maxDNA

TRAINING COURSE

Introduction to System Architecture

maxDNA - Power Supplies

The power supplies commonly supplied in each RPU are :
System power supply
Field transmitter power supply
Logic (field contact wetting) power supply.

System 24V

System 24V

I/O Bus
Connector

I/O Bus
Connector
I/O Bus
Connectors

Field 48V

I/O Bus
Connectors

Field 48V
Field 24V

Field 24V

Six-Pack Rack with DPU

Eight-pack rack

maxDNA BASIC COMPONENTS OF DCS

Remote Processing Unit

Switch A
Switch B
MAXNET Network
MAXSTATION

D I I I
P O O O
U
D I I I
P O O O
U
I I I I
O O O O

I
O
S
I
G
N
A
L
S

maxDNA THE REMOTE PROCESSING UNIT

The Remote Processing Unit (RPU) is the group of
equipment
that provides
The control
Data acquisition
And I/O processing functions for the DCS
The equipment includes
DPUs
Field I/O modules
Field terminations
Communication networks
And peripheral equipment such as power supplies, &
cabinets.

maxDNA RPU COMPONENTS

The Distributed Processing Unit (DPU4E) is the process

controller.
The Model 4E Distributed Processing Unit (DPU) is a
multifunction controller and data acquisition processor
that executes
control algorithms,
sequence logic,
sequence of events time tagged to 1 ms resolution
data acquisition.

maxDNA DPU4E

DPU Hardware
Control Processor (CP)
Pentium microprocessor dedicated to scanning and
executing all function blocks (i.e., algorithm and data
processing).
I/O Processor (IOM)
A 25MHz 68332 microprocessor dedicated to scanning
and processing the I/O modules connected to a parallel
I/O bus.

maxDNA DPU4E (CONT.)

The heart of the DPU is a database called the
Distributed Point Management System (DPMS). The
DPMS is fully aware of the tag names, hierarchy, and
other text attributes of its configured points. It is
loaded with a configuration created by the Systems
engineer and executes that configuration to provide
the control and data acquisition functions required.
The DPU 4E resides directly on the MAXNET
communications network without the need for
servers.
It is fully compatible with existing
MAX1000 Model 564 I/O. It also has redundant and
remote I/O capability.

maxDNA DPU4E FUNCTIONALITY

P
S

P
S

P
S

P
S

P
S

P
S

DPU Functions:
The DPU4E is the process
controller.

MCBs

Relays

I/O

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

The DPU4E is a
multifunction processor
that executes
control algorithms,
sequence logic,
SOE time tagged
to 1 ms resolution
data acquisition.

maxDNA DPU4E FUNCTIONALITY

The DPU provides the following functions to the maxDNA
Master of I/O Bus
Up to 60 I/O modules per Bus (expandable using BEM)
Up to 255 I/O addresses
Up to 32 DI Modules (soe)
Up to 254 normal DI Modules
Up to 254 DO Modules
Up to 72 AI Modules
Up to 72 RTD Modules
Up to 72 TC Modules
Up to 31 AO Modules
Analog and Digital I/O Buffering
I/O alarming

Input hardware failure (open TC, transmitter fail)

Hi, Lo
I/O communications failure

maxDNA DPU4E FUNCTIONALITY

The DPU provides the following functions to the maxDNA
Address Requirement

255 I/O Total addresses.

DIs, DOs :- 1 Address per card
AI,RTD,TC :- 2 Address per card
AO :- 8 Address per card

