DESIGO I/O modules and P-bus Mounting and installation guide

Transcription

1 2D20 2D20 2D20 2D20 DESIGO I/O modules and P-bus Mounting and installation guide CM2M8102en Siemens Building Technologies Building Automation

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3 Table of contents 1 Introduction Revision history About this document Document contents Safety notes System-specific regulations Device-specific regulations I/O module system and accessories I/O modules in the control cabinet The I/O module system I/O modules I/O module accessories Control cabinet Control cabinet requirements EMC compliant control cabinet I/O module and accessories layout Allocation and sequence of I/O modules Installation positions for module groups Overall layout of the control cabinet Example 1: Control cabinet for HVAC plant Example 2: Control cabinet for I/O data points Example 3: Control cabinet with frequency converters Mounting instructions for I/O modules Before you start Preparing I/O module systems Mounting the I/O module system Disassembling the I/O module system Shunts and bridges in I/O modules Mounting instructions for I/O compact units Before you start Ways to mount I/O compact units Mounting the I/O compact units Labelling and addressing equipment Procedures and allocation of labels Labelling of I/O bars and terminal blocks...41 Building Automation Table of contents /74

4 7.3 I/O module labelling I/O module addressing Labelling and addressing the I/O compact unit Wiring Supplementary information on safety Notes on EMC optimisation Supply and signal lines Wiring AC 24 V supply lines Wiring sample for AC 24 V supply Standard P-bus wiring Remote P-bus Connecting field devices Inspection and checks Placing and mounting equipment Wiring Power supply Labelling and addressing Function check Delivery Disposal Appendix Dimensions Referenced documents Feedback form /74 Building Automation Table of contents

5 1 Introduction 1.1 Revision history Remarks Reason The former document "Mounting and Installation handbook for UNIGYR Process Units and I/O Modules" M8012 has been divided into two separate parts: "DESIGO I/O modules and P-bus" mounting and installation guide M8102 (this document) "UNIGYR process units" mounting and installation guide M8202 We separated the document for the following reasons: The I/O modules were developed for UNIGYR and VISONIK process units, but are now also used in DESIGO. As a result, they are system-independent and can no longer be part of UNIGYR-specific documentation. The following items have changed from the previous edition of : Changes Chapter Pages "Siemens Building Technologies, Building Automation" (short form: SBT BAU) replaces "Landis & Staefa" throughout the document various "Automation station" replaces "process unit" throughout the document various Sensor designation "LG-Ni 1000" instead of "L&S-Ni 1000" various various 1.2 About this document Main audience The mounting and installation guide is primarily intended for the following audience: Control cabinet builders and factory staff Electrical experts Purpose The mounting and installation guide provides information for the above persons on: Expert mounting and wiring of I/O modules, devices/units and accessories in the control cabinet, and connections to the plant. Building Automation Introduction /74

6 A uto Note The mounting instructions for I/O compact units are also part of this user's guide: they are available in chapter 6 " Mounting instructions for I/O compact units". Due to the device and market-specific features of the I/O compact units, this chapter only provides mounting instructions which are delivered together with the units. Further engineering information is available in the respective data sheets on I/O compact units. Further application Restrictions Referenced documents Note The mounting and installation guide can also be used by project engineering staff of SBT BAU and by system houses for the following topics: Defining the control cabinet size Integration variants for devices Regulations and notes (e.g., safety, EMC-compliant control cabinet, EMC optimisation) The mounting and installation guide contains all documentation in text and graphics required for the above audiences and purposes. It does not contain information on plant-specific mounting and wiring tasks. This type of information is available in the respective project documentation. Chapter 11 "Appendix" contains a list of documents on the I/O module system providing detailed information on engineering. In this document, reference numbers for documents are always printed in an abbreviated form. The complete numbers (e.g., CM2M8202en) are available in section 11.2 "Referenced documents". 1.3 Document contents Overview A building automation and control system by Siemens Building Technologies, Building Automation (SBT BAU) typically comprises the following hardware ranges distributed over three levels: DESIGO Insight management station Control cabinet (described in this document) Building services plants 8102Z40E Management level DESIGO Insight Building Level Network Automation level Control cabinet Process units Field level P-bus I/O modules Wiring to periphery NIDES.RX LON T T Building services plants DESIGO RX 6/74 Building Automation Introduction

7 Individual ranges The above described ranges can be described in brief as follows: Range Management station Control cabinet Building services plants Brief description The DESIGO Insight management station allows the operator to run and monitor all building services plants within the associated building automation and control system. The following devices are integrated in the control cabinet: Automation stations, e.g., for UNIGYR I/O modules, connected via P-bus (process bus) This document describes expert mounting and wiring of I/O modules in the control cabinet. These are the connected plants such as heating, ventilating and air conditioning plants, electrical systems, etc. Linking of system levels The following connections generally lead from and to the control cabinet: Automation level to management level Automation level to field level Building Level Network (BLN): A bus line that connects the automation stations with each other and with the management station. Floor Level Network (FLN): The FLN bus establishes the following connections between: FLN master units (e.g., PRU10.64) and FLN slave units (e.g., RWP80) FLN slave units and end units (e.g., Terminal Equipment Controller) P-bus: A bus line leads to the I/O modules or to the I/O compact unit. They are wired directly to the field devices (sensors, actuating valves, motors, etc.) in the building services plants. Local Operating Network (LON): A bus line leads from the NIDES.RX interface to the units of the DESIGO RX product range. Building Automation Introduction /74

