EXTER™ T100

Installation manual
MAEN774C, 2008-05 English
 Foreword

Installation manual for the EXTER series operator panels

Foreword
The EXTER operator panel is developed to satisfy the demands of human-machine
communication. Built-in functions such as displaying and controlling text, dynamic
indication, time channels, alarm and recipe handling are included.

The operator panel work, for the most part, in an object-oriented way, making it easy
to understand and use. The configuration operation of the panel is made in a person-
al computer, using the configuration tool Information Designer. The project is then
transferred and stored in the operator panel.

The operator panel can be connected to many types of automation equipment, such
as PLCs, servos or drives. In this manual the expression “the controller“ is used as a
general term for the connected equipment.

This manual explains how to install the operator panel. Please refer to the reference
manual for further information.

© Beijer Electronics AB, MAEN774C, 2008-05

The information in this document is subject to change without notice and is provided as available at the time
of printing. Beijer Electronics AB reserves the right to change any information without updating this
publication. Beijer Electronics AB assumes no responsibility for any errors that may appear in this document.
Read the entire installation manual prior to installing and using this equipment.
Only qualified personnel may install, operate or repair this equipment. Beijer Electronics AB is not responsible
for modified, altered or renovated equipment.
Because the equipment has a wide range of applications, users must acquire the appropriate knowledge to use
the equipment properly in their specific applications.
Persons responsible for the application and the equipment must themselves ensure that each application is in
compliance with all relevant requirements, standards and legislation in respect to configuration and safety.
Only parts and accessories manufactured according to specifications set by Beijer Electronics AB may be used.
BEIJER ELECTRONICS AB SHALL NOT BE LIABLE TO ANYONE FOR ANY DIRECT, INDIRECT,
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE
INSTALLATION, USE OR REPAIR OF THIS EQUIPMENT, WHETHER ARISING IN TORT,
CONTRACT, OR OTHERWISE. BUYER'S SOLE REMEDY SHALL BE THE REPAIR,
REPLACEMENT, OR REFUND OF PURCHASE PRICE, AND THE CHOICE OF THE APPLICABLE
REMEDY SHALL BE AT THE SOLE DISCRETION OF BEIJER ELECTRONICS AB.

Beijer Electronics, MAEN774C

 Table of Contents

Table of Contents
1 Safety Precautions................................................................................. 5
1.1 UL and cUL Installation ................................................................... 5
1.2 General ............................................................................................. 6
1.3 During Installation............................................................................ 6
1.4 During Use ....................................................................................... 7
1.5 Service and Maintenance................................................................... 7
1.6 Dismantling and Scrapping............................................................... 7
2 Installation ........................................................................................... 9
2.1 Space Requirements .......................................................................... 9
2.2 Installation Process............................................................................ 9
2.2.1 Mode Switches ................................................................................................ 11
2.2.2 Connections to the Controller ......................................................................... 11
2.2.3 Other Connections and Peripherals ................................................................. 11
3 Technical Data ................................................................................... 13
4 Chemical Resistance ........................................................................... 15
4.1 Metal Casing................................................................................... 15
4.2 Touch Screen and Overlay .............................................................. 15
4.2.1 Autotex F157/F207 ......................................................................................... 15
4.2.2 Touch Screen Surface ...................................................................................... 16
4.2.3 Autoflex EB ..................................................................................................... 16
5 Operator Panel Drawings ................................................................... 17
5.1 Communication Ports..................................................................... 17
5.2 EXTER T100 Outline .................................................................... 18
6 Additional Installation Tips................................................................ 19
6.1 Grounding the Operator Panel ....................................................... 19
6.2 Ethernet Connection in the Panel ................................................... 20
6.3 To Achieve Better EMC Protection ................................................ 21
6.4 Ambient Temperature..................................................................... 22
6.5 Safety .............................................................................................. 23
6.6 Galvanic Isolation ........................................................................... 24
6.7 Cable and Bus Termination RS485................................................. 25

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Table of Contents

Beijer Electronics, MAEN774C

 Safety Precautions

1 Safety Precautions
Both the installer and the owner and/or operator of the operator panel must read and
understand this installation manual.

