Chapter 6 Cutout and Unit Dimensions ses 31 PanelMate 5000 Keypad Unit Dimensions ceeeeeceeeseeceeeeesseecseeeeeeeeeeneeesaeeeeee 32 PanelMate 5000 Keyboard Cutout Dimensions 33 PanelMate 5000 Split Architecture Unit Dimensions 34 PanelMate 5000 Split Architecture Cutout Dimensions iii 35 PanelMate 5000 Touchscreen Unit Dimensions 36 PanelMate 5000 Touchscreen Cutout Dimensions 37 PanelMate 4000 Keypad Unit Dimensions ce seeseeceseeceseeeeececeeeeeneeeesaeeesaeereee 38 PanelMate 4000 Keypad Cutout Dimensions 39 PanelMate 4000 Split Architecture Unit Dimensions 40 6 PanelMate Power Series Installation Guide2. PanelMate 4000 Split Architecture Cutout Dimensions 41 PanelMate 3000 Keyboard Unit Dimensions 42 PanelMate 3000 Keypad Cutout Dimensions 43 PanelMate 3000 Touchscreen Unit Dimensions 44 PanelMate 3000 Touchscreen Cutout Dimensions ii 45 PanelMate 2000 Model 26xx Keyboard Unit Dimensions 46 PanelMate 2000 Model 26xx Keyboard Cutout Dimensions 00 47 PanelMate 2000 Model 24xx Keyboard Unit Dimensions 48 PanelMate 2000 Model 24xx Keyboard Cutout Dimensions 49 PanelMate 1700 Keyboard Unit Dimensions 50 PanelMate 1700 Keyboard Cutout Dimensions i SI PanelMate 1700 Touchscreen Unit Dimensions 52 PanelMate 1700 Touchscreen Cutout Dimensions 53 PanelMate 1500 Keyboard Unit Dimensions 54 PanelMate 1500 Keyboard Cutout Dimensions 55 PanelMate 1500 Touchscreen Unit Dimensions 56 PanelMate 1500 Touchscreen Cutout DimensionsS 57 Chapter 1 Introduction 7 1 Introduction PanelMate Power Series Installation Guide Thank You for choosing the PanelMate Power Series for your operator interface When properly installed your PanelMate Po
3. by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in HIGH Noise Environment with HIGH Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units and ac coupled through a 0 01 uf capacitor at the other end to the chassis of the second unit The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Attaching the capacitor at the ac coupled end will require some ingenuity to achieve a secure connection at both the shield and chassis while keeping the capacitor lead length as short as possible 16 PanelMate Power Series Installation Guide Recommended Distance Up to 4000 feet Up to 2000 feet for RS 422 connected to A B Channel 0 Recommended Cable Type Size 22 gauge shielded pair RS 422 Communications RS 422 Grounding Recommendations This balanced interface will operate with common mode DC or peak AC voltages differentials of 7 to 7 volts between grounds at each end of the cable In cases where the common mode voltage approaches either extreme
4. are in the U S or Canada you can take advantage of our toll free line for technical assistance with hardware and software product selection system design and installation and system debugging and diagnostics Technical support engineers are available for calls during regular business hours 8 am 5 30 pm EST by calling 1 800 809 2772 International calls can be made to either the Tech Line at 1 800 809 2772 toll call or the Cutler Hammer main business line at 614 882 3282 Emergency Technical Support 1 800 809 2772 Because machines do not run on a nine to five schedule we offer emergency after hours technical support A technical support engineer can be paged for emergencies involving plant down situations or safety issues Emergency support calls are automatically routed directly to our answering service after hours 5 30 pm 8 am EST and weekends For emergency technical support call 1 800 809 2772 Note that the Emergency Technical Support phone number does not currently support product repairs or shipping outside normal business hours Technical Support Fax 614 882 0417 You can also contact our technical support engineers by faxing your support requests directly to the Advanced Product Support Center APSC located in Westerville Ohio at 614 882 0417 Information Fax Back Service 614 899 5323 The latest Cutler Hammer product information specifications technical notes and company news is available to you via fax through our
5. choice should be based on the requirements of your total control system The communications option you choose determines the precautions you need to take when installing and connecting your PanelMate Power Series unit For easy reference this chapter contains a summary of seven popular communication interface options Each summary provides specific recommendations guidelines and installation tips Note Low signal level conductors Category 2 have a low tolerance for induced electrical noise Electrical noise can cause a wide range of communications problems resulting in slow or error prone PanelMate operation Be certain to follow all of the installation recommendations for the communication option you choose Also be sure to follow good wiring placement practices as outlined in Chapter 4 Cable Segregation and Placement Chapter 3 Communication Cable Selection 15 Recommended Distance Up to 50 feet Recommended Cable Type Size 24 gauge shielded pair RS 232 Communications RS 232 Grounding Recommendations Grounding of the communication cable shield at both ends will provide the most immunity to high frequency electrical interference However the introduction of low frequency interference by high ground currents in the shield may require grounding only one end Should this approach result in unacceptable high frequency interference then an RS 422 interface should be considered For RS 232 communications the maximum r