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9 2 Safety notes Please observe the following notes Safety note General regulations This chapter explains general and system-specific regulations. It also contains important information regarding your own safety and that of your plant. The warning triangle to the left means that you must observe all respectively listed regulations and notes. If ignored, injuries and equipment damages may result. Observe the following general regulations during engineering and project execution: Electric and high-power regulations of the respective country Other required country regulations House installation regulations of the respective country Regulations by the energy supplier Diagrams, cable lists, dispositions, specifications and instructions as per the customer or the engineering business Third-party regulations from, e.g., the general contractors or building contractors 2.1 System-specific regulations Safety SELV, PELV Unit safety Earthing of G0 (system neutral) Recommendation on earthing G0 Electrical safety in SBT building automation and control systems primarily depends on extra-low voltage with safe isolation from mains voltage. Depending on the earthing of extra-low voltage, SELV or PELV applications as per HD384 "Electrical plants in buildings" result: Unearthed = Safety Extra-Low Voltage SELV Earthed = Protection by Extra-Low Voltage PELV Safety for the units is ensured by (among other aspects) Supply of AC 24 V extra-low voltage as per SELV or PELV Double isolation between AC 230 V mains voltage and SELV/PELV circuits Microfuse in the module supply block Primary fuses of the I/O bars Please note the specific regulations on electric wiring of the I/O module groups as per the following sections. Observe the following for grounding G0: As a rule, earthing as well as non-earthing of G0 is permissible for AC 24 V operating voltage. However, observe all local regulations and customary procedures Earthing may be required or illegal for functional reasons. Earth all AC 24 V systems unless otherwise specified by the respective manufacturers To avoid earth loops, connect systems with PELV to the earth at only one point in the system, normally at the transformer, unless otherwise specified You can also prevent earth loops through connected PC interfaces (PC tools) via electrical isolation Building Automation Safety notes /74

10 Mains and operating voltage The following regulations apply to mains and operating voltages: Topic AC 24 V operating voltage Specification on AC 24 V transformers Fuse of AC 24 V operating voltage Regulation The operating voltage must comply with the requirements for SELV or PELV. Permissible deviation of AC 24 V reference voltage at the I/O modules: +/- 20 % Safety transformers as per EN 61558, with double isolation, designed for 100 % runtime to supply SELV or PELV circuits The capacity used from the transformer should at least amount to 50 % of the nominal load for efficiency reasons (power efficiency) The nominal capacity of the transformer must be at least 25 VA. For smaller transformers, the ratio between voltage at idle time to voltage at full load is unsatisfactory (> + 20 %) Transformers, secondary side: according to the effective load of all connected devices as per the transformer sizing: Line G (system potential) must always be fused Where required, additional line G0 (system neutral). Important: The 10 A microfuses for G and G0 to protect the I/O bar in the module supply block do not replace this loaddependent primary fuse! Fuse of AC 230 V mains voltage Transformers, primary side: Control cabinet fuse (control fuse) Mains voltage supplied to the I/O bars must be fused by max. 10 A before the phase supply blocks Observe third-party voltages Introduction of dangerous voltages to the extra-low-voltage system circuits e.g., through faulty wiring or formation of vagabond voltages at the I/O modules poses an immediate danger to persons and may result in partial or complete destruction of the building automation and control system! Lightning protection measures Adhere to local regulations on lightning protection and equipotential bonding. Information on external protective measures and protective components is available in the UNIGYR System Manual CM2Z /74 Building Automation Safety notes

11 2.2 Device-specific regulations Safety notes for engineering If you are responsible for engineering the entire control cabinet, make sure that you have all of the documents listed below. Observe all respective engineering notes and safety regulations. Document I/O module summary Technical basics: I/O module system I/O module system accessories Document No. N8100 Z8102 N8105 I/O modules The following regulations apply to I/O modules: Topic Double-modules for mains voltage or extra-low voltage Signalling contacts Manual switch Regulation For safety reasons, connect only mains voltage or extralow voltage to the same I/O module in double modules with inputs or outputs for mains and extra-low voltage. This applies to: Various switching modules (PTM1..Q250..) Signalling module with voltage inputs (PTM1.2D250) Connect only potential-free, mechanical contacts to the inputs of a signalling module. Exception: Signalling module with voltage inputs. Do not use the manual switch on the switching and positioning modules for safety shutdown, e.g., during service and maintenance procedures. Field devices connections at I/O modules Devices with differing voltage circuits Interfaces for different voltage circuits Field devices and interfaces The devices must have the required isolation of voltage circuits in order to be connected without additional isolation (see "Principal display: I/O modules and peripherals"). Connections via the interfaces may lead to distribution of dangerous voltages throughout the building. For these cases, make sure that the required isolation exists and that you have observed all associated installation regulations. The following applies to field devices and interfaces with extra-low voltage: Topic Field devices on I/O modules Interfaces for extralow voltage Regulation Field devices such as sensors, signalling contacts, actuators, etc. that are connected to extra-low voltage inputs and outputs of I/O modules must comply with the requirements as per SELV or PELV. Interfaces of peripheral devices and other systems must also comply with SELV or PELV Building Automation Safety notes /74