1.1 UL and cUL Installation

– This equipment is suitable for use in Class I, Division 2, Groups A, B, C and D
OR non-hazardous locations only. [Combinations of equipment in your system
are subject to investigation by the local Authority Having Jurisdiction at the time
of installation.]
– Maximum ambient temperature 40 °C when mounted horizontal or 50 °C when
mounted vertical.
– WARNING – EXPLOSION HAZARD – Do not disconnect equipment unless
power has been removed or the area is known to be non-hazardous.
– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – AVANT DE
DECONNECTER L’EQUIPEMENT, COUPER LE COURANT OU
S’ASSURER QUE L‘EMPLACEMENT EST DESIGNE NON DANGEREUX.
– WARNING – EXPLOSION HAZARD - Substitution of components may
impair suitability for Class I, Division 2.
– For Canada also AVERTISSEMENT – RISQUE D’EXPLOSION – LA
SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATERIEL
INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I,
DIVISION 2.
– WARNING – EXPLOSION HAZARD – only UL and cUL approved expansion
units are allowed to be connected to the port designated “EXPANSION”. At the
moment there are no such units evaluated or allowed.
– WARNING – EXPLOSION HAZARD - Do not replace expansion unit unless
power has been switched off or the area is known to be non-hazardous.
– This product contains battery, this must only be changed in an area known to be
non-hazardous. Permitted types are shown in the section Technical Data.
– For use on a flat surface of a type 4X enclosure indoor use only.
– To make wiring connections to the power supply connector, use an AWG 28-12
cable and a tightening torque of min. 0.5 Nm.

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 Safety Precautions

1.2 General
– Read the safety precautions carefully.
– Check the delivery for transportation damage. If damage is found, notify the
supplier as soon as possible.
– Do not use the operator panel in an environment with high explosive hazards.
– The supplier is not responsible for modified, altered or reconstructed equipment.
– Use only parts and accessories manufactured according to specifications of the
supplier.
– Read the installation and operating instructions carefully before installing, using
or repairing the operator panel.
– Never allow fluids, metal filings or wiring debris to enter any openings in the
operator panel. This may cause fire or electrical shock.
– Only qualified personnel may operate the operator panel.
– Storing the operator panel where the temperature is lower/higher than
recommended in this manual can cause the LCD display liquid to congeal/become
isotopic.
– The LCD display liquid contains a powerful irritant. In case of skin contact, wash
immediately with plenty of water. In case of eye contact, hold the eye open, flush
with plenty of water and get medical attention.
– The figures in this manual serves an illustrative purpose. Because of the many
variables associated with any particular installation, the supplier cannot assume
responsibility for actual use based on the figures.
– The supplier neither guarantees that the operator panel is suitable for your
particular application, nor assumes responsibility for your product design,
installation or operation.

1.3 During Installation

– The operator panel is designed for stationary installation on a plane surface, where
the following conditions are fulfilled:
• no high explosive risks
• no strong magnetic fields
• no direct sunlight
• no large, sudden temperature changes
– Install the product according to the accompanying installation instructions.
– Ground the product according to the accompanying installation instructions.
– Only qualified personnel may install the operator panel.
– Separate the high voltage, signal and supply cables.
– Make sure that the voltage and polarity of the power source is correct before
connecting the product to the power outlet.
– Peripheral equipment must be appropriate for the application and location.

6 Beijer Electronics, MAEN774C

 Safety Precautions

1.4 During Use

– Keep the operator panel clean.
– Emergency stop and other safety functions may not be controlled from the
operator panel.
– Do not use too much force or sharp objects when touching the keys, touch screen
etc.

1.5 Service and Maintenance

– Only qualified personnel should carry out repairs.
– The agreed warranty applies.
– Before carrying out any cleaning or maintenance operations, disconnect the
equipment from the electrical supply.
– Clean the display and surrounding front cover with a soft cloth and mild
detergent.
– Replacing the battery incorrectly may result in explosion. Only use batteries
recommended by the supplier.

1.6 Dismantling and Scrapping

– The operator panel or parts thereof shall be recycled according to local regulations.
– The following components contain substances that might be hazardous to health
and the environment: lithium battery, electrolytic capacitor and display.

