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Contents
Figures
1640-IN-031-C-08

Table of Contents

1.
............................................................................................... 4
1.1
CE EMC Compliance .................................................................... 5
1.2
Notes on EMC Shielding ............................................................... 5
2.
Installing & Wiring the T/C-Analog Board ................................................ 23
3.
Installing & Wiring the Communications Board ....................................... 30
4.
Installing & Wiring the Data Handler Board ............................................ 33
5.
Installing & Wiring the Analog I/O Board ................................................ 36
6.
6.1
Introduction ................................................................................. 41
6.2
Wiring of All Analog Inputs & Outputs ......................................... 41
6.2.1
Input/Output Specifications .................................................. 41
6.2.2
Analog Input/Output Wiring Guidelines ................................ 42
6.2.3
Analog I/O Applications Wiring ............................................ 42
6.3
Wiring of DC Inputs & Outputs .................................................... 42
7.
Installing & Wiring the Seq/Hydraulics Board ......................................... 54
8.
Installing & Wiring the Power Supply Board ........................................... 56
9.
Installing & Wiring AC Output Boards ..................................................... 61
10. Installing & Wiring DC Output Boards ..................................................... 66
11. Installing & Wiring Analog Output Boards ............................................... 72
12. Installing & Wiring AC Input Boards ........................................................ 77
13. Installing & Wiring DC Input Boards ........................................................ 81
14. Installing & Wiring AC/DC Input Boards .................................................. 86
15.1
Introduction ................................................................................. 90
15.2
Specifications .............................................................................. 90
16. MACO Series Specifications ................................................................... 97
17. Application Guide for Sensors and Analog Signals ............................... 102
17.1
General ..................................................................................... 102
17.2
Hydraulic Pressure Transducers ............................................... 102
17.3
Position Transducers ................................................................ 102
17.4
Tachometer ............................................................................... 102
17.5
Analog Outputs ......................................................................... 102
17.6
Extrusion/Parison Pressure Transducers .................................. 102
Figure 1.0 12 Slot Enclosed Controller Dimensions ....................................... 6
Figure 1.1 16 Slot Enclosed Controller Dimensions ....................................... 7
Figure 1.2 12 Slot Open Frame Controller Dimensions ................................. 8
Figure 1.3 9 Slot Open Frame Controller Dimensions ................................... 9
Figure 1.4 7 Slot Open Frame Controller Dimensions ................................. 10
Eurotherm/Barber-Colman
MACO Series Controller Installation
MACO Series Controller Installation
Page 1 of 104

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Summary of Contents for Barber-Colman MACO Series

  • Page 1: Table Of Contents

    15. Wiring the 32 In/32 Out or 24 In/24 Out Digital I/O Boards ..... 90 15.1 Introduction ................. 90 15.2 Specifications ................90 16. MACO Series Specifications ..............97 17. Application Guide for Sensors and Analog Signals ....... 102 17.1 General ..................102 17.2 Hydraulic Pressure Transducers ..........
  • Page 2 MACO Series Controller Installation Figures (continued) Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O) ..... 13 Figure 1.6C 16 Slot Controller Board Locations (6 Slots of I/O) ..... 14 Figure 1.6D 9 Slot Controller Board Locations (3 Slots of I/O) ....... 15 Figure 1.7 7Slot Controller Board Locations ..........
  • Page 3 MACO Series Controller Installation Figures (continued) Figure 11.0 Locating the Analog Output Boards ..........73 Figure 11.1 A-60033 Analog Output Board ............ 74 Figure 11.2 Analog Output Wiring ..............75 Figure 11.3 Wiring the Analog Output Board ..........76 Figure 12.0 A-13900 or A-60089 Standard Density AC Input Board ..... 78 Figure 12.1 High Density AC Input Board Assembly ........
  • Page 4: General

    MACO Series Controller Installation 1. General The wiring guidelines outlined in this manual are to be used in addition to all applicable electrical and safety codes. Be sure to follow all requirements of such codes as well as other recognized safety practices.
  • Page 5: Ce Emc Compliance

    MACO Series Controller Installation 1.1 CE EMC Compliance This MACO control system is in full compliance with CE EMC requirements as long as AC input boards, AC output boards and analog output boards are excluded. Use of these boards will require additional EMC testing by the machine manufacturer.
  • Page 6: Figure 1.0 12 Slot Enclosed Controller Dimensions

    MACO Series Controller Installation Figure 1.0 12 Slot Enclosed Controller Dimensions Front View 1.37" (35mm) Approx. 1" (25.4mm) Approx. (4) .531" Latch (2) (13.48mm) 13.562" (345mm) 10.500" (266.70mm) Ref. 6-32 EMC Bond Stud 2" (50mm) 18.312" (465.12mm) Approx. (4) .281"...
  • Page 7: Figure 1.1 16 Slot Enclosed Controller Dimensions

    MACO Series Controller Installation Figure 1.1 16 Slot Enclosed Controller Dimensions Front View 1.37" (35mm) Approx. 1" (25.4mm) Approx. (4) .531" Latch (2) (13.48mm) 13.562" (345mm) 10.500" (266.70mm) Ref. 6-32 EMC Bond Stud 2" (50mm) 26.625" (676.28mm) Approx. (4) .281"...
  • Page 8: Figure 1.2 12 Slot Open Frame Controller Dimensions