6. direct document request service at 614 899 5323 Using a touch tone phone you can select any of the info faxes from our automated product literature and technical document library punch in a fax number and receive the information immediately Website and E mail Address http www cutlerhammer eaton com automation chatechsupport ch etn com If you have Internet capabilities you also have access to technical support via our website at http www cutlerhammer eaton com automation The website includes technical notes frequently asked questions release notes and other technical documentation This direct technical support connection also offers you the ability to request assistance and exchange software files electronically Technical support messages and files can be sent to chatechsupport ch etn com 4 PanelMate Power Series installation Guide Bulletin Board Service 614 899 5209 Parameters 8 data bits 1 stop bit parity none 9600 28 8K baud If you have modem access you can dial in directly to our electronic bulletin board service for the latest product and company information File sharing product software downloads and our user message service are just a few of the things you will find online at 614 899 5209 Software Update Service 1 800 809 2772 FAX 614 899 4141 We also offer you the opportunity to take advantage of software upgrades advanced software notices and special software promotions through our Software U
7. the system may operate properly when the shield is grounded at only one end of the cable However this arrangement will make the system susceptible to high frequency interference If the systems will not operate properly due to high frequency interference and grounding the cable shield at both ends is ineffective then total isolation must be considered or eliminate ground potentials in your plant RS 422 Shielding Recommendations Application Short or Long Runs in LOW or HIGH Noise Environment with INSIGNIFICANT Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended An unshielded line is not recommended because the unshielded connectors may act as an antenna resulting in radiated emissions that may exceed the CE required limit Additionally shielded cable provides greater ESD protection The shield should be connected directly to the chassis of the interconnected units at both ends The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in LOW Noise Environment with HIGH Leve
8. 2 Correspondence Address Cutler Hammer P O Box 6166 Westerville OH 43086 6166 Shipping Address Cutler Hammer 173 Heatherdown Drive Westerville OH 43081 Table of Contents 5 Table of Contents Chapter 1 Introduction scssscssssscssscsssecssssssssssssssscsssecssssessssssssscsssscssssessssees 7 The Three Most Critical Installation Issues 8 Replacing Existing PanelMate Power Series Units 8 Chapter 2 Enlosure Selection esrrrsrrrrrrrerereeressenesee sere sessenescesseneseeseeneseoneneeneoseno 9 Enclosure Rating pancia ini te ie eaten 10 Enclosure Construction see 10 Enclosure Sizing and Unit Positioning ii 10 Chapter 3 Comm Cable Selection Shielding Grounding amp Termination 13 RS 232 COMMUNICATIONS 255702582288 subs stress lia aio 15 RS 232 Grounding Recommendations 15 RS 232 Shielding RecommendationsS i 15 RS 422 Communications 16 RS 422 Grounding Recommendations 16 RS 422 Shielding RecommendationsS i 16 RS 485 Multi Drop Communications 17 RS 485 Shielding Recommendations 17 Allen Bradley DH 485 Communications 18 Allen Bradley Data Highway Data Highway Plus Communications 19 Allen Bradley Remote I O Link Communications
9. 7 and 8 activates 120 Ohm AC termination All 120VAC PanelMate Power Series Models Jumpers on the processor board terminate the serial port Jumper JP1 for serial port 1 must be set in position A for 120 Ohm termination All 24VDC PanelMate Power Series Models except 1500 An external switch is located on the bottom of the unit 12086 SERIAL PORT 1 SERIALPORT2 42086 24V I KYSW 290 1268 ve rl h AUDIO 2200 52 2200 pst ue i NONE H NONE lt RS232 RS232 rh FAULT RELAY When using A B DH 485 communications it may be necessary to modify your communications wiring when replacing an existing PanelMate operator station with a new unit Refer to Chapter 5 Replacing Existing PanelMate Units for additional information Chapter 3 Communication Cable Selection 19 Allen Bradley Data Highway Data Highway Plus Recommended Communications Distance Up to 10 000 feet at Data Highway and Data Highway Plus are proprietary communication networks of 57 6Kbaud Shorter lengths Allen Bradley Generally the structure and components of the two networks are the at higher baud rates same but there are differences in communications protocols Refer to your Allen Bradley Cable Installation Manual for detailed information Recommended Cable The following tips are useful when installing a PanelMate on A B Data Highway and Type Size Data Highway Plus communication
10. 8 11 1 55 P o C237 22 Dia Slot 5 59 48 PanelMate Power Series Installation Guide PanelMate 2000 Model 26xx Keyboard Unit Dimensions 11 50 DM 292 10 E SS Appendix A Cutout and Unit Dimensions 49 PanelMate 2000 Model 26xx Keyboard Cutout Dimensions 5 47 5 47 138 94 138 94 DE 4 50 Ria A 114 La eo deo 6 27 159 26 4 95 125 73 6 27 159 26 22 Dia Hole 5 59 50 PanelMate Power Series Installation Guide PanelMate 2000 Model 24xx Keyboard Unit Dimensions 11 50 e 292 10 Appendix A Cutout and Unit Dimensions 51 PanelMate 2000 Model 24xx Keyboard Cutout Dimensions 5 47 138 94 5 50 139 70 52 PanelMate Power Series Installation Guide PanelMate 1700 Keyboard Unit Dimensions 12 00 304 80 11 00 279 40 Z Lg YN T FN YN oN TS y Optional Fieldbus Module Appendix A Cutout and Unit Dimensions 53 PanelMate 1700 Keyboard Cutout Dimensions 201 Dia Hole 5 11 PF EEE LA AS Me aw A J ff VA A 17 54 PanelMate Power Series Installation Guide PanelMate 1700 Touchscreen Unit Dimensions 10 51 266 95 7 7 63 193 80 0 63 17 27 Optional Fieldbus Module DN Fa ial OQ 9 2 Appendix A Cutout and Unit Dimensions PanelMate 1700 Touchscreen Cutout Dimensions 56 PanelMate Power Series Installation Guide PanelMate 1500 Keyboa