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 Safety Precautions

8 Beijer Electronics, MAEN774C

 Installation

2 Installation
2.1 Space Requirements
– Installation plate thickness: 1.5 - 9.0 mm (0.06 - 0.35 inch)
– Space requirements when installing the operator panel:

100 mm
(4.0 inch)

228 mm
(8.98 inch)
100 mm
(4.0 inch)
50 mm 50 mm
(2.0 inch) (2.0 inch)

100 mm
(4.0 inch)
58 mm
(2.28 inch)
302 mm
(11.89 inch)

Caution
The openings on the enclosure are for air convection. Do not cover these
openings.

2.2 Installation Process

1. Unpack and check the delivery. If damage is found, notify the supplier.

Panel cut out 264.5 x 206.0 mm

(10.41 x 8.11 inch)

x 13

Note:
Place the operator panel on a stable surface during installation.
Dropping it or letting it fall may cause damage.

2. Place the panel cut out where the operator panel is to be situated, draw along the
outer sides of the holes and cut according to the markings.

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 Installation

3. Secure the operator panel in position, using all the fastening holes and the
provided brackets and screws:

x 13

0.5 - 1.0 Nm

4. Connect the cables in the specified order.

A Caution
Ensure that the operator panel and the controller system have the
same electrical grounding (reference voltage level), otherwise errors
in communication may occur.

B Use an M5 screw and a grounding conductor (as short as possible)

with a cross-section of minimum 2.5 mm2.
C
Caution
- Use only shielded communication cables.
- Separate high voltage cables from signal and supply cables.

D Caution
- The operator panel must be brought to ambient temperature
before it is started up. If condensation forms, ensure that the
operator panel is dry before connecting it to the power outlet.
- Ensure that the voltage and polarity of the power source is correct.

Power

Controller
CF CARD

B
1

RS422/RS485 24V DC
RS232 24V DC
C

Ethernet

5. Carefully remove the laminated film over the operator panel display, to avoid
static electricity that could damage the panel.

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 Installation

2.2.1 Mode Switches

All mode switches must be in OFF position during operator panel use.
The mode switches should not be touched unless by qualified personell.

MODE
1 2 3 4

ON DIP

EXPANSION
MODE
1 2 3 4

ON DIP
CF CARD
BUSY

24V DC
RS485
RS422
COM 1

10/100

RS232
COM 2

1
2.2.2 Connections to the Controller
For information about the cables to be used when connecting the operator panel to
the controller, please refer to the help file for the driver in question.

2.2.3 Other Connections and Peripherals

– Cables, peripheral equipment and accessories must be suitable for the application
and its environment. For further details or recommendations, please refer to the
supplier.

Caution
When using a compact flash card, do not remove the card when the busy
indicator is illuminated.

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 Installation

12 Beijer Electronics, MAEN774C

 Technical Data

3 Technical Data
Parameter EXTER T100
Front panel, W x H x D 302 x 228 x 6 mm
Mounting depth 58 mm (158 mm including clearance)
Front panel seal IP 66
Rear panel seal IP 20
Keyboard material/ Touch screen: Polyester on glass, 1 million finger touch
Front panel operations. Overlay: Autotex F157 or F207 *.
Reverse side material Powder-coated aluminum
Weight 2.1 kg
Serial port RS422/ 25-pin D-sub contact, chassis-mounted female with
RS485 standard locking screws 4-40 UNC.
Serial port RS232C 9-pin D-sub contact, male with standard locking screws 4-40
UNC.
Ethernet Shielded RJ 45
USB Host type A (USB 1.1), max output current 500mA
Device type B (USB 1.1)
CF-slot Compact flash, type I and II
Flash memory for 12 MB (incl. fonts)
application
Real time clock ±20 PPM + error because of ambient temperature and supply
voltage. Total maximum error: 1 min/month at 25 °C
Temperature coefficient: 0.004 ppm/°C2
Real time clock CR2450 (UL and cUL: Sanyo or Panasonic)
battery Minimum lifetime: 3 years
Power consumption at Normal: 0.5 A
rated voltage Maximum: 1.0 A
Display TFT-LCD. 800 x 600 pixels, 64K color.
CCFL backlight lifetime at the ambient temperature of
+25 °C: >50,000 h.
Active area of display, 211.2 x 158.4 mm
WxH
Fuse Internal DC fuse, 3.15 AT, 5 x 20 mm
Power supply +24V DC (20 - 30V DC). Power supply connector.
CE: The power supply must conform with the requirements
according to IEC 60950 and IEC 61558-2-4.
UL and cUL: The power supply must conform with the
requirements for class II power supplies.
Ambient temperature Vertical installation: 0 ° to +50 °C
Horizontal installation: 0 ° to +40 °C
Storage temperature -20 ° to +70 °C
Relative humidity 5 - 85 % non-condensed
CE approvals Noise tested according to EN61000-6-4 emission and
EN61000-6-2 immunity.
UL, cUL approvals UL 1604 Class I, Div 2 / UL 508 / UL 50 4x indoor use only
(when procuct or
packing is marked)
DNV Yes
NEMA 4x indoor use only
* See section Chemical Resistance for more information.