    MACO Series Controller Installation Figure 1.2 12 Slot Open Frame Controller Dimensions 1.705 Front View (43mm) .531 (13.49mm) (4) 8.750 (222.3mm) 12.160 6-32 EMC (106.4mm) Bond Stud .281 (7.14mm) (4) 19.250 (489mm) 1.705 (43mm) .400 (10mm) 20.050 (509mm) Reference Side View Allow Approx.
  • Page 9: Figure 1.3 9 Slot Open Frame Controller Dimensions

    MACO Series Controller Installation Figure 1.3 9 Slot Open Frame Controller Dimensions 1.705 Front View (43mm) .531 (13.49mm) (4) 8.750 (222.3mm) 12.160 6-32 EMC (106.4mm) Bond Stud .281 (7.14mm) (4) 15.665 (398mm) 1.705 (43mm) .400 (10mm) 16.415 (417mm) Reference Side View Dimensions are in inches Allow Approx.
  • Page 10: Figure 1.4 7 Slot Open Frame Controller Dimensions

    MACO Series Controller Installation Figure 1.4 7 Slot Open Frame Controller Dimensions 8.300 (210.8mm) 0.640 (16.2mm) 0.500 Ø 0.281 (12.7mm) (7.14mm) Ø 0.531 13.49mm) 11.300 (287mm) 8.750 (222.3mm) 1.275 (32.38mm) 14.000 (355.6mm) 0.400 (10mm) 14.800 (376mm) Reference Dimensions are in inches...
  • Page 11: Figure 1.5 12 Slot Controller Board Locations (5 Slots Of I/O)

    MACO Series Controller Installation Figure 1.5 12 Slot Controller Board Locations (5 Slots of I/O) Mother Board IMPORTANT: EMC Critical Item Temperature #1 Slot #12 Slot #2 Slot #11 Slot #10 Slot #3 Data Handler Slot # 9 Slot #5...
  • Page 12: Figure 1.6A 16 Slot Controller Board Locations (8 Slots Of I/O)

    MACO Series Controller Installation Figure 1.6A 16 Slot Controller Board Locations (8 Slots of I/O) Mother Board Energize CR 605 Energize CR 607 (if Hi Density I/O) IMPORTANT: EMC Critical Item See Wiring Detail Below Slot #1 Slot #16 Slot #2...
  • Page 13: Figure 1.6B 16 Slot Controller Board Locations (7 Slots Of I/O)

    MACO Series Controller Installation Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O) Mother Board Energize CR 604 Energize CR 607 (if Hi Density I/O) IMPORTANT: EMC Critical Item See Wiring Detail Below Slot #1 Slot #16 Slot #2...
  • Page 14: Figure 1.6C 16 Slot Controller Board Locations (6 Slots Of I/O)

    MACO Series Controller Installation Figure 1.6C 16 Slot Controller Board Locations (6 Slots of I/O) Mother Board Energize CR 606 Energize CR 607 (if Hi Density I/O) IMPORTANT: EMC Critical Item See Wiring Detail Below Slot #1 Slot #16 Slot #2...
  • Page 15: Figure 1.6D 9 Slot Controller Board Locations (3 Slots Of I/O)

    MACO Series Controller Installation Figure 1.6D 9 Slot Controller Board Locations (3 Slots of I/O) Mother Board Energize CR 605 Energize CR 607 (if Hi Density I/O) 3 Slots of I/O IMPORTANT: EMC Critical Item See Wiring Detail Below Slot #1...
  • Page 16: Figure 1.7 7Slot Controller Board Locations

    MACO Series Controller Installation Figure 1.7 7 Slot Controller Board Locations Sequence/Hydraulics Slot #7 Slot #2* Slot #6 Data Handler Power Supply & Communications Slot #4 *If process control/line graphs is specified in sequence options, this slot must have Analog I/O card.
  • Page 17: Figure 1.8 Multi-Chassis Installation

    MACO Series Controller Installation Figure 1.8 Multi-Chassis Installation Controllers in a multi-rack configuration can be any combination of 7 Slot, 9 Slot, 11 Slot, 12 Slot or 16 Slot Chassis. Controller 1 is the "primary" controller. Controllers 2, 3 and 4 are "secondary" controllers.
  • Page 18: Figure 1.9 12 Slot Motherboard Bus Layout

    MACO Series Controller Installation Figure 1.9 12 Slot Motherboard Bus Layout A-13394 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11 Slot 12 DC POWER ANALOG DATA BUS CONTROL DATA BUS COMM.
  • Page 19: Figure 1.10 16 Slot Motherboard Bus Layout

    MACO Series Controller Installation Figure 1.10 16 Slot Motherboard Bus Layout A-13888 A-13887 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5...
  • Page 20: Figure 1.11 9 Slot Motherboard Bus Layout

    MACO Series Controller Installation Figure 1.11 9 Slot Motherboard Bus Layout Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 DC POWER ANALOG DATA ANALOG DATA BUS 1 BUS 2 CONTROL DATA BUS COMM.
  • Page 21: Figure 1.12 Ac Power Connections For 9 Slot Controllers