11. PanelMate Power Series Installation Guide Cutler Hammer E T N PanelMate Power Series Installation Guide Information in this manual is subject to change without notice and does not represent a commitment on the part of Cutler Hammer Inc Permission is granted to duplicate this material without modification only for your use or the internal use of other members of your company or your agents to assist you in the use and servicing of products purchased from Cutler Hammer No permission is granted to modify this material or include this material in a compilation PanelMate is a registered trademark of Cutler Hammer Inc Commercial names of products from other manufacturers or developers that appear in this manual are registered or unregistered trademarks of those respective manufacturers or developers which have expressed neither approval nor disapproval of Cutler Hammer products Copyright Cutler Hammer Inc 1999 All rights reserved P N 01 00436 00 mi Preface 3 Support Services It is Cutler Hammer s goal to ensure your greatest possible satisfaction with the operation of our products We are dedicated to providing fast friendly and accurate assistance That is why we offer you so many ways to get the support you need Whether it s by phone fax modem or mail you can access Cutler Hammer support information 24 hours a day seven days a week Preface Technical Support 1 800 809 2772 If you
12. anelMate Power Series Installation Guide Modicon Modbus Plus Communications This proprietary communications network consists of twisted pair shielded cable extending up to 1500 feet with up to 32 nodes For detailed installation instructions refer to your Modicon Modbus Plus Network Planning and Installation Guide The following tips are useful when installing a PanelMate on Modicon Modbus Plus communication networks Tip 1 Trunkline drop line is the only acceptable network configuration Star or tree configurations are NOT acceptable Tip 2 A drop cable is used to connect the PanelMate unit to the trunk line tap The drop cable is equipped with a ground lug that must be connected to PanelMate unit s panel ground Tip 3 The minimum cable length between nodes must be at least 10 Chapter 3 Communication Cable Selection 23 Recommended Distance Up to 1640 feet at 125Kbaud Recommended Cable Type Size Refer to your Cutler Hammer DeviceNet Installation Guide DeviceNet Communications DeviceNet is a non proprietary communications network consisting of 5 conductor shielded cable in trunk line thick and drop line thin styles Up to 64 nodes can be installed on the network Refer to Cutler Hammer s DeviceNet Planning and Installation Guide for detailed information on DeviceNet networks The following tips are useful when installing a PanelMate on a DeviceNet communication network Tip 1 Tip 2 Ti
13. ated input voltage at the PanelMate unit s serial port is 30 to 30V RS 232 Shielding Recommendations Application Short or Long Runs in LOW or HIGH Noise Environment with INSIGNIFICANT Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended An unshielded line is not recommended because the unshielded connectors may act as an antenna resulting in radiated emissions that may exceed the CE required limit Additionally shielded cable provides greater ESD protection The shield should be connected directly to the chassis of the interconnected units at both ends The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in LOW Noise Environment with HIGH Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units one end only Never connect the shield
14. ble Cutler Hammer offers communications cables for these applications Contact Cutler Hammer Support Services for additional information Option 3 Place a jumper in the existing cable connector between the Ground Pin 5 and the connector shell cover This would provide the required ground reference for the new 24VDC unit but the port would now be non isolated If the existing unit functioned properly with a non isolated port the new unit will probably work equally as well with this modification Chapter 5 Replacing an Existing PanelMate Power Series Unit 29 Caution You can not simply add a DB 9 to RJ adapter when using RS 422 485 DH 485 communications You must jumper the existing cable connector as described Otherwise the serial ports will remain optically isolated and you may experience unreliable communications and unexpected operational failures Upgrading a PanelMate Power Series Model 1500 unit with a PanelMate Power Series Model 1700 unit When upgrading a Model 1500 unit to a Model 1700 unit three issues should be reviewed power supply enclosure sizing and communications cable Power Supply Although both PanelMate Power Series 1500 and 1700 models operate on 24VDC 1700 models draw additional current Check to make sure your 24VDC power supply is adequately rated for the 1700 Enclosure Sizing Due to the 1700 s higher current usage it produces more BTUs of heat energy that must be dissipated by the en
15. ble entry opening Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in LOW Noise Environment with HIGH Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units one end only Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in HIGH Noise Environment with HIGH Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units and ac coupled through a 0 01 uf capacitor at the other end to the chassis of the second unit The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Attaching the capacitor at the ac coupled end will requ
