Schneider Electric 890 USE 155 Installation Guide

35014629 00www.telemecanique.comModiconRemote I/O CableSystem Planning andInstallation Guide890 USE 101 00 eng Version 3.0This document provided by Ba

About the Book10890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

Installing an RIO Network100890 USE 101 00 October 2006Preparing RG-6 Cable for a ConnectorHow to Prepare an RG-6 Cable for a ConnectorThe following p

Installing an RIO Network890 USE 101 00 October 2006 1014 Open the jaws and remove the cable. Twist off the cable dielectric and jacket by hand. Remov

Installing an RIO Network102890 USE 101 00 October 2006Installing F Connectors on Quad Shield RG-6 CableOverview The following steps describe how to i

Installing an RIO Network890 USE 101 00 October 2006 1033 Remove the F connector by sliding it out the side of the cassette. 4 Align the 60-0544-000 C

Installing an RIO Network104890 USE 101 00 October 20066 Install the F connector onto the cable port of the RIO drop adapter, tap, or other cable hard

Installing an RIO Network890 USE 101 00 October 2006 105Installing BNC or Self-terminating F Connectors on RG-6 CableOverview The following procedure

Installing an RIO Network106890 USE 101 00 October 2006Installing BNC ConnectorsTake the following steps to install BNC or self-terminating F connecto

Installing an RIO Network890 USE 101 00 October 2006 107RG-11 Cable ConnectionsOverview To make a connection to an RG-11 cable, use a 490RIO00211 F co

Installing an RIO Network108890 USE 101 00 October 2006The RG-11 Installation ToolOverview The Modicon 490RIO0S411 is used to strip RG-11 cable for in

Installing an RIO Network890 USE 101 00 October 2006 109Installing F Connectors on RG-11 CableOverviewInstalling F ConnectorsThe following steps demon

890 USE 101 00 October 2006 111Remote I/O Networks—A Communications OverviewAt a GlanceOverview This chapter provides an overview of remote I/O (RIO)

Installing an RIO Network110890 USE 101 00 October 20064 Release the tool handle and let the spring hold the tool on the cable. Slowly rotate the tool

Installing an RIO Network890 USE 101 00 October 2006 1118 To determine how far you should insert the cable, place the cable next to the connector as s

Installing an RIO Network112890 USE 101 00 October 200610 Insert connector (with cable) into installation tool #490RIO0C411. Seat plastic sleeve into

Installing an RIO Network890 USE 101 00 October 2006 113Semirigid Cable ConnectionsOverview The following products are recommended for making F connec

Installing an RIO Network114890 USE 101 00 October 2006Semirigid Cable Installation ToolsOverview The Ripley Company Cablematic® JCST-QR Jacket Coring

Installing an RIO Network890 USE 101 00 October 2006 115Preparing a Semirigid Cable for a ConnectorOverview Instructions for use are included with the

Installing an RIO Network116890 USE 101 00 October 2006Installing F Connectors on Semirigid CableOverview The following procedures are used for instal

Installing an RIO Network890 USE 101 00 October 2006 117Semirigid Trunk Cable Tap Port ConnectionsOverview Taps cannot accept two semirigid cable conn

Installing an RIO Network118890 USE 101 00 October 2006Providing Line Termination on the Drop CableOverview Drop cables running to J890/J892-00x drop

Installing an RIO Network890 USE 101 00 October 2006 119Optional Drop Cable In-line TerminationAll drop adapters—except those listed in RIO Network Ca

Communications Overview12890 USE 101 00 October 2006RIO Network CommunicationsOverview Modicon’s RIO network is a high speed (1.544 Mbit/s) local area

Installing an RIO Network120890 USE 101 00 October 2006Connecting/Disconnecting a Drop Cable at a TapOverview None of the three ports on an MA-0185-X0

Installing an RIO Network890 USE 101 00 October 2006 121Disconnecting a Drop Cable from a TapThe following procedure demonstrates how to disconnect a

