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Integrated Monitoring and Control System

iMAC2 User Manual

Version: 4

– October 2018

Designed and Manufactured in Australia by Ampcontrol Pty Ltd

Summary of Contents for iMAC2

Page 1: ...Integrated Monitoring and Control System iMAC2 User Manual Version 4 October 2018 Designed and Manufactured in Australia by Ampcontrol Pty Ltd ...

Page 2: ...RT WARNING The warning symbol highlights a potential risk of injury or death Please share these warnings with other operators CAUTION The caution symbol highlights a potential risk of damage to equipment Please share these cautions with other operators NOTE The note symbol highlights key information Please share these notes with other operators ENVIRO The enviro environmental symbol highlights are...

Page 3: ...mes no liability resulting from any omissions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserve...

Page 4: ...HER WARNINGS 12 Safe Use of Equipment 12 RECEIVING AND STORAGE 13 Receiving 13 Inspection 13 Storage after Delivery 13 Unpacking of Equipment 13 iMAC SYSTEM OVERVIEW 14 Typical Installation 15 Application Software 16 iMAC Modules 16 iMAC Address Range 17 Fault Finding Statistics 17 Networking 18 Local and Global Data 19 Sequence Control 19 Emergency Stop SIL Qualification 21 IECEx Certifications 2...

Page 5: ...rial Interface Modules 33 Specialty Modules 34 Protection Modules 34 End of Line Modules 34 INSTALLATION 35 General Warnings 35 Mandatory Installation Practices 36 Mechanical Arrangement 37 Electrical Connections 37 COMMISSIONING AND CALIBRATION 38 iMAC2 CONTROLLER OPERATION SUMMARY 39 iMAC2 Controller User Interface 40 System Menu 41 iMAC2 Controller LEDs 44 Selectors DIP Switches 44 SERVICE MAIN...

Page 6: ...3 Ampcontrol Pty Ltd ABN 28 000 915 542 iMAC System User Manual iMAC2B009 V4 10 18 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART Output Modules 51 Serial Interface Modules 52 Specialty Modules 52 Protection Modules 52 EOL and MEOL Modules 53 ...

Page 7: ...nveyor Sequence Control 20 Figure 4 5 An Implementation of Emergency Stops on a 2 Wire iMAC Fieldbus 21 Figure 5 1 Bipolar Pulse Width Modulated iMAC Fieldbus Signal 23 Figure 6 1 iMAC2 Controller Front 24 Figure 6 2 iMAC2 Controller Right Side 24 Figure 6 3 iMAC2 Controller Rear 24 Figure 6 4 iMAC2 Controller Terminal Layout 25 Figure 6 5 General Purpose Input Internal Circuitry 25 Figure 6 6 iMA...

Page 8: ...allation Requirements IMACB153 iMAC Controller Serial Communications Manual IMACB182 iMAC SIL Emergency Stop Qualification IMACB005 iMAC Module Programming Manual 1 2 2 Module Documentation IMACB003 iMAC RO4 Module Technical Datasheet IMACB018 iMAC LPU Module Technical Datasheet IMACB020 iMAC DI8 Module Technical Datasheet IMACB045 iMAC IIM Module Technical Datasheet IMACB046 iMAC DI4 Module Techn...

Page 9: ...ring Line in a 3 wire system or the Signal Line in a 2 wire system C Line The Common Line for 3 wire and 2 wire systems Common Line The Common Line as the name suggests is the common return communications line of the L1 fieldbus The Common Line is used in both 2 Wire and 3 Wire Systems CR The Control Relay CR of the iMAC2 Controller Provides emergency stop function via End Of Line module monitorin...

Page 10: ...iMAC L1 fieldbus Provides five voltage free contact inputs and four LED outputs for indication IRK iMAC Remote Keypad that connects to the iMAC L1 fieldbus Allows the user to operate the iMAC2 Controller s interface remotely LED4 LED Output Module that connects to the iMAC L1 fieldbus Provides four LED outputs for indication LIM LED Indication Module which interfaces directly to the iMAC Fieldbus ...