16. closure The table in Chapter 2 Enclosure Sizing can help you determine the suitability of the existing enclosure Communications Cable Model 1700 units are equipped with optically isolated serial ports using DB 9 connectors Model 1500 units are equipped with non optically isolated serial ports using RJ type connectors These issues are addressed differently depending on the type of communications used Proprietary Networks or DeviceNet Communications These communications cables use a special connector and attach to an optional communications module Since they do not use the 1700 s serial ports modifications are not necessary Simply plug in the existing cable s connector into the 1700s units optional communications module RS 232 Communications An RS 232 cable is already equipped with the ground return conductor required by the 1700 s optically isolated serial ports Therefore the only modification required to the cable is changing from the RJ type connector to a DB 9 connector An adapter is available from Cutler Hammer or the existing connector can be removed and replaced with a new DB 9 connector RS 422 485 DH 485 Communications When connected to an optically isolated serial port an RS 422 485 DH 485 cable must have a ground return conductor You can approach this issue from two directions provide a ground wire or defeat the optically isolation on the serial ports Without the modifications the new1700 unit may experience
17. ed on RS 485 network technology A Profibus DP network may have up to 126 nodes but maximum length of the network is determined by baud rate Profibus DP Shielding Recommendations A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended An unshielded line is not recommended because the unshielded connectors may act as an antenna resulting in radiated emissions that may exceed the CE required limit Additionally shielded cable provides greater ESD protection The shield should be connected directly to the chassis of the interconnected units at both ends The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Using PanelMate on a Profibus DP network The following tips are useful when installing a PanelMate on a Profibus DP communication network Tip 1 The Profibus network must be terminated at both ends of every segment The termination must be powered at all times Tip 2 As the Profibus DP network allows daisy chained connections wiring for Signal A and Signal B must remain consistent throughout the segment It is suggested that the green wire is used for Signal A and the red w
18. ew unit Refer to Chapter 5 Replacing Existing PanelMate Units for additional information Chapter 3 Communication Cable Selection 17 Recommended Distance Up to 4000 feet Up to 2000 feet for RS 485 connected to A B Channel 0 Recommended Cable Type Size 22 gauge shielded pair Note See separate section for Allen Bradley DH 485 Communications RS 485 Multi Drop Communications This network is an extension of RS 422 and is used for the distribution of data between multiple system components and peripherals over distances up to 4000 This system will tolerate common mode voltage differentials from 7 to 12 volts For more information refer to the EIA RS 485 Standard RS 485 Shielding Recommendations Application Short or Long Runs in LOW or HIGH Noise Environment with INSIGNIFICANT Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended An unshielded line is not recommended because the unshielded connectors may act as an antenna resulting in radiated emissions that may exceed the CE required limit Additionally shielded cable provides greater ESD protection The shield should be connected directly to the chassis of the interconnected units at both ends The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing ca
19. ire is used for Signal B Chapter 4 Cable Segregation amp Placement 25 4 Cable Segregation amp Placement 26 PanelMate Power Series Installation Guide Chapter Overview When planning the location and placement of wiring care should be taken to minimize electrical noise problems Noise is often the problem when intermittent communications problems are experienced Loss of data slow response and communication error messages are common indications of electrical noise contamination This chapter gives a brief overview of cable routing and placement issues Potential Problem Areas High and low power conductors routed in the same conduit or raceway Conduit with low power conductors routed in close parallel proximity to conduit containing high power conductors Cable or PanelMate unit located too close to devices generating high levels of magnetic or electrical interference Lack of continuous electrical continuity along the length of the conduit installation Cable Segregation The low power cabling used for PLC and PC based control systems is very susceptible to electrical noise generated by high power conductors Even when protected by conduit noise can interfere with your communication lines and networks Therefore it is important to segregate conductors according to their type DEEE ES LE SN Category 1 High Power Conductors AC power lines These conductors can cause High powe
20. ire some ingenuity to achieve a secure connection at both the shield and chassis while keeping the capacitor lead length as short as possible Note When using RS 485 communications it may be necessary to modify your communications wiring when replacing an existing PanelMate operator station with a new unit Refer to Chapter 5 Replacing Existing PanelMate Units for additional information 18 PanelMate Power Series Installation Guide Recommended Distance Up to 4000 feet Recommended Cable Type Size Belden 9842 cable Allen Bradley DH 485 Communications Refer to your Allen Bradley Cable Installation manual for detailed information The following tips are useful when installing a PanelMate on A B DH 485 communication networks Tip 1 Tip 2 Note All PanelMate units on the A B DH 485 communications network should have optical isolation to prevent serial port damage If the PanelMate model you are installing DOES NOT have built in optical isolation then an Allen Bradley AIC module should be used to provide optical isolation See Replacing Existing PanelMate Units Using R422 485 Communications for specific PanelMate model optical isolation information Verify the network is terminated Both ends of a DH 485 network must contain termination resistors PanelMate Power Series units have built in termination resistors that can be activated if needed PanelMate Power Series 1500 on the RJ 45 connector jumping pins