Installing an RIO Network122890 USE 101 00 October 2006Installing Fiber Optic RepeatersOverview Prior to installing 490NRP954 Fiber Optic Repeaters, f

Installing an RIO Network890 USE 101 00 October 2006 123For vertical mounting, use the brackets supplied with the unit for bolting to a panel. The bra

Installing an RIO Network124890 USE 101 00 October 2006RIO Shield-to-Chassis JumperSet the shield-to-ground jumper switch appropriately to specify the

Installing an RIO Network890 USE 101 00 October 2006 125GroundingThe repeater obtains its ground in the AC power cord via the green gnd wire or throug

Installing an RIO Network126890 USE 101 00 October 2006Terminating the Trunk CableOverview The trunk cable must be terminated by inserting a Modicon 5

Installing an RIO Network890 USE 101 00 October 2006 127Installing the Ground PointOverview The cable system should be grounded at a point within 20 f

Installing an RIO Network128890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

890 USE 101 00 October 2006 1295Testing and Maintaining an RIO NetworkAt a GlanceOverview This chapter provides information on testing and maintaining

Communications Overview890 USE 101 00 October 2006 13Processing Nodes on the RIO NetworkOverview The RIO network supports communications between a PLC

Testing and Maintaining an RIO Network130890 USE 101 00 October 2006Maintenance and Testing RequirementsOverview A properly installed RIO system will

Testing and Maintaining an RIO Network890 USE 101 00 October 2006 131RIO Drop Maintenance Information LogCustomer NetworkLocation PlantRevision/Approv

Testing and Maintaining an RIO Network132890 USE 101 00 October 2006Coax RIO System Network IntegrityOverview A battery of up to eleven tests can be p

Testing and Maintaining an RIO Network890 USE 101 00 October 2006 133Test 6 Time Domain Reflectometer (TDR) TestPerformed on all drop cables and at al

Testing and Maintaining an RIO Network134890 USE 101 00 October 2006RIO System Tests for Critical ApplicationsTests 8 ... 10 guarantee performance—if

Testing and Maintaining an RIO Network890 USE 101 00 October 2006 135Problem Sources on an RIO NetworkOverview Noise on the RIO network is a frequentl

Testing and Maintaining an RIO Network136890 USE 101 00 October 2006Problems Stemming from Poor InstallationDefective media products can account for s

Testing and Maintaining an RIO Network890 USE 101 00 October 2006 137On-line and Off-line Error IsolationOverview RIO troubleshooting is a process of

Testing and Maintaining an RIO Network138890 USE 101 00 October 2006Troubleshooting Fiber Optic RepeatersOverview Here is a typical point-to-point RIO

Testing and Maintaining an RIO Network890 USE 101 00 October 2006 139Broken Cable Detection and RemediesUnlike coaxial cable, fiber cable contains phy

Communications Overview14890 USE 101 00 October 2006RIO Adapters An adapter module resides at each remote drop on the RIO network. The type of adapter

Testing and Maintaining an RIO Network140890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr

890 USE 101 00 October 2006 141AppendicesAt a GlanceOverview These appendices provide information on RIO cable material suppliers as well as a glossar

Appendices142890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

890 USE 101 00 October 2006 143ARIO Cable Material SuppliersRIO Cable Material SuppliersRIO Cable Material SuppliersBelden Wire and Cable Company2200

RIO Cable Material Suppliers144890 USE 101 00 October 2006 Relcom, Inc.2221 Yew StreetForest Grove, OR 97116Telephone: (800) 382-3765Website: www.rel

RIO Cable Material Suppliers890 USE 101 00 October 2006 1453M Telecom Systems Division6801 River Place Blvd.Austin, TX 78726-9000Telephone: (800) 426-

RIO Cable Material Suppliers146890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

890 USE 101 00 October 2006 147Glossaryamplitude A measure of the strength of a signal.application A user programarmor A metal wrapping around a coaxi