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 Technical Data

14 Beijer Electronics, MAEN774C

 Chemical Resistance

4 Chemical Resistance
4.1 Metal Casing
The frame and casing material is powder-coated aluminum. This powder paint
withstands exposure to the following chemicals without visible change:
Acetic acid 10% Phosphoric acid 4%
Citric acid 10% Phosphoric acid 10%
Diesel Sea water
Distilled water Sodium chloride 2%
Edible oil Sodium chloride 20%
Fuel oil Sulphuric acid 20%
Hydrogen peroxide 3% Tap water

The powder paint shows limited resitance to the following chemicals at room
temperature:

Butanol Nitric acid 3%

Hydrochloric acid 5% Nitric acid 10%
Isopropyl alcohol Phosphoric acid 43%
Na-hypochlorite 10% Turpentine

Note:
If exposure to any of the above chemicals is demanded, it is recommended to first test
the chemical on an “invisble” spot of the metal casing.

The powder paint shows little or no resistance to the following chemicals at room
temperature:

Acetic acid, conc. Methyl-ethyl ketone Toluene

Acetone Nitric acid 30% Trichlorethylene
Ammonia 5% Phenol Xylene
Ammonia, conc. Sodium hydroxide 5% 97 octan unleaded petrol
Ethyl acetate Sodium hydroxide 30% 98 octan leaded petrol

4.2 Touch Screen and Overlay

4.2.1 Autotex F157/F207
Autotex F157 or F207 covers the overlay surrounding the touch screen.

Solvent Resistance
Autotex F157/F207 withstands exposure of more than 24 hours duration under DIN
42 115 Part 2 to the following chemicals without visible change:
Acetonitrile Diesel Downey / Lenor1 Phosphoric acid (<30%)
Ajax / Vim in solution Ethanol Potassium ferricyanide
Alkalicarbonate solution1 Glycerine Potassium hydroxide (<30%)

Ammonia (<40%)1 Glycol Pure Turpentine

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 Chemical Resistance

Acetic acid (<50%) Gumption1 SBP 60/951

Ariel powder in solution1 Hydrochloric acid (<36%) Sulfuric acid (<10%)

Bleach 1 Linseed oil Tomato ketchup

Castor oil Methanol Trichloroacetic acid (<50%)
Caustic soda (<40%) 1 Nitric acid (<10%) White Spirit
Cutting oil Paraffin oil Windex1
Cyclohexanol Persil powder in solution1 Wisk
Diacetone alcohol Petroleum spirit1 -
1
Extremely faint glossing of the texture was noted.

Autotex withstands DIN 42 115 Part 2 exposure of up to 1 hour duration to glacial

acetic acid without visible change.
Autotex is not resistant to high pressure steam at over 100 °C or the following
chemicals:
Concentrated mineral acids Benzyl alcohol
Concentrated caustic solution Methylene chloride

Outdoor Use
In common with all polyester based films Autotex F157/F207 is not suitable for use
in conditions of long term exposure to direct sunlight.

4.2.2 Touch Screen Surface

The touch screen surface on the panel withstands exposure to the following solvents
without visible change:

Solvents Time
Acetone 10 minutes
Isopropanol 10 minutes
Toluene 5 hours

4.2.3 Autoflex EB
It is recommended to use the Autoflex EB touch display protection film, that can be
ordered from Beijer Electronics.

Solvent Resistance
Autoflex EB withstands exposure to the same chemicals as Autotex F157 or F207
according to section Autotex F157/F207.