    MACO Series Controller Installation Figure 1.12 AC Power Connections for 9 Slot Controllers Power supply bond strap Use the bond strap provided is installed at the factory or one that maintains a 5:1 for CE EMC compliant length to width ratio Earth (Safety Earth) systems.
  • Page 22: Figure 1.15 Dc Power Connection For 7 Slot Controllers

    MACO Series Controller Installation Figure 1.14 AC Power Connections for 16 Slot Controllers Power supply bond strap is installed at the factory Use the bond strap provided for CE EMC compliant or one that maintains a 5:1 systems. length to width ratio...
  • Page 23: Installing & Wiring The T/C-Analog Board

    MACO Series Controller Installation 2. Installing & Wiring the T/C-Analog Board Make certain to use the proper extension wire. Do NOT run extension wire in the same trough with power wiring. Note that these boards cannot be calibrated in the field.
  • Page 24: Figure 2.0 Installing Resistors For Current Inputs

    MACO Series Controller Installation T/C-Analog Card Specifications Reference Accuracy: Common Mode Rejection: 0.25% of Span, ±1°C 135 dB @ 230 Vac 60Hz Range: Series Mode Rejection: Type J, 0 to 700°C (32 to 1292°F); 60 dB @ 150 mV 60 Hz Type K, 0 to 950°C (32 to 1742°F)
  • Page 25: Figure 2.1 A-60063-0Xx Or A-60133-0Xx 12 Zone Temperature Board

    MACO Series Controller Installation Figure 2.1 A-60063-0XX or A-60133-0XX 12 Zone Temperature Board EPROM 1 (U2) POWER SUPPLY See Cable Assemblies for OUTPUTS TO BUS Wire Description +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5Vdc Common Not Used 28 Vac ØA...
  • Page 26: Figure 2.2 A-60063-1Xx Or A-60133-1Xx 12 Zone Analog Input Board

    MACO Series Controller Installation Figure 2.2 A-60063-1XX or A-60133-1XX 12 Zone Analog Input Board EPROM 1 (U2) POWER SUPPLY See Cable Assemblies for OUTPUTS TO BUS Wire Description +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5Vdc Common Not Used 28 Vac ØA...
  • Page 27: Figure 2.3 A-60063-2Xx Or A-60133-2Xx 6 Zone Analog Input / 6 Zone T/C Input Board

    MACO Series Controller Installation Figure 2.3 A-60063-2XX or A-60133-2XX 6 Zone Analog Input / 6 Zone T/C Input Board EPROM 1 (U2) POWER SUPPLY See Cable Assemblies for OUTPUTS TO BUS Wire Description +5 Vdc Common +5 Vdc +5 Vdc Common...
  • Page 28: Figure 2.4 A-60063-3Xx Or A-60133-3Xx 6 Zone T/C Input Board

    MACO Series Controller Installation Figure 2.4 A-60063-3XX or A-60133-3XX 6 Zone T/C Input Board EPROM 1 (U2) POWER SUPPLY OUTPUTS TO BUS +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5Vdc Common Not Used See Cable Assemblies for 28 Vac ØA...
  • Page 29: Figure 2.5 Wiring T/C Inputs Using The T/C-Analog Card

    MACO Series Controller Installation Figure 2.5 Wiring T/C Inputs using the T/C-Analog Card Pin 18 Zone 1 T/C - Zone 1 T/C + Zone ... Zone ... Pin 17 Chassis Pin 18 bonded to EMC bond rail at factory Bond to...
  • Page 30: Installing & Wiring The Communications Board

    MACO Series Controller Installation 3. Installing & Wiring the Communications Board Check the following: 1.Make sure that the RS-232 daughterboard (A-60055-XXX) is in Slot 1 or Slot 2 of the Communications motherboard. 2.Make sure that the RS-485 daughterboard (A-60062-XXX) is in Slot 2 or Slot 3 of the Communications motherboard.
  • Page 31: Figure 3. A-60050 Communications Motherboard

    MACO Series Controller Installation Figure 3. A-60050 Communications Motherboard Slot 3 is reserved POWER SUPPLY Slot 3 for RS-485 Daughter Board OUTPUTS TO BUS +5 Vdc Common +5 Vdc +5 Vdc Common Slot 2 may be used Slot 2 +5 Vdc...
  • Page 32: Figure 3.1 Wiring Communications Daughterboards

    MACO Series Controller Installation Figure 3.1 Wiring Communications Daughterboards Common Data - Data + SGND (Installed at Factory) (Braided Shield) Bond to Chassis Standard Cable Assembly (no bonding required) Bond to Chassis (Braided Shield and Overbraid) 1640-IN-031-C-08 Eurotherm/Barber-Colman Page 32 of 104...
  • Page 33: Installing & Wiring The Data Handler Board

    MACO Series Controller Installation 4. Installing & Wiring the Data Handler Board The A-60010 assemblies support the following: 7, 9, 12 or 16 Slot Chassis 72 Zones of T/C-Analog Control Maximum 2 Sequence & Hydraulic Cards 2 Analog I/O Cards...
  • Page 34: Figure 4.0 A-60010 Data Handler Board