Glossary148890 USE 101 00 October 2006cable shield The outer conductor of a coaxial cable used to protect the signal on the cable from noise.cable swe

Glossary890 USE 101 00 October 2006 149dispersion The cause of bandwidth limitations in a fiber optic signal. Dispersion causes a broadening of input

Communications Overview890 USE 101 00 October 2006 15RIO Drop AddressingOverview Each RIO drop adapter on the network must be assigned a unique addres

Glossary150890 USE 101 00 October 2006frame A message unit, particularly that part between the start delimiter and the end delimiter.frame check seque

Glossary890 USE 101 00 October 2006 151input module A device used to connect field inputs. This module mounts into an I/O housing at a drop/channel lo

Glossary152890 USE 101 00 October 2006network A system consisting of the cable media components and the communication nodes.node An intelligent unit o

Glossary890 USE 101 00 October 2006 153pull strength The maximum allowable torque that may be used to pull a cable through a conduit or enclosure.redu

Glossary154890 USE 101 00 October 2006RG-11 A standard coaxial cable type, providing good shielding and medium to low signal loss.RG-6 A standard coax

Glossary890 USE 101 00 October 2006 155tap A passive device used to isolate a node from the trunk cable. It allows only a portion of the signal to be

Glossary156890 USE 101 00 October 2006wavelength The distance between the same point on adjacent waves.zero crossing The condition when the wave form

CBA890 USE 101 00 October 2006 157Numerics043509432 Crimp Toolfor RG-6 connectors, 97illustration, 99043509446 BNC Connectorfor quad shield, 81490NRP9

Index158890 USE 101 00 October 2006600-558-000 Cable Cuttersillustration, 99AAS-MBII-003 Pre-assembled Drop Cable50 ft length, 68AS-MBII-004 Pre-assem

Index890 USE 101 00 October 2006 159environmental considerationsfor coaxial cables, 44FF adaptersfor semirigid cable, 80F connectordescription, 78for

Communications Overview16890 USE 101 00 October 2006RIO Network Cable SystemOverview The RIO processor at the controller head-end is connected to an a

Index160890 USE 101 00 October 2006MA-0186-100 splitterdescription, 76Revision B, 77specifications, 76MA-0329-001 F Connectorfor quad shield RG-6 cabl

Index890 USE 101 00 October 2006 161RIO processordescription, 13Sself-healing ring topologyusing fiber optic repeaters, 38Self-terminating adapterproc

Index162890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

Communications Overview890 USE 101 00 October 2006 17Terminating the Cable SystemA proper impedance match is maintained across the network with 75 Ω t

Communications Overview18890 USE 101 00 October 2006RIO Network Node Part Number SummaryRIO Devices The following table shows RIO device types.*These

890 USE 101 00 October 2006 192Planning and Designing an RIO Cable SystemAt a GlanceOverview This chapter provides information on planning and designi

2 This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

Planning and Designing RIO Cable System20890 USE 101 00 October 2006Linear Cable TopologiesOverview There are many possible topologies that may be use

Planning and Designing RIO Cable System890 USE 101 00 October 2006 21Redundant RIO Cable SystemsIf both the head processor and the drop adapters have

Planning and Designing RIO Cable System22890 USE 101 00 October 2006The two cables are treated as two separate networks, and each cable is an independ

Planning and Designing RIO Cable System890 USE 101 00 October 2006 23z Each drop on the two trunks must have a unique RIO network addressPart Numbers

Planning and Designing RIO Cable System24890 USE 101 00 October 2006Hot Standby Cable TopologiesOverview A Hot Standby (HSBY) system is comprised of t

Planning and Designing RIO Cable System890 USE 101 00 October 2006 25Single-cable Hot Standby SystemThe following is an illustration of the single-cab

Planning and Designing RIO Cable System26890 USE 101 00 October 2006Redundant Hot Standby Cable SystemsUsing redundant cabling in a Hot Standby system

Planning and Designing RIO Cable System890 USE 101 00 October 2006 27Hot Standby Coaxial Cable Interconnection LengthsSelf Terminating Adapters (STFA)

Planning and Designing RIO Cable System28890 USE 101 00 October 2006Trunk Splitter UseOverview The following are examples of trunk splitter use in sta

Planning and Designing RIO Cable System890 USE 101 00 October 2006 29Using a Trunk Splitter in a Hot Standby SystemUsing a single MA-0331-000 splitter

3Table of ContentsSafety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7About the Book . . . . . . . . . . . . .