12 Principal display: I/O modules and field devices AC 24 V P-bus G G0 PC PU PD L N AC 230 V Mains AC 230 V D SELV/ PELV Mains AC 230 V SELV/PELV A B SELV / PELV Mains AC 230 V Relay Q... C B Mains AC 230 V Mains AC 230 V SELV/PELV Mains AC 230 V I/O modules for mains AC 230 V and/or mixed SELV/PELV 8102Z39E Mains AC 230 V D SELV/ PELV Mains AC 230 V SELV/PELV A B SELV / PELV I/O modules only for SELV/PELV I/O bar PTX1... Legend The above designations are: A B C D Field devices only with SELV/PELV circuits Field devices with mains and SELV/PELV circuits Field devices only with mains circuits Double or increased isolation as per EN , proof voltage AC 3750 V 12/74 Building Automation Safety notes

13 3 I/O module system and accessories 3.1 I/O modules in the control cabinet Purpose of this chapter Simple example The following pages provide an overview of the I/O modules for control cabinet integration and make you familiar with the most important properties of these devices. The illustration below shows a diagram of I/O modules in the control cabinet, their connections to the automation station and the respective internal and external elements: Building Process Station SW-Version Zeit Datum Control panel S N T1 P-bus P-bus U1 U2 M1 M2 M3 8102Z41E p p Legend The designations in the above illustration are: N Automation station with P-bus connection T1 AC 230 V / AC 24 V transformer U1 I/O module group with internal connections to the devices in the control cabinet U2 I/O module group with external connections to field devices P-bus Process bus for data communication between the automation station and the I/O modules M1 Heating coil pump M2, M3 Supply air fan, extract air fan Task of I/O modules I/O modules are used as signal converters. They represent the interface between the automation station and the respective devices in the building services plants. The plugin bases of the I/O modules serve as the connecting terminals for plant wiring. They additionally are used for terminal disconnection; separate terminal blocks are superfluous. Building Automation I/O module system and accessories /74

14 3.2 The I/O module system Example for a module group The following illustration shows a complete module group consisting of four I/O modules: Parts of the module system I/O module range The individual parts of the I/O module system are: Pos. Designation 1 I/O bar PTX1 with end cover PTX Standard rail (not Siemens accessory) 3 Phase supply block PTX I/O modules PTM Module supply block PTX Address plug PTG1 The I/O module range includes modules for all basic functions of building automation and control. The I/O modules process the uniform signals of a automation station and convert them to the various signals for the plant components and vice versa. A colour coding system at the module front helps differentiate the modules by their basic functions: Basic Function Colour Example SIGNALLING White Signalling contact, continuous signal (normally open contact/normally closed contact) MEASURING Blue Sensor such as LG-Ni1000 SWITCHING Green Relay output, continuous command, monostable POSITIONING Yellow Positioning signal DC 0 10 V continuous, three-position signal COUNTING Brown Counting pulse transmitter, for electric and gas demand Depending on the type of module, there are single, two-fold, four-fold, or eight-fold modules in the same housing. Refer to document 8100E "I/O module summary" for a listing of all modules. I/O compact units Standard rails The I/O compact units include functions for signalling, measuring, switching, and positioning of the building automation and control technology in a single housing. Refer to data sheets 181E, N8182 and to the mounting instructions M8181 for further information. The following standard rails can be used as part of the I/O module system: Top-hat rail (DIN rail) EN x 7.5 G-rail EN50035-G32 14/74 Building Automation I/O module system and accessories

15 3.3 I/O modules I/O modules PTM1 The illustrations below show a single I/O module with accessories, snapped onto the rail and the I/O bar, and a stand-alone I/O module: I/O module parts The main mechanical parts of the I/O modules are: Pos. Designation 1 Module housing (function part of the I/O module) 2 Terminal base (connection part of the I/O module) 3 I/O bar 4 Standard rail 5 Transparent module front (labelling) 6 Colour bar for module type labelling 7 Display and operating elements field 8 Labelling plate 9 Address plug 10 Plug connection between module housing and I/O bar for P-bus, module supply and AC 24 V system supply 11 Plug connection between module housing and I/O bar for phase conductor and neutral conductor (mains voltage) 12 Plug contacts between module housing and terminal base 13 Mechanical coding between module housing and terminal base 14 Terminal screws 15 Terminal test sockets 16 Address plate 17 Terminal labelling plate with holder 18 Pluggable, labelled plate (terminal labelling variant) Building Automation I/O module system and accessories /74