Page 11: ...SW Speed Switch Module that connects to the iMAC L1 fieldbus This module provides conveyer belt slip protection and speed indication Fieldbus System Configurations The iMAC fieldbus can be configured as either a 2 wire or 3 wire system depending on the required application Each of these configurations can be used within hazardous areas provided that the fieldbus is correctly installed utilising an...

Page 12: ...ommunicate across the Monitoring Line The A line and B line are separated using a resistor the resistor value is typically 47 ohms and allows faults to be detected Monitoring and comparing the EOL and MEOL module resistance readings allows the system to detect short circuit cabling faults between the A and B lines Figure 1 2 3 Wire iMAC Fieldbus System Configuration 1 4 3 Intrinsically Safe System...

Page 13: ...y and may compromise the integrity of the system into which it is installed and other connected equipment 2 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore please read and understand this manual prior to use Competency based training courses are recommended and are available on request 2 1 3 Ma...

Page 14: ...place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications Stor...

Page 15: ...ise the most cost effective cable to meet your requirements Key Features Remote monitoring and control using a flexible range of I O modules Digital input modules most input modules are powered directly from the fieldbus Relay output modules Analogue input modules Serial interface modules Fault tolerant fieldbus with high electrical noise immunity Advanced fieldbus diagnostics including individual...

Page 16: ...AC output modules require a local power supply to operate A host system e g PLC can communicate with the iMAC2 Controller via a configurable RS232 RS485 serial port using Modbus protocol Data can be exchanged between iMAC2 Controller and host system via a read wire Modbus register map The iMAC2 Controller provides an Ethernet TCP IP port that allows read only access to the iMAC2 Controller s Data ...

Page 17: ...ble for monitoring temperature via PT100 RTD sensor elements 4 3 2 Output Modules Output modules can be controlled directly from input modules or indirectly via iMAC2 Controller application SLP software In addition to general relay output modules specialised output modules are available for duplicating the iMAC2 Controller Control and Auxiliary relays for redundancy and for passing belt sequence L...

Page 18: ...ed for specialised applications for example CRM ARM and GRM modules utilise Address 0 If a standard iMAC module is set to Address 0 the module will go offline and will not respond to fieldbus datascans This can be a handy feature for fault finding A module set to Address 0 will appear offline but will still respond to rollcall scans allowing to its address to be set to a valid Address from 1 to 25...

Page 19: ... Tree Network of iMAC2 Controllers WARNING The L1 fieldbus lines from two Controllers must never be connected together This would violate the Intrinsic Safety Approval and may damage the drive circuits In a networked iMAC system each individual Controller will drive its own fieldbus via the L1 port The L2 fieldbus port shall only be used for connection to a Parent L1 Line owned by a Controller fur...

Page 20: ...resses for display and control at other Controllers Sequence Control The iMAC System provides four specialised control bits for sequence control These are generally used for conveyor sequence control but can be re purposed for other applications The sequence control bits are called L1 Sequence Down Bit L1 Sequence Up Bit L2 Sequence Up Bit L2 Sequence Down Bit The L1 Sequence Down Bit and the L2 S...

Page 21: ...tiates a sequenced conveyor start 7 Controller 3 Controller 2 Controller 1 Conveyor 3 Conveyor 2 Conveyor 1 L1 L1 L1 L2 L2 Controller 1 initiates Conveyor 1 start by closing the CR if the system is healthy 2 Controller 1 receives input indicating that the speed of Conveyor 1 has exceeded the required threshold and transmits the L1 Sequence Down Bit on the L1 fieldbus port 3 Controller 2 receives t...

Page 22: ...pen de energise Figure 4 5 An Implementation of Emergency Stops on a 2 Wire iMAC Fieldbus Refer to IMACB182 iMAC Emergency Stop SIL Qualification document for detailed safety information IECEx Certifications The iMAC System has been Ex ia Group I certified for use in hazardous areas such as underground coal mines Certification details are as follows Certification Date Issued Approved Module Types ...

Page 23: ...relationship between approved module hardware types and the actual module types The following table illustrates the relationship between approved hardware types and module types IECEx Approved Hardware Type iMAC Module Type MLB MLB GM1 DI4 LED4 LIM IIM RTD1 IRK RKM GM1 D EOL MEOL GM2 SSW SA16 ARM CRM EMM GRM SQM SLB AIM AIM 4 20mA AIM 0 10V SIM SIM T SIM G SIM G2 SIM P CAUTION The user is responsi...