Planning and Designing RIO Cable System30890 USE 101 00 October 2006CAUTIONPossible Equipment FailureThe use of more than one splitter as a branching

Planning and Designing RIO Cable System890 USE 101 00 October 2006 31Illegal Coaxial Cable TopologiesOverview The following are several examples of co

Planning and Designing RIO Cable System32890 USE 101 00 October 2006Open Taps If a tap is inserted on the trunk for future use and does not currently

Planning and Designing RIO Cable System890 USE 101 00 October 2006 33Illegal Drop Cable ConnectionsBranching is not permitted on a coaxial drop cable:

Planning and Designing RIO Cable System34890 USE 101 00 October 2006Using Fiber Optics in an RIO SystemOverview 490NRP954 Fiber Optic Repeaters can be

Planning and Designing RIO Cable System890 USE 101 00 October 2006 35Point-to-point Topology with Fiber OpticsThe following illustration shows two seg

Planning and Designing RIO Cable System36890 USE 101 00 October 2006Bus Topology with Fiber OpticsAdditional fiber optic repeaters can be chained toge

Planning and Designing RIO Cable System890 USE 101 00 October 2006 37Tree Topologies with Fiber OpticsTree topologies, which cannot be established wit

Planning and Designing RIO Cable System38890 USE 101 00 October 2006Self-healing Ring Fiber Optic TopologyThe 490NRP954 Fiber Optic Repeaters have spe

Planning and Designing RIO Cable System890 USE 101 00 October 2006 39Note: No sense bit is sent in a self-healing ring topology, and fault detection c

4RG-11 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Semirigid Cable . . . . . . . .

Planning and Designing RIO Cable System40890 USE 101 00 October 2006RIO System DesignOverview When designing an RIO cable system, consider:z whether y

Planning and Designing RIO Cable System890 USE 101 00 October 2006 41Planning for System ExpansionThe potential for system expansion should be conside

Planning and Designing RIO Cable System42890 USE 101 00 October 2006Choosing Coaxial Cables for an RIO NetworkOverview Your choice of cables for an RI

Planning and Designing RIO Cable System890 USE 101 00 October 2006 43Flexible Cable Two types of flexible cable can be used in Modicon RIO cable syste

Planning and Designing RIO Cable System44890 USE 101 00 October 2006Coaxial Cable CharacteristicsCable Bend RadiusAll cables have a minimum allowable

Planning and Designing RIO Cable System890 USE 101 00 October 2006 45Electrical Characteristics of Coaxial Media ComponentsOverview The following elec

Planning and Designing RIO Cable System46890 USE 101 00 October 2006Return Loss Return loss is the measurement of reflected signal strength due to imp

Planning and Designing RIO Cable System890 USE 101 00 October 2006 47EMI/RFI Considerations in a Coaxial Cable Routing PlanOverview Electromagnetic in

Planning and Designing RIO Cable System48890 USE 101 00 October 2006Tap Connections and LocationsOverview Each tap has three ports—a trunk-in port, a

Planning and Designing RIO Cable System890 USE 101 00 October 2006 49Optional Tap Enclosure ConsiderationsAlthough not required for overall network in

5Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141At a Glance . . . . . . . . . . . . . . . .