21. ity must be maintained along the entire length of the conduit raceway installation including entry into the enclosure 5 Replacing an Existing PanelMate Power Series Unit 28 PanelMate Power Series Installation Guide Chapter Overview When replacing and existing PanelMate Power Series unit with a new PanelMate Power Series unit it may be necessary to modify your installation This chapter will help you determine if modifications are required Potential Problem Areas Existing enclosure is too small for the new PanelMate unit Different power supply requirements for the new PanelMate unit Optically vs non optically isolated serial ports Replacing a 120VAC PanelMate Power Series unit with another 120VAC PanelMate Power Series unit The only issue to investigate in this retrofitting is enclosure size Be sure to confirm the expected enclosure ambient temperature with the new unit installed The table in Chapter 2 Enclosure Sizing can help you determine the suitability of the existing enclosure Also confirm that the minimum free space above and below the new unit will meet the requirements for the model installed See the table provided in Chapter 2 Enclosure Sizing Replacing a 120VAC PanelMate Power Series unit with a 24VDC PanelMate Power Series unit When replacing a 120VAC unit with a 24VDC unit there are two issues to address The need for a 24VDC power supply and the PLC Communications cab
22. le The power supply issue is self explanatory The communications issues discussed apply to all 24VDC PanelMate Power Series models except 1500 models Proprietary Networks or DeviceNet Communications These communications cables use a special connector and attach to an optional communications module or board Since they do not use the PanelMate unit s serial ports modifications are not necessary Simply plug in the existing cable s connector into the new unit s optional communications module RS 232 Communications An RS 232 cable is already equipped with the ground return conductor required by the 1700 s optically isolated serial ports RS 422 485 DH 485 Communications When connected to an optically isolated serial port an RS 422 485 DH 485 cable must have a ground return conductor You can approach this issue from two directions provide a ground wire or defeat the optical isolation on the serial ports Without the modifications the new 24VDC PanelMate Power Series unit may experience unreliable communications and unexpected operational failures Option 1 If the existing cable was installed without a ground conductor but contains an unused conductor that conductor can be connected and the cable shield connection revised to conform with the noise reduction recommendations provided in Chapter 3 Communication Cable Selection Shielding Grounding and Termination Option 2 Replace the existing communication cable with a new ca
23. ls of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units one end only Never connect the shield by way of a drain wire pigtail unless absolutely necessary If a pigtail is required the shield should be terminated as close as possible to the connector to minimize the pigtail length Application Short or Long Runs in HIGH Noise Environment with HIGH Levels of Low Frequency Ground Differential Voltage Between Connected Units A good quality shielded cable consisting of twisted pairs for the required communication wires and logic common is recommended The shield should be connected directly to the chassis of one of the interconnected units and ac coupled through a 0 01 uf capacitor at the other end to the chassis of the second unit The connector housing should contact the cable shield uniformly around the entire 360 degree periphery of the housing cable entry opening Attaching the capacitor at the ac coupled end will require some ingenuity to achieve a secure connection at both the shield and chassis while keeping the capacitor lead length as short as possible Note When using RS 422 communications it may be necessary to modify your communications wiring when replacing an existing PanelMate operator station with a n
24. networks Belden 9463 blue hose twinaxial cable Tip 1 Verify the network is terminated Both ends of an A B Data Highway Data Highway Plus network must contain termination resistors Resistor value is determined by the network baud rate The resistor value must be the same at both ends of the network 57 6 K 115 2K 150 or 82 5 Ohm 230 4K 82 5 Ohm Tip 2 The minimum cable length is 20 between any two nodes Tip 3 On Data Highway Plus networks daisy chained networks are preferred but trunkline drop line is acceptable Star or tree configurations are NOT acceptable Tip 4 In order to comply with CE Mark requirements ferrite cores must be installed on the PanelMate unit s AcceleratI On cable Steward number 28B0735 000 is recommended Refer to Cutler Hammer s PanelMate AcceleratI On Interface Installation I L for installation details 20 PanelMate Power Series Installation Guide Allen Bradley Remote I O Link Communications The Remote I O Link is a proprietary communication network of Allen Bradley The following tips are useful when installing a PanelMate on Remote I O Link networks Tip 1 Verify the network is terminated Both ends of an A B Remote I O Link network must be terminated Resistor value is determined by the network baud rate The resistor value must be the same at both ends of the network 57 6 K 115 2K 150 or 82 5 Ohm 230 4K 82 5 Ohm Tip 2 On Remote I O networks daisy chained netw