    MACO Series Controller Installation Figure 4.0 A-60010 Data Handler Board EPROM 1 (U26) EPROM 3 POWER SUPPLY (U25) NO FUSES OUTPUTS TO BUS BT1 (+) EEPROM +5 Vdc Common See Cable Assemblies for (U24) +5 Vdc Wire Description SRAM +5 Vdc Common...
  • Page 35: Figure 4.1 Wiring The Dh Board (Overbraid In Conduit To Op Station)

    MACO Series Controller Installation Figure 4.1 Wiring the Data Handler Board (Overbraid in Conduit to Op Station) ISO Com Overbraid in Conduit Data - Data + to Operator Station (Braided Shield) Bond to Chassis Figure 4.2 Wiring the Data Handler Board (Overbraid to Op Station)
  • Page 36: Installing & Wiring The Analog I/O Board

    MACO Series Controller Installation 5. Installing & Wiring the Analog I/O Board Important! Note that depending on the application, not all sensors need be used. Refer to the "Application Guide for Sensors & Analog I/O Signals" at the back of the Controller Installation &...
  • Page 37: Figure 5.0 A-60051 Analog I/O Motherboard

    MACO Series Controller Installation Figure 5.0 A-60051 Analog I/O Motherboard EPROM 1 POWER SUPPLY (U35) OUTPUTS TO BUS +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 38: Figure 5.1 Analog I/O Wiring (Connector P2)

    MACO Series Controller Installation Figure 5.1 Analog I/O Wiring (Connector P2) ANALOG I/O CARD CONNECTOR ASSEMBLY Analog Outputs can be either 0 to -10 Vdc or 0 to +10 Vdc (by Hydraulics Control Relay - see Programming and Setup) Analog Output #1 Output current limited to approx.
  • Page 39: Figure 5.2 Analog I/O Wiring (Connector P3)

    MACO Series Controller Installation Figure 5.2 Analog I/O Wiring (Connector P3) ANALOG I/O CARD Analog Outputs can be either 0 to -10 Vdc or 0 to +10 Vdc CONNECTOR ASSEMBLY (by Hydraulics Control Relay - see Programming and Setup) Output current limited to approx. 3mA.
  • Page 40: Figure 5.3 Wiring The Analog I/O Board

    MACO Series Controller Installation Figure 5.3 Wiring the Analog I/O Board Do NOT connect shields at this end (Braided Shield) Bond to Chassis Bond to Chassis (Braided Shield and Overbraid) 1640-IN-031-C-08 Eurotherm/Barber-Colman Page 40 of 104...
  • Page 41: Installing & Wiring The High Speed Ana Sig Processor (Parison) Board

    MACO Series Controller Installation 6. Installing & Wiring the High Speed Ana Sig Processor (Parison) Board 6.1 Introduction The high speed analog signal processor card can be specified with 1, 2, or 4 channels of control. The number of channels required will depend on the amount of control needed by the process.
  • Page 42: Analog Input/Output Wiring Guidelines

    MACO Series Controller Installation 6.2.2 Analog Input/Output Wiring Guidelines 1. Use braided shield cables on ALL analog inputs and outputs. Use separate cables for each function and keep cables less than 3 meters in length. If cables are over 3 meters long, an overbraid is required. If overbraid has been used, terminate both the internal braided shield and the overbraid at the ground distribution block (see figures 6.3 and 6.4).
  • Page 43: Figure 6.0 A-13815 High Speed Ana Sig Processor (Parison) Board

    MACO Series Controller Installation Figure 6.0 A-13815 High Speed Ana Sig Processor (Parison) Board EPROM 1 (U212) JUMPER D E T A I L POWER SUPPLY OUTPUTS TO BUS CURRENT +5 Vdc Common VOLTAGE +5 Vdc +5 Vdc Common +5 Vdc...
  • Page 44: Figure 6.1 High Speed Analog (Parison) Sensor Wiring

    MACO Series Controller Installation Figure 6.1 High Speed Analog (Parison) Sensor Wiring Notes: 1. Excitation voltage from the parison card is limited to +10 Vdc @ 20 mA. 2. All shields must be connected directly to panel earth ground at one end only.
  • Page 45: Figure 6.2 High Spd Ana (Parison) Card Pressure Transducer Wiring

    MACO Series Controller Installation Figure 6.2 High Speed Analog (Parison) Card Pressure Transducer Wiring Analog In Plus (+) Analog In Minus (-) Sig+ Sig- Analog Out (+) Wire shield directly to Excitation (+) panel earth ground Analog Common (-) Cal A...
  • Page 46: Figure 6.4 One-Head Time-Based Machine With B-C Servo Amp

    PARISON PCB Rotation Detector DC Input 1 Count Pulse DC Input 2 Home Pulse DC Input 3 DC Input 4 VBIAS (+DC for Outputs) DC Input/Output Common DC Common DC Output 1 DC Output 2 – DC Output 3 DC Output 4 External DC Supply A-13441 SERVO AMP...
  • Page 47: Figure 6.5 Two-Head Time-Based Machine With B-C Servo Amp