8000 Control Blocks Control Functions

Comprehensive process alarming
External device communications

maxDNA DPU4E
DPU Features
-

Pentium embedded processor

Windows CE Operating System
Real-Time multitasking
Object Oriented database
One-to-one redundancy capability
Diagnostics that are accessible by WorkStation and PC direct
connection
- 8,000 alarm/event queue to insure no-loss of alarms and events
- Flash memory for non-volatile configuration storage and on-line
and off-line firmware updates
- Software Backplane compliant

maxDNA DPU4E Front Panel

The DPU4E is Designed to Minimize Switches and
Connectors on Front Panel
LEDs to indicate network comm.
Green - Transmit and Receive Messages Good
Red - Link Errors
Yellow - Good and Bad transactions
Serial Ports
Green - Transmit Good
Red - Receive Message Good
Yellow - Both TX and RX Good
IO Status
Green - All IO Bus transactions Good
Red - All IO Bus transactions Bad
Yellow - Some Good and some Bad IO Bus transactions
Flash Sequences for Diagnostic Errors

maxDNA DPU4E Front Panel

Battery
Green - Battery Good
Red - Battery Bad
Yellow - Battery Under Test
CP Health
Green - Health OK
Blink/Red - Problem with CP detected and indicated
Observes IOM Health also
IOM Health
Green - Health OK
Blink/Red - Problem with IOM detected and indicated
Observes CP Health also
State
Green - Active DPU
Red - Offline
Yellow - Inactive
OFF - Problem with CP or IOM?

maxDNA DPU4E Front Panel

Reset Button - Shutdown and Restart function
Initiates Shutdown/Restart during Normal DPU
operation
Performs Hard Reset when Key Switch is in MAINT(in
between settings) mode or Mode Switch is in
"MAINT" setting.
Takeover Button
Used for manual takeover locally at the DPU
BDM connector
On the edge of the DPU Mother Board for ESD
protection reasons is used for flashing the IOM.
RJ-45 Ethernet connectors
Network A, B, and backup
Disconnect RJ-45 connections to break network.
3 Station Address network Switches (hex) set a unique
address for the DPU.

maxDNA - Redundancy Capabilities

Distributed Processing Units may be redundant
Input/Output Modules may be redundant or shared.
Individual modules may be redundant while others are
shared.
Some I/O modules have Manual/Auto Station capability
Remote Processing Unit Power Supplies are usually redundant.
The MAXNET network is redundant (Network A/B)

maxDNA - DPU Redundancy

DPU Redundancy:
One-to-one redundancy for cost effective
reliability
Simple switching
Database always current in secondary via
direct DPU to DPU communication of:

Real time information

Configuration information

maxDNA - DPU Redundancy

Redundant DPUs are one-to-one redundant for the simplest,
most reliable transfer of control. The transfer can be initiated by
the Primary DPU when it detects an internal fault condition or by
the Secondary DPU when communications with the Primary DPU
are disrupted. Control will not automatically transfer to the
Secondary DPU if it has detected an internal fault condition.
The Primary DPU continuously transfers its database to the
Secondary DPU, insuring that the entire secondary DPUs
database, including configuration, process values, and registers,
is completely updated periodically. At the same time, the
Secondary DPU keeps the Primary DPU aware of its status.

maxDNA RPU Cabinet

Schematic arrangement of RPU Cabinet

P
S

P
S

P
S

P
S

P
S

P
S

MCBs
System 24V

Relays
I/O Bus
Connector

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

Field 48V
Field 24V

D
P
U

I/O

I/O Bus
Connectors

Six-Pack Rack with DPU

System 24V

I/O

I/O Bus
Connector

I/O Bus
Connectors

Field 48V
I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

Field 24V

Eight-pack rack

maxDNA RPU Cabinet

IO Racks

Use a ribbon cable to interconnect in daisy chain style two or more

adjacent I/O chassis assemblies in the same I/O cabinet group. One end
of the ribbon cable plugs into P10 of the first I/O in the string. The other
end of the ribbon cable connects to P9 of the next I/O in the string.
Continue this P10 to P9 sequence until the last I/O in the string is
reached. See Figure.
P11