25. oducts Cutler Hammer offers no guarantee or warranty to the specific applicability of this table as actual conditions may vary and methods of the use of our products are beyond our control For specific information about enclosure selection and cooling methods contact your enclosure vendor Note Cutout and unit dimensional information for all PanelMate Power Series units is provided in Appendix A 12 PanelMate Power Series Installation Guide Enclosure Size vs Average Internal PanelMate Model Enclosure Size Avg Internal Temp Rise Temperature Rise This table makes the 1500 w keypad 16x16x4 2i C following assumptions 16x16x6 6 2 C 20x16x6 5 6 C e Enclosure is fabricated 1500 w touchscreen 12x12x4 11 4 C from cold rolled steel 12x12x6 10 8 C e All sides of the 12x14x6 9 8 C enclosure are 1700 w keypad or touchscreen 16x16x4 10 8 C uninsulated free 16x16x6 93 C standing 20x 16x6 TTC da tee 1700 w touchscreen 12x12x6 14 4 C minimum clearance o between the PanelMate ai a bottom of the enclosure 24x24x12 8 9 C e No other heat generating 30x24x12 La c the enclosure 24x24x12 12 8 C Note The temperature rise 30x24x12 106 C shown represents the All 3000 24x20x8 7 2 C temperature rise in the 24x24x8 6 7 C enclosure above the outside All 4000 30x24x16 9 4 C temperature For example if 30x24x20 8 3 C the tempera
26. orks are preferred but trunkline drop line is acceptable Star or tree configurations are NOT acceptable Tip 3 All devices connected to the Remote I O Link must communicate at the same baud rate Chapter 3 Communication Cable Selection 21 Recommended Distance Up to 7500 feet at 38 4Kbaud Shorter lengths at higher baud rates Recommended Cable Type Size Refer to your GE Fanuc Automation Genius I O Systems and Communications User s Manual GE Fanuc Genius I O Communications This proprietary communications network uses twisted pair shielded cable and or fiber optics cable For detailed installation instructions refer to the GE Fanuc Automation Genius I O Systems and Communications User s Manual The following tips are useful when installing a PanelMate on Genius I O communication networks Tip 1 If the PanelMate unit is located at an end of the network termination is required The termination resistor value is dependent on the type of cable used Consult your Genius I O manual for exact requirements Tip 2 Cable type baud rate and cable length must all be compatible and determine the maximum number of nodes allowed on the network Tip 3 Shield Out and Shield In connections must be daisy chained with the first device s Shield In terminal and the last device s Shield Out terminal left unconnected Tip 4 In high electrical noise installations 153 6Kbaud provides better noise immunity 22 P
27. p 3 Tip 4 Tip 5 The drop line to the PanelMate unit must not exceed 20 If the PanelMate unit is the last node on the network termination is required Install a 120 Ohm terminator in the unused plug of the connector or install a 120 Ohm resistor between pins 4 and 2 of the Phoenix connector The PanelMate unit does not draw power from or supply power to the network It is not necessary to make the V connection but you should do so to secure the wires and prevent shorting In all PanelMate units the DeviceNet signal ground is isolated from chassis ground In locations where problems are caused by high electrical noise you can change the jumper setting on the PanelMate unit s DeviceNet communications card to connect signal ground to chassis ground Refer to Cutler Hammer s PanelMate DeviceNet Interface Installation I L for detailed jumper information In order to comply with CE Mark requirements ferrite cores must be installed on the PanelMate unit s drop line Steward number 28B1020 100 is recommended for thick line installations Steward number 28B0735 000 is recommended for thin line installations Refer to Cutler Hammer s PanelMate DeviceNet Interface Installation I L for installation details 24 PanelMate Power Series Installation Guide Recommended Distance Up to 3278 feet at 93 7Kbaud Recommended Cable Type Size 22 gauge shielded pair Profibus DP Communications Profibus DP is bas
28. pdate Service When you register your software you will receive one year of free or reduced price upgrades along with all the other benefits of membership including 48 hour shipping of software upgrades Contact the Software Update Service at 1 800 809 2772 or fax 614 899 4141 Repair and Upgrade Service 614 882 3282 ext 7601 FAX 614 882 3414 Our well equipped Customer Service department is ready to assist you with repairs upgrades and spare parts services If a situation arises where one of these services is needed just call 614 882 3282 x7601 or fax 614 882 3414 Product Ordering Service 614 882 3282 FAX 614 882 6532 Authorized Cutler Hammer distributors may place product orders directly with our Order Processing department by calling 614 882 3282 x406 or faxing 614 882 6532 For information on your local distributor call the Cutler Hammer Tech Line Customer Support Center 1 800 356 1243 Authorized Cutler Hammer distributors and Cutler Hammer sales offices can get assistance for Cutler Hammer standard and component product lines through the Customer Support Center Call the Customer Support Center for the following assistance 1 Stock availability proof of shipment or to place an order 2 Expedite an existing order 3 Product assistance and product price information 4 Product returns other than warranty returns For information on your local distributor or sales office call the Cutler Hammer Tech Line at 1 800 809 277
29. r digital AC and DC electrical noise in Category 2 lines conductors when in close proximity Are more tolerant of Typically these conductors are electrical noise than Category 2 used to connect hard contact switches relays solenoids Reference NEC article 725 class 1 motors generators and arc Reference IEEE level 3 and 4 welders Category 2 Low Signal Level Conductors Communication cables These conductors are less tolerant of electrical noise however they cause less noise in adjacent conductors Reference NEC article 725 class 2 class 3 Reference IEEE level 1 and level 2 Ethernet PLC networks etc Low power digital AC and DC T O lines Typically these conductors are used to connect PLCs and related modules with PanelMate operator stations Cable Placement The following guidelines should be used when installing your communication cables All Category 2 cables should be shielded and routed in a separate conduit or raceway from Category 1 cables Route Category 2 cables at least one foot from 120VAC power lines Route Category 2 cables at least two feet from 240VAC power lines Route Category 2 cables at least three feet from 480VAC power lines Route Category 2 cables at least five feet from high voltage enclosures If a Category 2 cable must cross Category 1 cables it should cross at a right angle If Category 2 cable is enclosed in metal conduit or a metal raceway electrical continu