    A-13441 SERVO AMP PARISON PCB Servo Assembly #1 LVDT Excitation Input LVDT Analog In 1 Plus (+) Position Analog In 1 Minus (-) Output Analog Out 1 (+) Excitation 1 (+) Analog Common 1 (-) Cal 1 A Cal 1 B Servo Control Input 1+ Output 1+...
  • Page 48: Figure 6.6 Two-Head Position-Based Machine With B-C Servo Amp

    A-13441 SERVO AMP PARISON PCB Servo Assembly #1 LVDT Excitation Input LVDT Analog In 1 Plus (+) Position Analog In 1 Minus (-) Output Analog Out 1 (+) Excitation 1 (+) Analog Common 1 (-) Cal 1 A Cal 1 B Input 1+ Output 1+ Servo Control...
  • Page 49: Figure 6.7 Two-Hd Position-Based Mach W/Pushout And B-C Servo Amp

    PARISON PCB A-13441 SERVO AMP Servo Assembly #1 LVDT Excitation Input LVDT Analog In 1 Plus (+) Position Analog In 1 Minus (-) Output Analog Out 1 (+) Excitation 1 (+) Analog Common 1 (-) Cal 1 A Cal 1 B Input 1+ Output 1+ Servo Control...
  • Page 50: Figure 6.8 Accumulator Machine (Velocity Control) With B-C Servo Amp

    PARISON PCB A-13441 SERVO AMP Position Detection Analog In 1 Plus (+) Analog In 1 Minus (-) 500 Ω Position Analog Out 1 (+) 2k Ω Output Excitation 1 (+) Analog Common 1 (-) Cal 1 A Cal 1 B Input to Input 1+ Output 1+...
  • Page 51: Figure 6.9 Two-Head Position-Based Machine With Moog Servo Amp

    PARISON PCB MOOG 121-105 SERVO AMP Position Detection Analog In 1 Plus (+) Analog In 1 Minus (-) 500 Ω Position Excitation (+) 11 Analog Out 1 (+) 2k Ω Output Excitation (-) 13 Excitation 1 (+) Analog Common 1 (-) Cal 1 A Cal 1 B Servo...
  • Page 52: Figure 6.10 Wiring The High Spd Ana (Parison) Board Dc Inputs

    MACO Series Controller Installation Figure 6.10 Wiring the High Speed Analog Signal Processor (Parison) Board DC Inputs DC In 1 DC In 2 DC In 3 DC In 4 DC Common Note that DC Inputs and Outputs have a shared common.
  • Page 53: Figure 6.12 Wiring The High Spd Ana (Parison) Board Analog Inputs

    MACO Series Controller Installation Figure 6.12 Wiring the High Speed Analog Signal Processor (Parison) Board Analog Inputs Ana In + Ana In - Ana Common (Braided Shield) Bond to Chassis Bond to Chassis (Braided Shield and Overbraid) Connect Input minus to Analog Common at the sensor Figure 6.13 Wiring the High Speed Analog Signal Processor (Parison) Board Analog Outputs...
  • Page 54: Installing & Wiring The Seq/Hydraulics Board

    MACO Series Controller Installation 7. Installing & Wiring the Seq/Hydraulics Board Different versions of Sequence/Hydraulics board assembly A-60012/A-60083 are meant for 9-slot, 12-slot or 16-slot control systems (see the table). Note: When counting boards in multi-rack systems (for switch settings, RLD/screen pro- gramming) count each control rack separately.
  • Page 55: Figure 7. A-60012 Or A-60083 Seq/Hydr Board

    MACO Series Controller Installation Figure 7. A-60012 or A-60083 Seq/Hydr Board POWER SUPPLY EPROM 2 OUTPUTS TO BUS (U67) +5 VDC Common +5 VDC +5 VDC Common +5 VDC +5 VDC Common Not Used 28 VAC ØA EPROM 1 (U11) 28 VAC ØB...
  • Page 56: Installing & Wiring The Power Supply Board

    MACO Series Controller Installation 8. Installing & Wiring the Power Supply Board Note that the 7 Slot System is a 24 Vdc system ONLY. DO NOT CONNECT AC POWER TO A 7 SLOT SYSTEM! AC Power Supplies (9 Slot, 12 Slot and 16 Slot Systems) 1.
  • Page 57: Figure 8.0 A-13395 Power Supply Board

    MACO Series Controller Installation Figure 8.0 A-13395 Power Supply Board POWER SUPPLY OUTPUTS TO BUS See Cable Assemblies +5 Vdc Common SPARE FUSES for Wire Description (1 each) +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA...
  • Page 58: Figure 8.1 A-60045 Power Supply Board

    MACO Series Controller Installation Figure 8.1 A-60045 Power Supply Board POWER SUPPLY OUTPUTS TO BUS See Cable Assemblies +5 Vdc Common SPARE FUSE for Wire Description +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB...
  • Page 59: Figure 8.2 Wiring The Power Supply Board In 9 Slot Systems

    MACO Series Controller Installation Figure 8.2 Wiring the Power Supply Board in 9 Slot Systems Overbraid in Conduit to Operator Station Overbraid +15 Vdc to Operator Station Flatpanel Common Power supply bond strap is installed at the factory Use the bond strap provided...
  • Page 60: Figure 8.4 Wiring The Power Supply Board In 16 Slot Systems