Page 24: ...d by line capacitance or inductance because of a fixed transmission baud rate The transmission speed is selectable so the data throughput can be optimised at commissioning for the particular system type All iMAC modules are auto bauding automatically adapting to the iMAC2 Controller s selected baud rate Both voltage and current are sampled on module data replies The Controller calculates the resis...

Page 25: ...kets on the outer points or two mounting brackets on the centre points Mounting Bracket Attachment Point When the iMAC2 Controller is panel mounted with the supplied fascia gasket it provides an IP55 ingress protection rating Fascia Gasket This rotary switch is accessed via a hole in the side wall of the iMAC Controller s enclosure The function of this selector is dependent upon the application so...

Page 26: ...er circuitry The cable connecting the Controller inputs to the voltage free contacts should be twisted pair with a maximum length of 20m Figure 6 5 General Purpose Input Internal Circuitry 24VDC 0VDC EARTH SUPPLY CR AR SW1 SW1 SW2 SW2 SW3 SW3 COMMON Rx T Tx T CTS R RTS R INPUT 1 INPUT 2 INPUT 3 RS232 RS422 RS485 LINE 2 LINE 1 L2 L2 EARTH EARTH L1 L1 24VDC INCOMING POWER SUPPLY CONTROL RELAY CONTAC...

Page 27: ... acts as a Modbus slave device the slave address is selectable via the Serial Communications section of the iMAC2 Controller s System Menu The Controller supports a number of standard Modbus commands and data is accessed via the Controller s Data Point Table 6 4 2 Ampcontrol IP Protocol The Ampcontrol IP Protocol reads data from the General Buffer area of the Controller s Data Point Table The appl...

Page 28: ...m non intrinsically safe systems 6 6 2 L2 Fieldbus Port The L2 fieldbus port is used for networking the iMAC2 Controller to a parent Controller s L1 fieldbus The L2 port is optically isolated Memory The iMAC2 Controller has 32k flash memory for storing application SLP software This memory is retained when power is removed from the Controller The Controller has an area of this memory reserved for s...

Page 29: ...omplete range of data definitions including system runtime variables refer to the IMACB153 iMAC Controller Serial Communications Manual or the IMACB2010 iMAC2 Controller Ethernet Communications Manual Modbus Address Block 000h 0FFh System Data Register Decimal 0 1 2 3 4 5 253 254 255 Hexadecimal 0h 1h 2h 3h 4h 5h FDh FEh FFh Modbus Address Block 100h 1FFh System Status Decimal 256 257 258 259 260 ...

Page 30: ...lly safe circuits to intrinsically safe circuits by the limitation of voltage and current The MLB allows approved modules to be connected to the iMAC L1 fieldbus within hazardous areas The MLB is DIN rail mounted and does not require a power supply The MLB must be located in the safe area or in a suitable flameproof enclosure WARNING The MLB is only to be connected to L1 Only one MLB is to be conn...

Page 31: ...isation of MLB and SLB Barriers in an Intrinsically Safe System MLB Barrier One per L1 Fieldbus iMAC2 Controller L1 L1 L1 L1 SLB Barrier CRM Module AIM Module DI8 Module RO4 Module Safe Area Safe Area or Flame Proof Box Hazardous Area L1 L1 L1 L1 L1 L1 ARM Module EOL Module One per L1 Fieldbus L1 L1 L1 L1 SLB Barrier Safe Area or Flame Proof Box DI8 Module RTD1 Module DI4 Module IIM Module L1 L1 C...

Page 32: ...y the iMAC2 Controller and any output modules that have been set to the same address Type Description Function Example Application DI4 4 x Digital Input Module Provides 4 x Digital Inputs Allows remote inputs into the iMAC System via the module s voltage free inputs Can be used in hazardous areas DI8 8 x Digital Input Module Provides 8 x Digital Inputs Allows remote inputs into the iMAC System via...