P9

P11

P10

P11

P9

P9
P10

P11

P10

Terminator

Depending on the spacing between maxPAC chassis, the following ribbon

cable lenghts are available:
Part Number Description

P9
P10

CPO301 10 inches - 0 rack units between racks

CPO303 12 inches - 1 rack unit between racks

P11

P9

P11

P10

P9

CPO304 14 inches - 2 rack units between racks

P10

CPO305 26 inches - 10 rack units between racks

P11

P9
P10

P11

P9
P10

For I/O bus connections to a cabinet outside the cabinet group, use a 7foot cable (CPO307), a 15-foot cable (CPO315), or a special length cable.

maxDNA RPU Cabinet

The DPU and the I/O modules mount in an I/O chassis assembly. The
backplane in the chassis assembly provides the I/O bus connection
between the DPU and the I/O modules. It also provides the system
power and field power connections to the modules.
Three chassis assembly types are available for the installation of the
MAXPAC IO modules.
Multiple I/O chassis that share the I/O bus can be installed in a
cabinet.
Up to seven chassis assemblies may be installed in a standard
cabinets.
Standard Size 85 7/8 h x 24 w x 38 7/8d
The I/O modules are rugged enclosed printed circuit board
assemblies. The edge connection at the rear of each module provides
the interface to the backplane and the I/O bus. System power and
field power, when applicable, is also available through this
connection.
The I/O modules may be inserted and withdrawn safely with 24 Vdc
and field power applied.

maxDNA RPU Cabinet

The I/O system requires a 24 Vdc 4.0 Vdc power supply.
The +24 Vdc power supply used to power any System hardware
should never be used for external relay contact wetting or to
power any other field equipment. Use a separate supply for
contact wetting to provide noise and interference protection for
the System hardware.
In general, wherever possible, modules receiving the same type
and level of signals should be grouped together, with similar
signal types arranged in vertical columns. High and low signal
levels and AC and DC wiring should be kept separate.
Addresses for each I/O module using rotary switches mounted in
the lower or upper right corner of the printed circuit board of the
module, depending on module type. These hexadecimal switches
permit 255 logical addresses.

maxDNA RPU Cabinet

IO
Terminations

Field Termination Options

Local Terminations - Field cables terminate directly on the I/O module.
Remote Terminations - Field cables terminate on terminal blocks
remotely to the I/O module with an interconnecting cable back to the I/O
module.
Local Terminations (standard)
Each I/O module is supplied with two 16 point, Euro-Style screw clamp
plugs that mate to the Printed Circuit Board Header on the module. Field
cables would be routed directly to these Euro-Style plugs which can
accept up to a #12awg conductor.
Remote Terminations (option)
Many remote field cable termination options are possible. Listed below
are a few examples:
I/O in front of cabinet, terminations in the rear of cabinet.
Termination cabinet mounted adjacent to I/O cabinet.
Termination cabinet located remotely from I/O cabinet.
The types of terminal blocks installed in the termination facility are too
numerous to list; typically these terminations are DIN rail style. The
cabling back to the I/O module is typically made using two multiconductor cables, one to each of the 16 point Euro-Style plugs supplied
with the individual I/O module.

maxDNA RPU Cabinet

IO Bus Length
Minimum length of electrical I/O cable: 0 feet (DPU & I/O modules in the
same rack)
Maximum length of electrical I/O cable: L = B + (0.7 x M) - (3 x R) - H,
where
L is the maximum length, in feet, of the I/O bus electrical cable
B is the base length of cable (40 feet if bus is terminated, 30 feet if not
terminated)
M is the number of I/O modules on the electrical bus
R is the number of I/O rack on the electrical bus
H is the number of Heavy duty Relay panels (0 or 1)
Minimum length of Fiber Optic I/O (BEM) cable: 10 meters
Maximum length of Fiber Optic I/O (BEM) cable: 2000 meters

maxDNA - I/O Redundancy

There are three levels of I/O configurations available with
redundant DPUs:
Shared (or common) I/O modules
Separate (or redundant) I/O modules
Mixed (both shared and redundant) I/O modules
Each of these options is illustrated below.
Shared (Common) I/O Modules
With shared I/O modules, one set of I/O modules is used for the field
interface. The active DPU is the master of the I/O bus and the
process values in the inactive DPU are updated through the DPU
backup link.