    MACO Series Controller Installation Figure 8.4 Wiring the Power Supply Board in 16 Slot Systems Overbraid in Conduit to Operator Station +15 Vdc Flatpanel Common Overbraid to Operator Station Use the bond strap provided Power supply bond strap or one that maintains a 5:1...
  • Page 61: Installing & Wiring Ac Output Boards

    MACO Series Controller Installation 9. Installing & Wiring AC Output Boards AC output boards have NOT been validated for conformance with the CE EMC directive. Additional measures beyond those specified here may be needed in order to demonstrate EMC compliance at the machine level. Proof of EMC conformance lies with the machine manufacturer.
  • Page 62 MACO Series Controller Installation If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and route straight down through the wiring trough in order to meet minimum spacing requirements. Class 2 Wiring must be separated a minimum of In order to insure that triac outputs will fully turn on, the load 1/4 inch from any Class 1 conductors.
  • Page 63: Figure 9.0 A-13402 Standard Density Ac Output Board

    MACO Series Controller Installation Figure 9.0 A-13402 Standard Density AC Output Board POWER SUPPLY OUTPUTS TO BUS DS16 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 64: Figure 9.1 A-13904 High Density Ac Output Board

    MACO Series Controller Installation Figure 9.1 A-13904 High Density AC Output Board POWER SUPPLY OUTPUTS TO BUS DS24 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 65: Figure 9.2 Ac Output Wiring

    MACO Series Controller Installation Figure 9.2 AC Output Wiring Field Wiring Simplified Circuit Field Wiring 2 Amp OUTPUT #1 OUT 1 LOAD 100/240 Vac 2 Amp (Outputs 1, 2, 3, 4) OUTPUT #2 OUT 2 LOAD Common for 2 Amp...
  • Page 66: Installing & Wiring Dc Output Boards

    MACO Series Controller Installation 10. Installing & Wiring DC Output Boards Note that DC Output Boards require an external, regulated DC supply capable of providing a voltage of plus (+) 16 Vdc to plus (+) 24 Vdc. The power supply must be CE recognized.
  • Page 67 MACO Series Controller Installation If both Class 1 and Class 2 Input/Output Boards are present, it may be necessary to bundle wires and route straight down through the wiring trough in order to meet minimum spacing requirements. Note: When counting boards in multi-rack...
  • Page 68: Figure 10.0 A-60068 24 Output Dc Out Board

    MACO Series Controller Installation Figure 10.0 A-60068 24 Output DC Out Board POWER SUPPLY OUTPUTS TO BUS DS24 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 69: Figure 10.1 A-60107 16 Output Dc Out Board

    MACO Series Controller Installation Figure 10.1 A-60107 16 Output DC Out Board POWER SUPPLY OUTPUTS TO BUS DS16 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 70: Figure 10.2 Dc Output Wiring

    MACO Series Controller Installation Figure 10.2 DC Output Wiring +24 Vdc from External Supply 2 Amp Control +24 Vdc Output 6.8k Output DC OUTPUT CIRCUIT LOAD 2.2k Power Supply Common Opto-Isolator Logic Common - DC (Common) +24 Vdc Supply +24 Vdc IN...
  • Page 71: Figure 10.3 Wiring The Dc Output Board

    MACO Series Controller Installation Figure 10.3 Wiring the DC Output Board DC Out 1 DC Out 2 DC Out ... 24 Vdc DC Common Supply Power Supply outputs MUST have ferrite beads capable of filtering 30 MHZ to 100 MHZ Note that NO Shield or Overbraid is necessary.
  • Page 72: Installing & Wiring Analog Output Boards

    MACO Series Controller Installation 11. Installing & Wiring Analog Output Boards Analog output boards have NOT been validated for conformance with the CE EMC directive. Additional measures beyond those specified here may be needed in order to demonstrate EMC compliance at the machine level. Proof of EMC conformance lies with the machine manufacturer.
  • Page 73: Figure 11.0 Locating The Analog Output Boards

    MACO Series Controller Installation 2.Connect the outputs to the loads. Each output has two separate connections from the board. Analog Output Operating Specifications Outputs per Card: 2, 4 or 12 Card Supply Voltage: 24 Vdc, ±0.5 Vdc (external supply) @ 0.6 Amps minimum current.
  • Page 74: Figure 11.1 A-60033 Analog Output Board

    MACO Series Controller Installation Figure 11.1 A-60033 Analog Output Board POWER SUPPLY OUTPUTS TO BUS +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used P 1 0...
  • Page 75: Figure 11.2 Analog Output Wiring

    MACO Series Controller Installation Figure 11.2 Analog Output Wiring Current Outputs 750 Ω Maximum Load Voltage Outputs 3.3k Ω Minimum Load 24 Vdc External Supply 600 mA minimum 1640-IN-031-C-08 Eurotherm/Barber-Colman Page 75 of 104...
  • Page 76: Figure 11.3 Wiring The Analog Output Board

    MACO Series Controller Installation Figure 11.3 Wiring the Analog Output Board Out 1 + Out 1 - Out 2 + Out 2 - Out ... Earth (no connection) (Installed at Factory) 24 Vdc (Braided Shield) Supply Bond to Power Supply outputs MUST have...
  • Page 77: Installing & Wiring Ac Input Boards