16 Mechanical properties Primary mechanical properties of the I/O modules: Properties Snap-on holders connect the terminal base and the module housing Mechanical coding between terminal base and module housing according to the module function Signal pick-off via contact springs on the conductor rails of the I/O bar Connecting terminals in the terminal base simultaneously assume the function of control cabinet terminal blocks Terminal isolation Explanation/Use Both parts can be inserted and removed without additional tools Prevents insertion of non-matching parts and thus, for example, destruction through mains voltage applied to the base P-bus signals and AC 24 V on top, mains voltage at the bottom of the I/O bar No additional terminal block required for connected field devices Achieved by swinging the module housing into a position of rest Electrical properties Refer to chapter 8, "Wiring", for information on electrical properties. 3.4 I/O module accessories I/O bars PTX1... The I/O bars accommodate the I/O modules and establish mechanical and electrical connections to the modules. The conductor rails in the I/O bars run the signals for: Three-pole process bus (P-bus) AC 24 V operating voltage Max. 250 V AC mains voltage 8017Z11 Four standard lengths The following table provides information on both I/O bar standard length and maximum number of I/O modules that can be accommodated. Type Length *) I/O modules PTX mm 10 PTX mm 14 PTX mm 18 PTX mm 26 *) Linear dimension including end covers of ca. 2 x 2.5 mm The bars can be shortened at increments of 32 mm by using a metal saw. On the upper side, the conductor rails are covered with protective foil; remove the foil after only mounting procedures are complete. 16/74 Building Automation I/O module system and accessories

17 End covers PTX1.080 The end covers serve the following purpose: Mechanical end of the I/O bar Protection from accidental contact with the conductor rails The I/O bars are supplied with installed end covers. The end covers can be ordered separately for the following cases: When a longer bar is separated into several sections As spare parts The following illustration shows the end cover and how it is installed: Module supply block PTX1.01 Phase supply block PTX1.00 Neutral supply block PTX1.02 The module supply block supplies voltage to the I/O modules. The module supply block runs the following signals to the I/O bar: Process bus (P-bus) AC 24 V operating voltage The block has two integrated 10 A microfuses as a short-circuit protection for AC 24 V operating voltage. It also serves as a connection between two I/O bars (section 3.4). These two terminal blocks connect the mains voltage (max. 250 V AC) or the neutral conductor to the I/O bar. The two units differ as follows: PTX1.00 is used to connect the phase conductor PTX1.02 is used to connect the neutral conductor, where required Mechanically, the phase supply and neutral supply blocks are identical. Address plug PTG1 Address plugs are used to address the I/O modules. They are delivered in sets of 16 plugs each. The following sets are used (module addresses ): Plug Addr. No. Plug Addr. No. PTG PTG PTG PTG PTG PTG PTG PTG PTG PTG Building Automation I/O module system and accessories /74

18 Blank labels PTP1.10 The blank labels are used for plant-specific labelling of I/O modules. One sheet (A4) suffices for 8 modules. It provides tearoff designation labels for the module front and the connecting terminals. Normally, these sheets are pre-printed when delivered to the control cabinet builder. Labelling occurs plant-specifically via the engineering system at SBT BAU. Terminal label holder PTX1.070 The snap-on holder is used to attach the terminal designation labels at the I/O module. The illustration shows a holder (left) and a partially inserted label (right). 18/74 Building Automation I/O module system and accessories

19 4 Control cabinet Topics in this chapter This chapter contains information on the following topics: Control cabinet requirements EMC compliant control cabinet I/O module and accessories layout Allocation and sequence of I/O modules Installation positions for module groups Overall control cabinet layout with samples 4.1 Control cabinet requirements Requirements The table below contains information on general control cabinet requirements: Please ensure that the individual requirements have been met. Step Requirements OK Mechanical design Ambient conditions EMC compliant control cabinet Construction, stability and sealing of the control cabinet comply with the relative regulations applicable at the plant location For the devices, adhere to the permissible values as indicated in section "Technical data" of the respective data sheets: Temperature, humidity, vibrations Protection class and degree of protection for devices Important: These regulations apply to the plant location! The regulations described in section 4.2 correspond to an EMC compliant control cabinet. Mechanical dimensions To determine the control cabinet dimensions, use: The information on layout options in this chapter The dimension diagrams for the devices in chapter 11 "Appendix". Building Automation Control cabinet /74