Planning and Designing RIO Cable System50890 USE 101 00 October 2006Grounding and Surge SuppressionOverview Choose a low impedance earth ground for yo

Planning and Designing RIO Cable System890 USE 101 00 October 2006 51Terminating a Coaxial Cable SystemOverview Ideally, all connections on the RIO ne

Planning and Designing RIO Cable System52890 USE 101 00 October 2006Designing a Coaxial Cable System to an Attenuation LimitOverview Attenuation happe

Planning and Designing RIO Cable System890 USE 101 00 October 2006 53Calculating Maximum System AttenuationTo calculate maximum attenuation, add all s

Planning and Designing RIO Cable System54890 USE 101 00 October 2006Calculating Attenuation on a Coaxial Network—An ExampleHere is a sample calculatio

Planning and Designing RIO Cable System890 USE 101 00 October 2006 55Each drop cable is run from a Modicon MA-0185-100 tap in the trunk cable. Four of

Planning and Designing RIO Cable System56890 USE 101 00 October 2006Attenuation Considerations in an Optical PathOverview Attenuation that occurs on a

Planning and Designing RIO Cable System890 USE 101 00 October 2006 57Example—Attenuation on a Simple Optical LinkHere is an example of a point-to-poin

Planning and Designing RIO Cable System58890 USE 101 00 October 2006Maximum Number of Repeaters and Jitter ConsiderationsOverview Due to the cumulativ

Planning and Designing RIO Cable System890 USE 101 00 October 2006 59Connecting More than Five DropsThe accompanying illustration shows how six RIO dr

6This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.com

Planning and Designing RIO Cable System60890 USE 101 00 October 2006Drop 7= Coaxial CableP/S CPU CRPLocal DropCoaxDrop 2 Drop 3 Drop 4 Drop 5 Drop 6NR

Planning and Designing RIO Cable System890 USE 101 00 October 2006 61Planning RIO DropsOverview The maximum length for Modicon’s recommended drop cabl

Planning and Designing RIO Cable System62890 USE 101 00 October 2006Problems related to dynamic range can be difficult to find, and can vary from day

Planning and Designing RIO Cable System890 USE 101 00 October 2006 63 Misc. Connector ManufacturerModel #:Quantity Needed:Misc. Connector Manufacturer

Planning and Designing RIO Cable System64890 USE 101 00 October 2006 Drop Loss (dB):Quantity Needed:Tap Port Terminator Manufacturer:Model #:Quantity

Planning and Designing RIO Cable System890 USE 101 00 October 2006 65Trunk Cable LengthTap Number Trunk length (from head) Trunk Length (from last tap

Planning and Designing RIO Cable System66890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr

890 USE 101 00 October 2006 673RIO Network Hardware ComponentsAt a GlanceOverview This chapter provides information on RIO network hardware components

RIO Network Hardware Components68890 USE 101 00 October 2006RG-6 CableOverview The following table shows specifications for the Modicon 97-5750-000 RG

RIO Network Hardware Components890 USE 101 00 October 2006 69RG-11 CableOverview The following table shows the specifications for the Modicon 97-5951-

890 USE 101 00 October 2006 7§Safety InformationImportant InformationNOTICE Read these instructions carefully, and look at the equipment to become fam

RIO Network Hardware Components70890 USE 101 00 October 2006Semirigid CableOverview The following tables show the specifications for recommended semir

RIO Network Hardware Components890 USE 101 00 October 2006 71Selecting Fiber Optic CableOverview If you are using 490NRP954 Fiber Optic Repeaters in y

RIO Network Hardware Components72890 USE 101 00 October 2006Hardware OverviewOverview This section provides detailed information about the requirement

RIO Network Hardware Components890 USE 101 00 October 2006 73RIO Coaxial Cable System Hardware ComponentsThe following table shows the RIO coaxial cab

RIO Network Hardware Components74890 USE 101 00 October 2006Tap SpecificationsOverview Modicon MA-0185-100 Taps connect the drop cables to the main tr

RIO Network Hardware Components890 USE 101 00 October 2006 75The following table shows the specifications for the MA-0185-100 Tap.MA-0185-100 Tap Spec