Outdoor Use
In common with all polyester based films Autoflex EB is not suitable for use in
conditions of long term exposure to direct sunlight.

16 Beijer Electronics, MAEN774C

 Operator Panel Drawings

5 Operator Panel Drawings

5.1 Communication Ports

RS-232

RS-422 RS-485
RS-422/485

USB

Ethernet

Drawing No. S-5005, Date 2004-10-27

Beijer Electronics, MAEN774C 17

 Operator Panel Drawings

5.2 EXTER T100 Outline

Drawing No. S-5113, Date 2004-10-26

18 Beijer Electronics, MAEN774C

 Additional Installation Tips

6 Additional Installation Tips

When experiencing communication problems in for example noisy environments or
when operating close to temperature limits, the following recommendations are to be
noticed.

6.1 Grounding the Operator Panel

Door Mounting plate in the cabinet

Operator panel 3

Power supply
1

24 V DC
5
Ferrite core

1. The operator panel’s mounting clamps do not provide a secure grounding con-
nection between the panel and the device cabinet.
2. Connect a 2.5 mm2 wire between the operator panel’s quick-connect plinth and
the panel chassis.
3. Connect a 6 or 4 mm2 wire or grounding braid between the panel’s chassis and
the closest grounding point on the door.
4. Connect a strong but short grounding braid between the door and the device
cabinet.
5. Twist the cables onto the 24 V DC feed.
6. A ferrite core suppresses disturbances to the 24 V feed.
2 turns around the ferrite core provide 4 times the suppression of 1 turn.
3 turns around the ferrite core provide 9 times the suppression of 1 turn.

Remember:
The grounding wires should be short and the conductor should have a large area.
A long, thin grounding wire has a very high impedance (resistance) at high frequencies
and will not guide disturbances to the ground.
Multi-wire conductors are better than single wire conductors with the same area.
A braided conductor wire with the same area is even better.
The best is a short, thick grounding braid.

Beijer Electronics, MAEN774C 19

 Additional Installation Tips

6.2 Ethernet Connection in the Panel

Industrial Ethernet
RJ45

RJ45
1
RJ45

RJ45

Operator panel
RJ45
2

3 Operator panel
RJ45

4 Short and
Shielded 1-1
unshielded Operator panel
2-2
3-3
RJ45
8-8

Operator panel
5
RJ45
0.1 uF
250 V
5351

1. In some industrial units for Ethernet, the RJ45 contact’s shield is connected to
the chassis via a capacitor.
2. The operator panel’s Ethernet shield is directly connected to the chassis.
Check whether the other Ethernet unit has its shield directly grounded or grounded
via a capacitor.
In many cases, connecting the shielded Ethernet cabling to the chassis at both ends
is inappropriate. Hum or grounding loops can occur. Unshielded cabling may even
result in fewer communication errors.
A good solution may be to use a shielded Ethernet cable, but to connect the shield at
one end only.
3. One option is to break the shield.
4. A more elegant method is to expand the shielded Ethernet cabling with a piece
of unshielded Ethernet cable.
5. You can ground the shield via an external 0.1 uF/250 V plastic capacitor. This
will connect the HF transients to the ground.

20 Beijer Electronics, MAEN774C

 Additional Installation Tips

6.3 To Achieve Better EMC Protection

– Initially, use the original cabling from Beijer Electronics primarily.
– Use shielded cables for RS232 communication.
– Use twisted pair and shielded cabling for RS422 and RS485.
– Use the cabling intended for the bus type; Ethernet, Profibus, CC-Link, CAN,
Device Net etc.
– Install and connect according to applicable specifications for the relevant bus stan-
dard.
– Use shielded cabling for Ethernet, preferably with foil + braided shield.
– D-sub covers should be shielded, and the shield should be connected to the cover
360 ° where the cable comes in.
– Connect the shield at both ends.
Shielded cable

0.1 uF/250 V

Ground plane 1 Ground plane 2

Not same potential

5352

Ground plate Ground plate

in another building
With longer distances, there is a risk that the ground potential may be different. In
that case, the shield should only be connected at one end. A good alternative is to
connect the other end of the shield to the ground via a 0.1 uF/250 V plastic capacitor.
Both ends are then connected to the ground in terms of HF, but only connected to
the ground at one end in terms of LF, thus avoiding the 50 Hz grounding loops.
Metal cabinet Metal cabinet
Terminal or Terminal or
connector connector
Short distance