20 4.2 EMC compliant control cabinet Introduction General regulations Mechanical setup of the control cabinet Equipment allocation Screening CE labelling not required for control cabinets One of the purposes of a control cabinet lies in reducing electromagnetic interference. Interference depends on the internal and/or external EMC interference of the control cabinet. Internal EMC interference may be a power inverter within the same control cabinet; external EMC interference may be a nearby radio station. Control cabinets represent the reference point for screening cables and housings. They are tasked with decoupling interferences and short-circuiting interference voltages. The following regulations generally apply to EMC conformant control cabinets: Do not paint the interior walls Mounting plates and rails must be electrically conductive and must not be painted Attach screw fittings directly to unpainted parts of the control cabinet Create ground connections with the doors by means of flat copper bands (possibly in addition to the normal protective earth connection) When designing the control cabinet, high-interference equipment must be segregated from potentially interference-susceptible equipment. As a result, be particularly careful with connections between these two types of equipment: Use separate control cabinets for high-interference equipment and potentially interference-susceptible equipment. Place high-interference equipment outside the control cabinet. When doing so, ensure that you do no infringe on safety specifications for the equipment. Separate the equipment groups inside the control cabinet by using metal shielding. Lay the cable screens at the entry point on the metallic structure of the control cabinet and connect them to the building's equipotential bonding. To do this, use the screen connection clamps and the locations specifically reserved for this purpose in the control cabinet (see section 8.2 "Notes on EMC optimisation"). All equipment by SBT BAU complies with EMC regulations and the EMC standards as listed in the data sheets. A control cabinet (without independent function) is a part of a fixed installation and intended for the connection of further parts. The guideline of the European Commission on the application of the Council Directive 89/336/EEC on EMC describes exceptions to CE labelling. Even though the EMC guideline also applies to fixed installations, metrological proof and CE labelling is not required. 20/74 Building Automation Control cabinet

21 4.3 I/O module and accessories layout Forming groups Simple group The I/O modules are arranged on the I/O bars and summarised in groups together with the following devices: Module supply block PTX1.01 Phase supply block PTX1.00 Neutral supply block PTX1.02 (where needed) The groups are then snapped and fastened to the standard rails in the mounting frames of the control cabinet. This illustration shows a simple group with phase and module supply blocks: PTX1.00 PTX1.01 EN x7,5 8017Z12 The phase or module supply block can be located to the right or left. A possible neutral supply block PTX1.02 is then fitted next to the phase supply block PTX1.00. Linked groups Two I/O bars can be mounted next to each other and the transition points to the module supply block PTX1.01 can be linked mechanically and electrically: PTX1.00 PTX Z13 EN x7,5 The conductor rails for mains voltage L and N are not connected. They must be fed through separate phase supply blocks or neutral supply blocks. Space requirements Observe spacing! The space requirements for each fitted I/O bar in the control cabinet can be determined as follows: Number of modules x 32 mm + 32 mm + 16 mm + (16 mm *) * if neutral terminal block is used The supply terminal block (32 mm) and the phase terminal block (16 mm) are always required. They serve as a mechanical connection between the I/O bar and the standard rail. Reserve sufficient space for connecting the devices as well as swinging them in and out (see dimensions, section 11.1 "Dimensions"). Building Automation Control cabinet /74

22 4.4 Allocation and sequence of I/O modules Introduction Module allocation This chapter provides information on: Allocation of I/O modules to groups on various I/O bars Sequence of I/O modules on I/O bars In order to allocate an I/O module to groups on different I/O bars, the following allocation is suitable: I/O module group with... Internal control cabinet connections External control cabinet connections Example Connections to contactors for motor control Direct wiring to field devices such as sensors, transmitters, actuating devices, etc. Further criteria for allocation of I/O modules on several I/O bars: Number of I/O modules Standard length of I/O bars Control cabinet layout Cable entries to the control cabinet Module sequence Allocation of I/O modules on I/O bars normally follows the sequence of the module addresses. Variants are: Sequence according to voltage types: AC 230 V mains voltage AC 24 V extra-low voltage Plant-specific sequence: For example: According to the series of functions of the individual control loops (I/O modules for sensors, transmitters, and actuating devices together for each control loop) Sequence according to module types: For example: All signalling, measuring, counting, switching, and positioning modules in groups Further criteria on allocation: Country-specific regulations and own working practices Note If the building automation and control system is designed using a PC software program of SBT BAU (e.g., UNIGYR Design), the module sequence and addressing can be entered via the tool. 22/74 Building Automation Control cabinet

23 4.5 Installation positions for module groups Horizontal installation In the following two examples, the module groups are installed horizontally, with terminals and connections pointing upward or downward: Connections upward Connections downward 8017Z14 230V~ 24V~ 230V~ 24V~ 8017Z15 Vertical installation The following, slightly bigger control cabinet has vertically mounted module groups with: Cable entries to the side and Feeding up or feeding down 230V~ 24V~ 8102Z34 Building Automation Control cabinet /74

24 4.6 Overall layout of the control cabinet General layout The following illustration shows a simple control cabinet as a general example for meaningful allocation of module groups and devices. Control cabinet Door 230V~ 24V~ 8102Z35 Assembly in the control cabinet Control cabinet Door In this sample control cabinet, the module groups have been arranged as follows: Position Assembly Top Left Terminals for power sections: Supply feed, outputs to motors, etc. Right I/O module group with direct AC 230/24 V connections to field devices (control) Centre Left Isolating and fuse components Right I/O module group with direct AC 230/24 V connections to internal control cabinet devices (contactor, etc.) Bottom Left Mains voltage range with relay and contactor Door Right AC 230/24 V transformer for control section Automation station Note on space requirements for module wiring Examples Note the following points to ensure accessibility: Keep the minimum distance for wiring and swinging range of units between the I/O modules and the neighbouring cable ducts (see dimensions in chapter 9) The distance between two cable ducts must be at least 175 mm if I/O modules are mounted between them All connecting terminals must be available for easy connection and tests The next few pages provide layout samples for various applications. 24/74 Building Automation Control cabinet