RIO Network Hardware Components76890 USE 101 00 October 2006Splitter SpecificationsOverview The Modicon MA-0186-100 Splitter is used as a signal combi

RIO Network Hardware Components890 USE 101 00 October 2006 77Interconnections F connector, torque 90 in./lb maxF connector, torque 90 in./lb maxNote:

RIO Network Hardware Components78890 USE 101 00 October 2006F Connectors for Coaxial CablesOverview Flexible cables (RG-6 and RG-11) use F connectors

RIO Network Hardware Components890 USE 101 00 October 2006 79F Connectors for Semirigid CableThe following F connectors are suggested for use with Com

Safety Information8890 USE 101 00 October 2006PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualifi

RIO Network Hardware Components80890 USE 101 00 October 2006F Adapters for Semirigid CableOverview A Modicon 52-0480-000 Right Angle F Adapter is usua

RIO Network Hardware Components890 USE 101 00 October 2006 81BNC Connectors and AdaptersOverview Some drop cables may require a BNC connector to conne

RIO Network Hardware Components82890 USE 101 00 October 2006F-to-BNC Adapters for RG-11 CableThere is no approved BNC connector for RG-11 cable. Where

RIO Network Hardware Components890 USE 101 00 October 2006 83Network TerminatorsOverview All terminators used on the RIO network must have a power han

RIO Network Hardware Components84890 USE 101 00 October 2006BNC In-line TerminatorsA Modicon 60-0513-000 BNC In-line Terminator is used to terminate t

RIO Network Hardware Components890 USE 101 00 October 2006 85Self-terminating F Adapter OptionsSelf-terminating F Adapters for RG-6 Hot Standby System

RIO Network Hardware Components86890 USE 101 00 October 2006Ground BlocksOverview A cable system must be grounded at all times to assure safety and pr

RIO Network Hardware Components890 USE 101 00 October 2006 87Ground blocks have a low insertion loss, and they usually are not figured into the attenu

RIO Network Hardware Components88890 USE 101 00 October 2006Surge SuppressorsOverview Surge protection is available for coaxial network trunks that sp

RIO Network Hardware Components890 USE 101 00 October 2006 89The following diagram shows the surge suppresor. 1/4” Mounting Hole6.4 mmIsolatedPortMar

890 USE 101 00 October 2006 9About the BookAt a GlanceDocument Scope This manual is intended for the design engineer, cable system installer and netwo

RIO Network Hardware Components90890 USE 101 00 October 2006Fiber Optic RepeaterOverview The 490NRP954 Fiber Optic Repeater provides communication bet

RIO Network Hardware Components890 USE 101 00 October 2006 91Related DocumentationSee the Modicon Fiber Optic Repeaters User’s Guide, part number GM-F

RIO Network Hardware Components92890 USE 101 00 October 2006In a point-to-point optical connection, one repeater is always the head and the other is a

RIO Network Hardware Components890 USE 101 00 October 2006 93Recommended Materials for Fiber Optic LinksOverview Modicon does not manufacture fiber op

RIO Network Hardware Components94890 USE 101 00 October 2006This document provided by Barr-Thorp Electric Co., Inc. 800-473-9123 www.barr-thorp.c

890 USE 101 00 October 2006 954Installing an RIO NetworkAt a GlanceOverview This chapter provides information on installing an RIO network.What's

Installing an RIO Network96890 USE 101 00 October 2006Installation OverviewOverview This chapter presents cable preparation and installation procedure

Installing an RIO Network890 USE 101 00 October 2006 97RG-6 Cable ConnectionsOverview Connectors available for RG-6 cable are:Installation Tools Tools

Installing an RIO Network98890 USE 101 00 October 2006RG-6 Cable Installation ToolRG-6 Cable Installation ToolA Modicon 490RIO00400 RG-6 Installation

Installing an RIO Network890 USE 101 00 October 2006 99The Modicon 043509432 Crimp Tool is used to install BNC connectors onto RG-6 cable. The tool ma