Page 33: ...remote location or as cross checking for the iMAC2 Controller s AR Relay Note requires specific application SLP software for operation CRM Control Relay Module Mimics the state of the iMAC2 Controller s CR Provides an additional CR output for the iMAC2 Controller Can be used to provide a control output at a remote location or as cross checking for the iMAC2 Controller s CR Relay Note requires spec...

Page 34: ...mitted to an iMAC2 Controller across the iMAC Fieldbus Type Description Function Example Application SIM G Serial Interface Module 1 x GasGuard Controller Communications Bridge between the iMAC System and a single GasGuard Controller s RS485 Modbus interface Allows RS485 Communications from a GasGuard Controller installed in the field to be transmitted back to the iMAC2 Controller over the fieldbu...

Page 35: ...odule for 2 Wire Modules Provides lightning protection for 2 wire iMAC modules Sacrificial lightning transient protection for 2 wire modules e g DI4 module LPU3 Lightning Protection Module for 3 Wire Modules Provides lightning protection for 3 wire iMAC Modules Sacrificial lightning transient protection for 3 wire modules e g IIM module End of Line Modules iMAC End of Line modules form a key part ...

Page 36: ...cation into which the iMAC System is being installed has been properly defined designed and approved Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choice of all components needed to impleme...

Page 37: ... must be powered within the specified voltage range The installation of the iMAC System must be carried out by suitably trained and qualified personnel Refer to IMACB094 iMAC System Installation Requirements Document for further information Identification labels fixed to the iMAC2 Controller must not be damaged removed or covered before during or after installation The installation is to be in acc...

Page 38: ...ket to maintain this IP rating Recommended panel cut out is 135Hx135Wmm overall dimensions of the enclosure are shown in Figure 8 1 Figure 8 1 iMAC2 Controller Enclosure Dimensions Electrical Connections Due to the many configurations that the iMAC System can be installed in the electrical installation requirements for the iMAC System are covered in a separate document Please refer to the IMACB094...

Page 39: ...ROL PTY LTD NOT TO BE REPRODUCED IN PART COMMISSIONING AND CALIBRATION Prior to being put into service the iMAC System must be correctly commissioned This manual does not cover system commissioning the full scope of commissioning tests should be determined during the risk assessment or FMEA covering the design of the electrical protection system For assistance in installing and commissioning an iM...

Page 40: ...ial Data OFF Controller Serial Receive Port Idle COMMS IN LED FUNCTIONALITY ON Controller Transmitting Serial Data OFF Controller Serial Transmit Port Idle COMMS OUT LED FUNCTIONALITY ON Application Software Dependent OFF Application Software Dependent L2 LED FUNCTIONALITY ON Application Software Dependent OFF Application Software Dependent L1 LED FUNCTIONALITY The iMAC2 Controller has six attachm...

Page 41: ...ontroller application SLP software From here it is possible for the user to navigate to a number of sub menus using the UP and DOWN arrow keys in combination with the function keys F1 to F4 The available sub menus are defined by the Controller s application SLP software and vary from one application software to another 10 1 3 ALARM Key The ALARM key allows the user to navigate directly to the alar...

Page 42: ...or modifying parameters when they selected System Menu The user can usually access the System Menu by pressing SHIFT MENU In some cases the application SLP software may have disabled this function in these cases the System Menu will be assessable according to an application software defined procedure refer to the specific application software documentation for instructions on accessing the System ...

Page 43: ... is stored in the data register of the module that is registered to the interrogated Address It is possible to change the way that the value within the data register is displayed by pressing the F3 key Possible display options are decimal d binary b hexadecimal x octal o F4 Fourth Line The Offlne and Clash counters are incremental counters that provide an indication of the number of times that the...

Page 44: ...nu press F4 to navigate to the Version page Figure 10 7 iMAC System Menu Version Page F1 F2 F3 F4 COMMS CONFIG PAGE PCOL SLAVE MODBUS BAUD RATE 9600 PARITY NONE STOP BITS 1 MODE RS232 MB SLAVE ADDRS 1 MASTER MODBUS PROTOCOL SLAVE MODBUS IP2 PROTOCOL L1 MAINTENANCE L2 MAINTENANCE RS232 MODE RS485 RS422 1 STOP BITS 2 1 to 32 MB SLAVE ADDRESS 600 BAUD RATE 1200 2400 4800 9600 19k2 19200 NONE PARITY E...