    MACO Series Controller Installation 12. Installing & Wiring AC Input Boards AC input boards have NOT been validated for conformance with the CE EMC directive. Additional measures beyond those specified here may be needed in order to demonstrate EMC compliance at the machine level. Proof of EMC conformance lies with the machine manufacturer.
  • Page 78: Figure 12.0 A-13900 Or A-60089 Standard Density Ac Input Board

    MACO Series Controller Installation Figure 12.0 A-13900 or A-60089 Standard Density AC Input Board POWER SUPPLY OUTPUTS TO BUS DS24 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB...
  • Page 79: Figure 12.1 High Density Ac Input Board Assembly

    MACO Series Controller Installation Figure 12.1 High Density AC Input Board Assembly POWER SUPPLY DS25 OUTPUTS TO BUS (1 - 24) (25 - 48) DS48 DS24 +5 Vdc Common +5 Vdc (Upper) (Lower) (Lower) (Upper) +5 Vdc Common +5 Vdc...
  • Page 80: Figure 12.2 Ac Input Wiring

    MACO Series Controller Installation Figure 12.2 AC Input Wiring Input Status Light Common Opto-Isolator Typical AC Input Circuit (120 Vac) Panel I/O AC Input Card Terminal Strip Connector Assembly AC IN 1 AC IN 2 AC IN 3 AC IN 4...
  • Page 81: Installing & Wiring Dc Input Boards

    MACO Series Controller Installation 13. Installing & Wiring DC Input Boards (Refer to Figures 13.0, 13.1, and 13.2) Note that DC Input Boards require an external, regulated DC supply capable of providing a voltage of plus (+) 12 Vdc to plus (+) 24 Vdc.
  • Page 82: Figure 13.0 A-60070 Standard Density Dc Input Board

    MACO Series Controller Installation Figure 13.0 A-60070 Standard Density DC Input Board POWER SUPPLY OUTPUTS TO BUS DS24 +5 Vdc Common +5 Vdc +5 Vdc Common +5 Vdc +5 Vdc Common Not Used 28 Vac ØA 28 Vac ØB Not Used...
  • Page 83: Figure 13.1 High Density Dc Input Board Assembly

    MACO Series Controller Installation Figure 13.1 High Density DC Input Board Assembly POWER SUPPLY DS25 OUTPUTS TO BUS (1 - 24) (25 - 48) DS48 DS24 +5 Vdc Common +5 Vdc (Lower) (Upper) (Lower) (Upper) +5 Vdc Common +5 Vdc...
  • Page 84: Figure 13.2 Dc Input Wiring

    MACO Series Controller Installation Figure 13.2 DC Input Wiring Common Opto-Isolator Typical DC Input Circuit 12 - 24 Vdc nominal 40 Vdc maximum Panel I/O DC Input Card (10 mA each @ 24 Vdc) Terminal Strip Connector Assembly 24 Vdc Supply...
  • Page 85: Figure 13.3 Wiring The Dc Input Board

    MACO Series Controller Installation Figure 13.3 Wiring the DC Input Board DC Common DC In 1 DC In 2 DC In 3 DC In ... DC Common Note that NO Shield or Overbraid is necessary. 1640-IN-031-C-08 Eurotherm/Barber-Colman Page 85 of 104...
  • Page 86: Installing & Wiring Ac/Dc Input Boards

    MACO Series Controller Installation 14. Installing & Wiring AC/DC Input Boards AC input boards have NOT been validated for conformance with the CE EMC directive. Additional measures beyond those specified here may be needed in order to demonstrate EMC compliance at the machine level. Proof of EMC conformance lies with the machine manufacturer.
  • Page 87 MACO Series Controller Installation AC Inputs Operating Specifications Supply Voltage: 100 to 240 Vac external On Voltage: ≥92 Vac Off Voltage: ≤30 Vac Input Current: 15mA @ nominal voltage Indicator: LED per Input Isolation: Optically isolated as a group For supply connections, use No. 18 AWG or larger wires rated for at least 75°C (165°F).
  • Page 88: Figure 14. High Density Ac/Dc Input Board Assembly

    MACO Series Controller Installation Figure 14. High Density AC/DC Input Board Assembly POWER SUPPLY DS25 OUTPUTS TO BUS (1 - 24) (25 - 48) DS48 DS24 +5 Vdc Common A-60070 A-13901 +5 Vdc (Lower) (Upper) A - 6 0 0 7 0...
  • Page 89: Figure 14.1 A-13991-100 High Density Dc/Ac Input Board Assembly

    MACO Series Controller Installation Figure 14.1 A-13991-100 High Density DC/AC Input Board Assembly POWER SUPPLY DS25 OUTPUTS TO BUS (1 - 24) (25 - 48) DS48 DS24 +5 Vdc Common A-13900 A-60071 +5 Vdc (Lower) (Upper) A - 1 3 9 0 0...
  • Page 90: Wiring The 32 In/32 Out Or 24 In/24 Out Digital I/O Boards