30. rd Unit Dimensions 12 00 304 80 11 00 279 40 Optional Fieldbus Module Appendix A Cutout and Unit Dimensions PanelMate 1500 Keyboard Cutout Dimensions 201 Dia Hole 5 11 58 PanelMate Power Series Installation Guide PanelMate 1500 Touchscreen Unit Dimensions 10 51 266 95 i OA 7 63 193 80 Optional Fieldbus Module Appendix A Cutout and Unit Dimensions PanelMate 1500 Touchscreen Cutout Dimensions 3 47 88 14 I gt 1 65 E 87 4 75 Dia Hole
31. s e Protection from ambient temperatures above or below unit specifications e Protection from electromagnetic interference This chapter reviews enclosure choice considerations and provides a guide for sizing your PanelMate unit s enclosure Potential Problem Areas Enclosure is too small for the operator interface not enough free space for efficient convection cooling Enclosure is filled with other heat generating devices internal temperature rises above the operator interface s ratings Enclosure is mounted near devices generating high levels of magnetic or electrical interference Free air space is not present around the outside of the enclosure prevents the enclosure s metal panels from dissipating internal heat Enclosure Rating The front panels of PanelMate Power Series units provide a NEMA 4 or NEMA 12 rating when mounted in a correspondingly rated enclosure Some PanelMate models are also rated for NEMA 4X installations Make sure the enclosure you choose will meet or exceed your application s NEMA rating requirement Enclosure Construction Cutler Hammer recommends an enclosure constructed of cold rolled steel This will help guard your unit against electromagnetic interference as well as provide proper structural support and good heat dissipation Enclosure Sizing and Unit Positioning Careful enclosure sizing is important for proper heat dissipation and easy installation and main
32. sions 354 58 0 1 O1 Ref D a 132 59 482 60 III 23 37 306 32 393 70 Appendix A Cutout and Unit Dimensions 41 PanelMate 4000 Split Architecture Cutout Dimensions 1 19 30 23 1 13 28 70 1 13 28 70 1 19 30 23 Minimum 9 75 247 65 Maximum 27 00 685 80 3 Do EE RUE 2 50 2 50 63 50 63 50 42 PanelMate Power Series Installation Guide PanelMate 4000 Touchscreen Unit Dimensions 15 00 381 00 17 94 455 68 a Appendix A Cutout and Unit Dimensions 43 PanelMate 4000 Touchscreen Cutout Dimensions 16 a a ci 86 170 1 90 Dia 1 90 n 48 26 48 26 gt 1 75 7 44 45 161 80 YT_ e 12 52 318 01 5 25 133 35 350 52 44 PanelMate Power Series Installation Guide PanelMate 3000 Keyboard Unit Dimensions 13 50 342 90 13 00 330 20 Appendix A Cutout and Unit Dimensions 45 PanelMate 3000 Keypad Cutout Dimensions 12 00 304 80 6 00 152 40 Z 6 25 _ 6 25 158 75 158 75 12 50 317 50 46 PanelMate Power Series Installation Guide PanelMate 3000 Touchscreen Unit Dimensions 12 30 312 42 11 97 304 04 30 73 Appendix A Cutout and Unit Dimensions 47 PanelMate 3000 Touchscreen Cutout Dimensions 5 87 Lu Eo 149 10 5 70 5 70 144 78 AAB 22 Dia Hole MRS 3 4 65 5 59 118 11 11
33. sions and cutouts are subject to change A Cutout Drawing is included with your PanelMate Power Series unit Confirm all of your cutout dimensions with that drawing prior to cutting 32 PanelMate Power Series Installation Guide PanelMate 5000 Keypad Unit Dimensions 19 00 482 60 19 22 488 19 Appendix A Cutout and Unit Dimensions PanelMate 5000 Keyboard Cutout Dimensions 4 00 101 60 i 34 PanelMate Power Series Installation Guide PanelMate 5000 Split Architecture Unit Dimensions 900 ee opaa Appendix A Cutout and Unit Dimensions 35 PanelMate 5000 Split Architecture Cutout Dimensions 25 Dia Slot N 6 35 Minimum 9 75 247 65 Maximum 27 00 685 80 36 PanelMate Power Series Installation Guide PanelMate 5000 Touchscreen Unit Dimensions 15 00 381 00 13 42 340 87 Appendix A Cutout and Unit Dimensions 37 PanelMate 5000 Touchscreen Cutout Dimensions 7 1 16 RI 5 181 PE Taarn 46 1 90 5 NTFS 48 26 48 26 1 75 7 44 45 161 80 YT_ 12 52 318 01 5 25 133 35 350 52 38 PanelMate Power Series Installation Guide PanelMate 4000 Keypad Unit Dimensions i 19 00 482 60 24 38 Appendix A Cutout and Unit Dimensions PanelMate 4000 Keypad Cutout Dimensions 40 PanelMate Power Series Installation Guide PanelMate 4000 Split Architecture Unit Dimen
34. tenance For efficient convection cooling free space is needed around the PanelMate unit Convection cooling draws a vertical column of air upward over internal circuitry through the vents in the unit In all installations the cooling air must not exceed the maximum specified ambient temperature This determination must be made for the maximum expected plant temperature maximum temperature of the air surrounding the enclosure e Maintain recommended free space above and below the PanelMate unit see table on next page e Avoid mounting other heat generating equipment near the PanelMate unit If no other location is available mount the equipment beside or behind the PanelMate unit If side rear space is not available it is preferable to mount the other equipment above rather than below the PanelMate unit Be sure to maintain the recommended free space area between the PanelMate unit and the other equipment e Leave room for easy access to circuit boards wiring cable connections and regular maintenance Maintain Minimum Recommended Clearance Chapter 2 Enclosure Selection 11 Recommended Free Space and Maximum Operating Temperature Table The free space area is the space between the PanelMate unit s electronics and the top or bottom of the enclosure Internal fans help provide a uniform ambient temperature inside the enclosure PanelMate Maximum Operating Ambient Unit Heat Recommended Power Series Temperature Outp