Page 45: ...OL fault or L2 Active etc The typical L1 and L2 LED operation is L1 on with CR and L2 on with AR while a fast flash usually indicates the L1 fieldbus is short circuited 10 3 2 Communications LEDs The COMMS IN and OUT LEDs are red in colour and indicate that the Controller is receiving and transmitting serial communications data The corresponding LEDs flash whenever serial data is being transmitted...

Page 46: ...s are free from water and dust ingress internally Door seals are in good condition Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted Check that labels on equipment wall boxes and cables are present and in good condition especially certification labels Check that no modifications have been carried out to inst...

Page 47: ... department agency only If a fault develops return the equipment to an authorised Ampcontrol service department agency for repair It is essential that no attempt be made to repair the equipment as any attempt to dismantle or repair the equipment will void the warranty and certification of the unit or system Disposal ENVIRO The electronic equipment discussed in this manual must not be treated as ge...

Page 48: ...ble type length and module quantity type distribution L2 Fieldbus L2 L2 Terminals Optically Isolated 10kVrms Minimum Baud Rate 300 Maximum Baud Rate 1000 Switches Selectors Type Location Function 16 Position Selector Access via right side of enclosure Application software SLP dependent 4x DIP Switches Access via right side of enclosure Application software SLP dependent Ethernet Reset Switch Acces...

Page 49: ...licable Standards IEEE 802 3u IEEE 802 3x Cable Requirements 10BASE T UTP category 3 4 5 cable maximum 100m 100BASE TX UTP category 5 5e cable maximum 100m Supported Protocols MODBUS TCP IP Port 502 NTP for time synchronisation Webserver for configuration data viewing and diagnostic functions Maximum Request Rate 100ms Recommended Response Timeout 100ms Maximum Concurrent Web Connections The iMAC2...

Page 50: ...ow the protection fuses of the iMAC MLB I S barrier Part Number Description Certification 171571 iMAC2 Controller Standard 24VDC N A 173552 iMAC2 Controller Long 24VDC N A 13 1 2 Accessories Part Number Description Certification 171010 Replacement Mounting Clip 1 Only Suitable for iMAC2 Controllers and iMAC Remote Keypads N A Intrinsically Safe Barriers iMAC Intrinsically Safe barriers are require...

Page 51: ...red IECEx 120942 iMAC DI8 Module 8 x Digital Inputs Rotary Address Plugged Type Fieldbus Powered N A 101495 iMAC DI8 Module 8 x Digital Inputs Rotary Address Terminal Type Fieldbus Powered N A 121891 iMAC IIM Module 5 x Digital Inputs 4 x LED Outputs IS Fieldbus Powered IECEx Analogue Input Modules The iMAC System has a number of analogue input modules available for voltage current or temperature ...

Page 52: ...del Mimics iMAC2 Controller CR Status IECEx 115156 iMAC GRM Module 1 x Relay Output IS 110VAC Model General Relay Module Controlled by iMAC2 Controller IECEx 115146 iMAC GRM Module 1 x Relay Output IS 240VAC Model General Relay Module Controlled by iMAC2 Controller IECEx 115155 iMAC GRM Module 1 x Relay Output IS 24VDC Model General Relay Module Controlled by iMAC2 Controller IECEx 115153 iMAC EMM...

Page 53: ...C SIM G2 Module IS Allows connection to two Ampcontrol GasGuard Controllers IECEx 143646 iMAC SIM P Module IS Allows connection to a generic Modbus RTU Slave Device IECEx 121917 iMAC SIM T Module IS Allows connection to a single Trolex 9042 Controller IECEx Specialty Modules The iMAC Speed Switch module allows monitoring for conveyor belt speed belt slip and belt sequencing Part Number Description...

Page 54: ...er Control Relay CR to be energised the Controller must be successfully communicating with the End of Line module There are two types of End of Line modules the End of Line EOL module and the Monitoring End of Line MEOL module In 2 Wire systems only the EOL module is required 3 Wire systems require both an EOL and a MEOL to be installed and communication to be healthy before the Control Relay CR c...

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