25 4.7 Example 1: Control cabinet for HVAC plant Brief description The illustration below shows the layout for a control cabinet containing all control and regulation parts for an HVAC plant: The I/O module groups are mounted horizontally in three rows The associated automation station is installed in the door Z21 The most important parts The above labelled parts of the control cabinet are: Pos. Designation 1 Rail for cable attachment 2 Terminal row 3 Cable ducts 4 I/O module groups 5 Mounting profile/mounting frame 6 SBT BAU devices 7 Time relay 8 Contactor 9 AC 230/24 V transformers Building Automation Control cabinet /74

26 4.8 Example 2: Control cabinet for I/O data points Brief description The following illustration shows a control cabinet for I/O data points: The I/O module groups are installed vertically. This allows for accommodating a large number of I/O modules by applying easy and transparent wiring Z36 The most important parts The above labelled parts of the control cabinet are: Pos. Designation 1 Rail for cable attachment 2 Cable ducts for cable runs 3 I/O module groups 4 Wiring ducts 5 Mounting profile/mounting frame 26/74 Building Automation Control cabinet

27 4.9 Example 3: Control cabinet with frequency converters Brief description The following illustration shows two fields of a larger control cabinet combination: The left contains a field with two frequency converters The right shows one of the fields for control devices with vertically arranged I/O module groups Z37 The most important parts The above labelled parts of the control cabinet are: Pos. Designation 1 Cable ducts for cable runs 2 Terminal rows 3 Wiring ducts 4 Automation station 5 I/O module groups 6 Frequency converters Allocation of all other devices such as SBT BAU devices, time relay, contactor, and transformers is largely identical to example 1. Engineering Note Discuss all aspects with regard to frequency converters with the responsible expert (electrical engineering). This applies to aspects such as: Device location either in the same or in separate control cabinet fields (with metal shielding) Manual or automatic mains bypass Regulations/measures with regard to feed, fusing, protection against interference, etc. Please refer to the regulations and instructions as described in sections 4.2 "EMC compliant control cabinet" and 8.2 "Notes on EMC optimisation". Building Automation Control cabinet /74

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29 5 Mounting instructions for I/O modules 5.1 Before you start Important! Important documents Checklist: Mandatory information The following documents are important for integrating the devices in the control cabinet: 1. This mounting and installation guide It contains general rules and instructions on allocation and mounting I/O modules and devices in the control cabinet. 2. Project-specific documents These include electrical diagrams for wiring as well as detailed device allocation illustrations for the control cabinet. Project-specific documentation must not oppose the basic rules and instructions of this manual. The project-specific documentation must contain the following information on the control cabinet. Topic Wire arrangements Mounting position of I/O modules Distribution on I/O bars Sequence of I/O modules Isthereananswertothisquestioninthe documentation? Where in the control cabinet are the wire arrangements from and to the field devices: At the top, at the bottom, or at both top and bottom? How will the I/O modules be mounted: Horizontally, with terminals facing up or down? Vertically, with terminals facing right or left? Are the I/O bars distributed in groups as follows: I/O modules that are to be wired internally in the control cabinet? I/O modules that are to be wired externally to the field devices and thus serve as terminal blocks? Does the electrical diagram show the sequence in which the I/O modules are to be arranged? OK Prior to mounting Please refer to the notes and regulations in the following sections: Section 4.3 "I/O module and accessories layout" Section 11.1 "Dimensions" (special emphasis on space requirements) Building Automation Mounting instructions for I/O modules /74

30 5.2 Preparing I/O module systems Brief description Instructions Preparations include: Mounting standard rails Shortening the I/O bars to the required length Removing the protective foil from the I/O bars Conduct the preparatory work by following these steps: Step Action 1 Mount the standard rails as per the control cabinet layout drawings; use either top-hat rails or G-rails. 2 If necessary: Shorten the I/O bars to the required length. This can be made in sections of 32 mm. Important! Refit the end covers after concluding your work (protection against accidental contact). 30/74 Building Automation Mounting instructions for I/O modules

31 Instructions Step Action 3 Remove the protective foil from the I/O bars only when required. This is the case for: Strip A: Prior to plugging in the terminal base Strip B: Prior to inserting the module housing Important! Leave the protective foil on the unused parts of the I/O bars to protect against dust. Building Automation Mounting instructions for I/O modules /74

32 5.3 Mounting the I/O module system Brief description Instructions Begin by mounting the I/O bar with module supply and phase supply block. Proceed by inserting the I/O modules in sequence. Mount the I/O module groups as per the following steps: Step Action 1 Plug in the module supply block PTX1.01 and the phase supply block PTX1.00 on the I/O bar. 2 Snap the I/O bar with the module supply block and the phase supply block onto the standard rail. 3 Mark the positions for drill holes for the I/O bar. 32/74 Building Automation Mounting instructions for I/O modules