35. ture outside the enclosure in 35 C and the 36x30x16 So C temperature rise in the 5000 w keypad 30x24x8 6 C enclosure is 10 C then the 30x24x10 5 6 C average temperature inside 5000 w touchscreen 24x24x8 LOC the enclosure will be 45 C 24x24x10 67 C 24x30x8 6 1 C Chapter 3 Communication Cable Selection 13 Communication Cable Selection Shielding Grounding amp Termination 3 14 PanelMate Power Series Installation Guide Chapter Overview This chapter contains a summary of seven popular communication interface options Each summary provides specific recommendations guidelines and installation tips Potential Problem Areas Improper grounding of communications cable causing excessive radiated emissions Incorrect cable or pinout Improper or lack of termination on PanelMate units located at the end of a communications network Failure to maintain minimum maximum cable lengths between nodes on a communications network Exceeding recommended cable or total network distance A variety of communication interface options are available for PanelMate Power Series products Options include RS 232 and RS 422 based communications RS 485 multi drop communications Open multi drop networks examples DeviceNet Profibus Proprietary PLC networks examples A B Data Highway Genius I O Modbus Plus Cutler Hammer does not recommend any specific communications option Your
36. unreliable communications and unexpected operational failures Option 1 If the existing cable was installed without a ground conductor but contains an unused conductor that conductor can be connected and the cable shield connection revised to conform with the noise reduction recommendations provided in Chapter 3 Communication Cable Selection Shielding Grounding and Termination If you elect to use this option you will need to remove the existing RJ connector and replace it with a DB 9 connector Option 2 Replace the existing communication cable with a new cable Cutler Hammer offers communications cables for these applications Contact Cutler Hammer Support Services for additional information Option 3 Place a jumper in the existing cable connector between the Ground Pin 5 and the connector shell cover This would provide the required ground reference for the new 24VDC unit but the port would now be non isolated If the existing unit functioned properly with a non isolated port the new unit will probably work equally as well with this modification If you elect to use this option you will need to remove the existing RJ connector and replace it with a DB 9 connector 30 PanelMate Power Series Installation Guide Appendix A Cutout and Unit Dimensions 31 Cutout and Unit Dimensions Before you begin cutting metal The information in this Appendix was accurate at the time of printing However product dimen
37. ut Free Space 1500 Series 50 C Gray scale amp Color TFT 41 BTU hr 2 minimum 40 C Color Dual scan 12W 1700 Series 50 C Grayscale amp Color TFT 78 BTU hr 2 minimum 40 C Color Dual scan 23W 4 recommended 2000 Series 50 C 188 6 minimum Grayscale BTU hr 55 W 2000 Series 50 C 273 6 minimum Color BTU hr 80 W 3000 Series 119 Grayscale amp 40 C BTU hr 6 minimum Color Dual 35W scan 3000 Series 50 C 119 6 minimum Color TFT BTU hr 35W 4000 Series 50 C 273 6 minimum BTU hr 80W 5000 Series 50 C 137 6 minimum BTU hr 40W If the inside temperature of the enclosure is above the PanelMate unit s recommended range see table you must use filtered fans heat exchangers or air conditioners to lower the temperature Because hot air rises to the top of an enclosure the temperature inside can vary greatly from bottom to top A fan can be used to circulate air within the enclosure to maintain a more uniform temperature Make sure the magnetic properties of the equipment used to cool the enclosure do not interfere with your PanelMate unit s operation CRT monitors are especially susceptible to magnetic fields Note If an air purged enclosure is used it is recommended that the inside outside pressure differential not exceed 5 PSI The following sizing table is offered as an aid in the selection of enclosures to be used with PanelMate pr
38. wer Series unit will provide years of dependable trouble free operation in rugged industrial environments The Three Most Critical Installation Issues With more than 100 000 PanelMate units currently in operation since its introduction in 1986 Cutler Hammer has helped many users troubleshoot their PanelMate installations This Installation Guide is intended to help you avoid the common mistakes made by first time PanelMate users Three aspects of your installation are critical to long life and reliable operation Enclosure selection Communication cable selection shielding grounding and termination Cable segregation and placement This Installation Guide reviews each of these areas providing recommendations and guidelines for making knowledgeable installation decisions Replacing Existing PanelMate Power Series Units If you are planning to replace an existing PanelMate Power Series unit with a new PanelMate Power Series unit there are several very important steps to take to ensure proper operation See Chapter 5 Replacing Existing PanelMate Units Chapter 2 Enclosure Selection 9 Enclosure Selection 10 PanelMate Power Series Installation Guide Chapter Overview The enclosure for your PanelMate unit must provide protection against conditions that can shorten the life of your PanelMate or cause improper operation e Protection from oil dust moisture corrosive vapors and other airborne contaminant
Download Pdf Manuals
Related Search