    MACO Series Controller Installation 15. Wiring the 32 In/32 Out or 24 In/24 Out Digital I/O Boards 15.1 Introduction The 32 In/32 Out Digital I/O board is capable of (both) 32 inputs and 32 outputs. Outputs are sourced in groups of 4, with Vcc 1-4 supplying Output 1 through Output 4, Vcc 5-8 supplying Output 5 through 8, etc.
  • Page 91: Figure 15.1 32 In/32 Out Or 24 In/24 Out A-60150-X

    MACO Series Controller Installation Figure 15.1 32 In/32 Out or 24 In/24 Out A-60150-x (bottom) Top Row Bottom Row *N/A on 24 In/24 Out *N/A on 24 In/24 Out WARNING: Hazardous extraneous voltage capable of causing severe injury or death may exist between sensor leads and ground.
  • Page 92: Figure 15.2 32 In/32 Out Or 24 In/24 Out Digital I/O Wiring

    MACO Series Controller Installation Figure 15.2 32 In/32 Out or 24 In/24 Out Digital I/O Wiring Vcc 1-4 Common Locate as close as possible to ASB Output 1-4 Input 1-4 Note that DC Inputs and Outputs have a shared common.
  • Page 93: Figure 15.3 32 In/32 Out Or 24 In/24 Out Sample Wiring

    MACO Series Controller Installation Figure 15.3 32 In/32 Out or 24 In/24 Out Sample Wiring Outputs Inputs Upper Lower Connector Connector Load Load Load Load Load Load Load Load Load Load Load Load Load Load Load Load See text for fuse and load limits...
  • Page 94: Figure 16. Communications Cable Pinouts

    MACO Series Controller Installation Figure 16. Communications Cable Pinouts Shield Black White Female DB9 to Female DB9 Green Brown Blue Orange Yellow Purple PC to MACO DB25 Shield Chassis Gnd Black White Female DB9 to Female DB25 Green Brown Blue...
  • Page 95: Figure 17. Communications Cable Part Numbers

    MACO Series Controller Installation Figure 17. Communications Cable Part Numbers DB25 Connector Kit, Male 7 1 - 7 7 6 25 Pin Male D Connector E 2 4 - 2 2 Jack Screws (2) 5 0 - 1 6 2 8...
  • Page 96: Figure 18. Firmware Model Numbers

    MACO Series Controller Installation Figure 18. Firmware Model Numbers Specials Location on Assembly Checksum Firmware Revision No. Firmware Version No. Reserved for Factory Use Firmware Type L o c a t i o n Sequence Sequence/Hydraulic (Ana I/O) Board EPROM 1...
  • Page 97: Maco Series Specifications

    MACO Series Controller Installation 16. MACO Series Specifications Control Specifications Process Control Closed-loop Process Control of Drive Speed or Melt Temperature Closed-loop process functions updated every 2.5 msec Drive Ratio Control (Math Function) Selectable Ramping Line Graphs of Melt Temperature, Melt Pressure, Drive Speed, etc. (EL and Color...
  • Page 98 MACO Series Controller Installation Physical Chassis Size: (Refer to Figures 1.0 to 1.4) 100/264 (Low/High Line) Vac; 50/60 Hz, ±3 Hz Voltage (AC Systems): Power (AC Systems): less than 200 VA at 120 Vac Typical Power Xfmr: 1 kVA Voltage (DC Systems): 24 Vdc, 1.5 Amps (nominal)
  • Page 99 MACO Series Controller Installation Emissions (reference standards CISPR 16 and CISPR 16-1) Port Frequency Range Limits Enclosure 30 MHz to 230 MHz 40 dB (mV/m) quasi-peak, measured at 10 meters 230 MHz to 1 GHz 47 dB (mV/m) quasi-peak, measured at 10 meters AC Mains 0.15 MHz to 0.5 MHz...
  • Page 100 MACO Series Controller Installation DC Outputs Operating Specs: 16 to 24 Vdc (External Voltage) Minimum Load: 5 mA Maximum Load: 2 Amps Maximum Leakage: 2 mA Fuse: 2 Amp Fuse per Output Indicator: LED per Output (load side) Maximum Output...
  • Page 101 MACO Series Controller Installation Offset: -2 to 10 Vdc Type 1 (3 Inputs) General Purpose, 0-10 Vdc (nominal) Excitation voltage: (+10 Vdc @ 20 mA) for potentiometers Potentiometer resistance: 2k to 10k Ohms Type 2 (2 Inputs): Pressure 0 to +10 Vdc (nominal)
  • Page 102: Application Guide For Sensors And Analog Signals

    The output of these sensors is applied to inputs on the Analog I/O board and used for display or control purposes. The following information is a general guide to the type of transducers required by the MACO Series controllers. For the best noise immunity, use sensors with large voltage swings and low resistance potentiometers.
  • Page 103 MACO Series Controller Installation 1640-IN-031-C-08 Eurotherm/Barber-Colman Page 103 of 104...
  • Page 104 Barber-Colman Company / Eurotherm Controls, Inc. 741-F Miller Drive, Leesburg VA 20175 Phone: 703-443-0000 Fax: 703-669-1300 http://www.barber-colman.com http://www.eurotherm.com An Invensys Company Copyright © 2002 Barber-Colman Company...

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