33 Instructions Step Action 4 Drill holes for max. 4 mm screws (outer thread) 5 Tighten the screws in the following sequence: 1. Clamping screws on the module supply and phase supply block 2. Screws for holding the I/O bar 6 Insert the I/O modules in sequence 1. The terminal base first 2. Then the module housing Note: Module and terminal base can be fitted together and then plugged into the I/O bar. Building Automation Mounting instructions for I/O modules /74

34 5.4 Disassembling the I/O module system Introduction Remove I/O modules The following sections show how to remove I/O modules, module supply blocks and phase supply or neutral supply blocks. Proceed as follows to remove an I/O module: A. Remove module housing B. Remove terminal base 1. Press the release catch 2. Swing out the housing 1. Press the snap-on clip. 2. Swing out the base Remove module supply blocks Remove a module supply block by conducting the following three steps: Picture module supply block Steps 1. Loosen the clamping screw 2. Simultaneously press all three release catches 3. Swing out the module supply block Remove phase supply or neutral supply blocks Remove a phase supply or neutral supply block by conducting the following three steps: Picture phase supply block Steps 1. Loosen the clamping screw 2. Press both release catches 3. Swing out the terminal block 34/74 Building Automation Mounting instructions for I/O modules

35 5.5 Shunts and bridges in I/O modules Introduction Change shunt on measured value module PTM1.2I25 Some I/O module types have shunts or bridges for setting the operating variants. This section provides the corresponding instructions. The measurement module for current signals has shunts to select the measuring range. The factory setting is for a range of ma. The following illustrations show how this shunt can be exchanged to set a different measuring range. A. Remove existing shunt B. Insert new shunt 1. Open the module housing 2. Pull out shunt Plug in the shunt for the new measuring range 4. Close the module housing List of shunts PTR1... Remove bridge for switching and positioning modules These are the shunts for measuring module PTM1.2I25 (sets at 10 pieces): PTR ma PTR ma PTR ma PTR ma For the following module types, removal of the bridge defines the path in which the switching voltage is fed. Refer to the plant wiring diagram for information. For PTM1 Q250 For PTM1.3Q-M3 and 2Y250T Remove this bridge if the switching voltage is not to be supplied via the I/O bar, but instead via the terminal base. Remove this bridge if switching voltage is to be supplied externally. Building Automation Mounting instructions for I/O modules /74

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37 6 Mounting instructions for I/O compact units 6.1 Before you start Important! Important documents The following documents are important for integrating I/O compact units in the control cabinet: 1. Data sheets for both I/O compact units PTK1.30V01 N8181 PTK1.23V02 N8182 These data sheets contain detailed technical information including diagrams, engineering, mounting, and commissioning instructions 2. This mounting and installation guide 3. Project-specific documents These include electrical diagrams for wiring as well as detailed device allocation illustrations for the control cabinet. Project-specific documentation must not oppose the basic rules and instructions of this manual and of the data sheets. 6.2 Ways to mount I/O compact units There are four ways to mount the I/O compact unit. Different types for mounting A. Attachment using mounting brackets B. Attachment using mounting brackets on top-hat rail 8181Z Z05 Attachment by using mounting brackets and without I/O bars Attachment by using mounting brackets on previously mounted top-hat rails (EN x7.5) without I/O bars C. Attachment using mounting brackets on leftward extension through I/O modules D. Attachment on I/O bar and top-hat rail on rightward extension through I/O modules 8181Z Z04 On leftward extension of I/O compact units through I/O modules: Attachment by using mounting brackets and a piece of I/O bar and top-hat rail for electrical connection and mechanical attachment of the I/O modules. On rightward extension of I/O compact units through I/O modules: Attachment on full I/O bar and full top-hat rail, without mounting brackets. Note You can mount several I/O compact units above each other on separate I/O bars and top-hat rails. The device dimensions are available section 11.1 "Dimensions". Building Automation Mounting instructions for I/O compact units /74

38 6.3 Mounting the I/O compact units This section provides step-by-step mounting instructions for each of the above four types of mounting the I/O compact units. Note Procedures for mounting type A The last two illustrations show how to remove the terminal blocks and how to disassemble the unit. Wall mounting by using mounting brackets J J21 4 Remove the mounting brackets (steps 1...3) Drill the holes into the wall as shown in the illustration. Attach the mounting brackets on the wall (step 4) J23 Attach the I/O compact unit (steps 5 and 6) 38/74 Building Automation Mounting instructions for I/O compact units

39 Procedures for mounting type B Attachment using the mounting brackets on a previously mounted top-hat rail J24 Attach the mounting bracket to the previously mounted top-hat rail (step 1). Drill holes for max. 4 mm dia. threaded screws Attach the mounting brackets on the wall (step 2). 8181J25 Attach the I/O compact unit (steps 3 and 4) Procedures for mounting type C Attachment using mounting brackets on leftward extension through I/O modules J J Drill holes for max. 4 mm dia. threaded screws for I/O bar and top-hat rail Mount the I/O module bar and top-hat rail as shown in the illustration (step 1) Attach the I/O compact unit (steps 2 and 3) J28 4 Insert the I/O modules in sequence: The terminal base (step 4) The I/O module (step 5) Building Automation Mounting instructions for I/O compact units /74