Cable clamp
in steel

EMC cable gland Plastic cable gland

Shielded cable Shielded cable 5353

– Use an EMC cable gland or regular plastic cable gland, remove the outer jacket
and connect the shield to the installation plate with a 360 ° metal cable clamp.
– Place the 24 V DC and communications cabling in one cable trunk/cable duct and
230/380 V AC in another. If the cables need to be crossed, cross them at 90 ° only.
Avoid combining the cabling for stronger 24 V DC outputs with the communi-
cation cabling.
– Ferrite cores that are snapped onto the shielded cabling may remove minor distur-
bances. Large ferrite pieces that are snapped onto unshielded cabling and where
the wires go 2-4 times around the cores are approximately 5-25 times more effi-
cient.

Beijer Electronics, MAEN774C 21

 Additional Installation Tips

6.4 Ambient Temperature

The maximum ambient temperature for the operator panel is provided in the
specifications. The ambient temperature refers to the temperature in the device
cabinet which cools the panel’s electronics.

Top
50° inside
Operator
panel Power

Power
Axial fan
120x120 mm
30°C outside Middle
45° inside
Airflow

Power

Bottom
40° inside
5354

In most cases, the ambient temperature for the operator panel is significantly higher
than the device cabinet’s ambient temperature.
If the cabinet is tall and there are a number of heat-generating devices, the
temperature at the top of the cabinet will be considerably higher than the theoretical
temperature increase that would be expected. All electronics are sensitive to heat. The
lifespan of an electrolytic capacitor is cut in half with an 8-10 ° increase in
temperature. A 15-20 ° temperature increase results in a quarter of the lifespan etc.
Rittal has a good program for estimating the anticipated average temperature in the
cabinet as well as a large program for controlling the temperature in the device
cabinet.
An enamel-coated steel cabinet has a radiant heat value of 5.5 W/m2 and degrees C.
Installing a fan inside the cabinet will even out the temperature, while moving air
provides considerably better cooling than still air. A suitable fan is a 120 x 120 mm
axial fan, available in 24 V DC, 115 and 230 V AC.
Install the fan so that it sits in the cooler area and will blow cold air against the
operator panel. If the fan is mounted at the top and sucks air upwards, the fan’s
ambient temperature will be higher = shorter lifespan.
A good fan with a ball-bearing mounting has an expected lifespan of at least 40,000
hours (not a guaranteed lifespan) at 40 °C. This corresponds to at least 4 years of
continuous use. If a thermostat is installed, the fan only needs to come on when
needed.
Large graphic terminals draw only one fifth of the current when the background
lighting is off. The loss effect drops from e.g. 25 W to only 5 W.
The operator panel’s loss effect = supply voltage x current. Virtually no power goes
to external users and no loss effects due to inputs.

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 Additional Installation Tips

6.5 Safety
Most of the operator panels are fed with 24 V DC.
Power supply
230 V AC to 24 V DC
Operator panel
+24 V

1 0V

4
Power supply
230 V AC to 24 V DC
+24 V Operator panel

2 0V

Distance?

Power supply
230 V AC to 24 V DC
+24 V Operator panel

3 0V

4
Small controller with expansion unit
COM1 Ch0

Ch1

COM100 Ch100
230 V AC
Ch101

5355

1. If you use a power supply that meets safety standards and only feeds the operator
panel, there is no problem.
2. However, if you have a 24 V unit that also feeds other units, there is reason to be
cautious.
The operator panel does not have insulation that meets safety requirements in
the event of a potential short circuit between 230 V AC and 24 V DC. It is
assumed that the 24 V feed is secure, for example, SELV according to
EN 60950 (protection against electric shock) and UL 950.

Example:
Here is an example that explains why a secure 24 V DC feed can be ruined by mixing 24
V relay contacts with 230 V AC relay contacts in a smaller controller. Check that the
“clearances and creepage distances between 24 V DC and 230 V AC fulfill EN 60950 or
UL 950”. If not, input a separate 24 V unit into the operator panel.

3. If there is a substantial distance between the relay contacts for 24 V DC and

230 V AC, it is OK to use the same 24 V devices for all feeds.
4. Connect 0 V on the 24 V feed to the ground. This offers three advantages:
–Safety is increased. The 24 V feed will not be live in the event of a faulty connec-
tion or short circuit between 0 V (24 V) and 230 V phase.
–Transients on the 24 V feed are connected to the ground.
–No risk that the 24 V feed is at a high level in relationship to the ground. This is
not unusual since there is high static electricity.

Beijer Electronics, MAEN774C 23

 Additional Installation Tips

6.6 Galvanic Isolation

Internal electronic
Ethernet
DC/DC
Filter galvanic isolation
DC/AC
VCC CFL
+24 V DC
0 V (GND)
0V

1.5 m

RS422/485 RS232 USB USB 5356

The operator panel has galvanic isolation against the 24 V DC feed but no galvanic
isolation between the communication ports for RS232, RS422/485 and USB. Only
the Ethernet connection has galvanic isolation.
Operator panel Modular controller Printer
Power CPU COM COM2
*
RS422 RS232 USB * * *
* *
*
PC PC
Not same ground potential
* *
5357
* = Internal 0 V (GND) connection

When a PC is connected to the panel, the panel’s internal 0 V (GND) will be

connected to the protective ground via the PC.
A number of USB devices can have the shield connected together with the protective
ground. Here, the panel’s 0 V (GND) is connected to the protective ground when,
for example, a USB memory stick, keyboard or similar device is plugged in.
If a number of units are connected that have a 0 V and a ground connection, and
these are connected to various grounding points, there is a substantial risk of
problems. Grounding currents go through communication cables, the rear plate of
the controller, and internally in the operator panel, and can cause errors.
Use external units to improve communication and achieve galvanic isolation.
Westermo has good industry-standard insulators that are also insulated from the 24
V DC feed.

Note:
It is very important to make sure that the 24 V feed in the external insulation unit is
not connected to one of the communication outlets. If it does not have 100% insulation
against the 24 V feed, disturbances and grounding currents from the 0 V on the 24 V
side will disrupt communication.
Using this type of unit solves one problem but creates a larger problem!
A substandard installation may work now, but problems may arise when other devices
are connected.

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 Additional Installation Tips

6.7 Cable and Bus Termination RS485

– Use shielded and twisted pair cable.
The pair capacitance may not exceed 52.5 pF/m and area at least 0.25 mm2 (AWG
24), if you want to use the maximum transfer distance and maximum transfer
speed.
– 0 V, the reference voltage for communication should be included in the cabling.
With two-way communication use two pairs; one pair for communication and
one pair for 0 V.
– The shield must be grounded at one end. The other end is usually grounded, but
with longer distances or when there is a difference in the ground potential, the
shield should be connected to the ground via 0.1 uF/250 V plastic capacitor to
prevent ground current in the braided shield.
A number of manufacturers recommend that the shield be grounded at each node.
Various manufacturers have different systems for bus termination. The RS485
standard does not describe how the “Fail Safe” function would be carried out, just
that the system should be able to handle the error.
Depending on the recipients’ design, the bus wires may be on the same level or
require pull-up or pull-down to ensure that no faulty signals are detected when the
bus is in resting mode (all transmitters are disconnected).
Inside operator panel
+5 V

+5 V
1 2 3 1K
1K

120 ohm 120 ohm

1K
0V 1K
(120 ohm)

0V
0V

4 CAB8
Operator CAB8 Bus
panel RS485
RS422

0V
0V

VCC Shield
1K
+5 V VCC 2.65 V
120 ohm
0V 2.35 V Bus termination
0V 1K

5358

1. Some (older) operator panels had pull-up and pull-down resistance except for
the actual bus termination at 120 ohm, similar to Westermo and Profibus.
2. Newer panels have another type of recipient, so-called built-in “Fail Safe”, where
simple bus termination resistance is sufficient.
If other nodes on the RS485 network require pull-up and pull-down and the
operator panel is at one end of the loop, one of the following procedures can be
carried out:
3. Connect two 1k/0.25 W resistors in the 25-pole D-sub contact. Set jumper pins
6-19.
4. Use CAB8. It offers the option of bus termination with pull-up/-down. It is also
easy to connect the bus cable via the screw terminal block.

Beijer Electronics, MAEN774C 25

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