40 Procedures for mounting type D Attachment on I/O bar and top-hat rail on rightward extension through I/O modules J J Drill holes for max. 4 mm dia. threaded screws for I/O bar and top-hat rail Mount the I/O module bar and top-hat rail as shown in the illustration (step 1) Attach the I/O compact unit (steps 2 and 3) J31 4 Insert the I/O modules in sequence: The terminal base (step 4) The I/O module (step 5) Remove terminal blocks, disassemble the I/O compact unit Remove terminal blocks Disassemble the I/O compact unit J J For device exchange or measurements on open lines, each terminal block can separately be inserted and removed as shown in the illustration. For disassembly, press both brackets (step 1). The device is now ready for removal (step 2). 40/74 Building Automation Mounting instructions for I/O compact units

41 7 Labelling and addressing equipment 7.1 Procedures and allocation of labels Differing procedures Documentation for proper allocation Depending on the project and logistics, labels are either delivered with the devices to be mounted, or inserted at the plant location on commissioning. Proper allocation of device labels is available in the following project documents: Module list Plant wiring diagram Control cabinet layout This chapter will show you where and how the labels are attached to the devices. 7.2 Labelling of I/O bars and terminal blocks I/O bar Module supply block Phase supply and neutral supply block The individual I/O bars (or module groups) are labelled in the front terminal field of the associated module supply block, e.g., by X1, X2, X3, etc. The connections for the supply terminal block PTX1.01 can be labelled identical to those of the module terminal base; refer to "I/O module labelling" later in this chapter. The labelling plates "dekafix 6.5" by company Weidmüller can be plugged into the terminal body and in the connecting terminal; refer to "I/O module labelling" below. 7.3 I/O module labelling Label positions For unambiguous identification of each I/O module and its associated connections, the associated information is available at the following positions: Position Housing top Module front Terminal base Information Type plate and connecting diagram (factory) Module type and symbols for display and operating elements Plug-in front plate, can be labelled as required Terminal designations and plates with address number of the I/O module address plug (at extra fee) Address plug Address numbers from Building Automation Labelling and addressing equipment /74

42 Front labels Positioning according to mounting position The slide-in front labels for the I/O modules can be labelled as required. If a plant is engineered at SBT BAU, engineering tools are used to create the front labels. In this case, the PTP1.10 labels sheets are printed automatically with the respective module designation. The front labels then contain the address and allocation of each individual module or module group for a automation station. The front labels are inserted from below or sideways into the transparent front. The illustrations below show insertion of front labels and terminal labels for various mounting positions of the I/O modules. Make sure that the address number on the front label matches that on the address plug! Vertically mounted module Horizontally mounted module A B Terminal connections at bottom Terminal connections on top C D Terminal connections to the right Terminal connections to the left Connecting terminals Two options If external connections to the control cabinet lead directly to the connecting terminals of the I/O modules, they normally have a plant-specific label in addition to the device label (e.g., by continuous numbers). If such labelling is intended as per the plant wiring diagram, there are two options: On paper strips which are inserted into the transparent terminal label holder (holder PTX1.070, can be ordered as an accessory). These strips can be torn off the same labelling sheet as the front labels. The strips can be labelled manually or by machine. Using slide-in, printed labelling plates such as "dekafix 6.5" by company Weidmüller. 42/74 Building Automation Labelling and addressing equipment

43 Inserting front and terminal labels This illustration shows how to tear off the front and terminal labels from the PTP1.10 sheet and how and where to attach them on the I/O module. Variant for terminal labelling This illustration shows a variant for terminal labelling with slide-in labelling plates such as "dekafix 6.5" by company Weidmüller. 7.4 I/O module addressing Introduction Addressing information In order for a automation station to identify and communicate with a specific I/O module, each I/O module must have its own address. This module address is defined by an address plug on the I/O module. Module addressing follows the addressing concept as designed by SBT BAU. The following points are important for control cabinet layout: The address range for I/O modules with connection to a automation station comprises addresses 1 to 255 The valid assignment of addresses to the respective job is available in the project documentation Building Automation Labelling and addressing equipment /74

44 Inserting address plugs This illustration and the following steps show the procedures to insert an address plug in the I/O modules: Step Action 1 Detach the address plug having the lowest required number from the bar as per the documentation 2 Locate the associated, mounted I/O module for this number by consulting the documentation 3 Separate the number plate from the address plug 4 Insert the number plate at the terminal base of the corresponding module to the left of the labelling field for the upper terminal row. Note: The number plate serves as a reference to relocate the proper position for a module removed temporarily from the base. 5 Plug in the address plug at the top left of the module front. Make sure that this is the previously numbered terminal base of the respective module. 6 Continue numbering by following steps 2 to Labelling and addressing the I/O compact unit Refer to data sheets 182E and N8182 for more information on device- and projectspecific labelling as well as on pre-printed labels. 44/74 Building Automation Labelling and addressing equipment