maxDNA I/O Redundancy

P9

Shared
Configuration

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

P10

DPU Backup Link

P9

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

Redundant network

P10

D
P
U

D
P
U

P9

I/O

I/O I/O I/O I/O I/O I/O

I/O

I/O Bus

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

P10

I
O

P9

I/O

I/O I/O I/O I/O I/O I/O

I/O

P10

MAXPAC IO Bus Terminator

Model No.: CPO402CPOTerminator

maxDNA - I/O Redundancy

Redundant (Separate) I/O Modules

With redundant I/O modules, each DPU has its own set of I/O
modules and the field wiring goes to both sets of terminations.
Each DPU is the master of its own I/O bus but the process values
in the inactive DPU are still updated through the DPU backup link.
However, when control is transferred to the inactive DPU, it
updates its database with the process values from its own I/O
modules before taking any control action.

maxDNA I/O Redundancy

Redundant
Configuration

P9

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

Redundant network

P10

P9

D
P
U

I/O

D
P
U

I/O

I/O

I/O

I/O

D
P
U

I/O

P10

P9

I/O Bus
I/O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I
O

P10

P9

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

P10

IO Backup Cable (3ft)

Model No.: CPO309

maxDNA - I/O Redundancy

Redundant and Shared I/O Modules

With both redundant and shared I/O modules, each DPU has its
own set of redundant I/O modules and the field wiring goes to
both sets of terminations. Another group of I/O modules is
shared by both DPUs. The Mixed I/O adapter switches the
shared Parallel I/O Bus to the active DPU. Each DPU is the
master of its own Parallel I/O bus but only the active DPU is the
master of the shared Parallel I/O Bus. The process values in
the inactive DPU are still updated through the DPU backup link.
However, when control is transferred to the inactive DPU, it
updates its database with the process values from its own I/O
modules before it takes any control action.

maxDNA I/O Redundancy

Mixed
Configuration

P9

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

Redundant network

P10

P9

D
P
U

D
P
U

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

P10

I/O Bus

I/O Bus

P9

I/O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I
O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I
O

P10

Model CPO401

P9

Backup
Adapter

Mixed I/O Adapter

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

Common I/O Bus

P10

I
O

I
O

I
O

I
O

P9

I
O
I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

P10

MAXPAC IO Bus Terminator

Model No.: CPO402CPOTerminator

PS: CPO401 includes 2 nos. 047460 MACPAC I/O mixed adapter cable (22) and 1 no. 047483 MAXPAC
mixed adapter cable (48)

maxDNA Remote I/O

The Bus Extender Unit (BEM) provides a
flexible way to distribute the system
throughout the plant, resulting in
reduced cabling costs and installation
time.

Remote
I/O
redundant network

D
P
U

D
P
U

Y
ADAPTER

B
E
M

B
E
M

backplane

I
O

I
O

Control
Room

backplane

I
O

I
O

I
O

I
O

I
O

I
O

Optical
Cable

B
E
M
I
O

I
O

I
O

I
O

I
O

I
O

I
O

Remote
location

B
E
M

I
O

I
O

I
O

I
O

I
O

I
O

I
O

BEMs may also be used to expand the

number of I/O modules that may be
configured locally. When BEMs are used,
a DPU could support up to 60 modules
per location (locally, remotely, or both),
and up to 255 addresses total for the
DPU.
BEMs may be employed in any of the
following configuration schemes:
1 Remote
I/O
only
(redundant,
common or mixed).
2 Remote I/O and local redundant I/O.
3 Remote I/O and local common I/O.
4 Remote I/O and mixed local I/O
consisting
of
common
and
redundant configurations.

maxDNA Remote I/O

I/O Bus Expansion Module (BEM)
Extends the I/O bus to remote location
Increases the I/O handling capacity of DPU
Maximum total distance is 2000 meters.
The expander module is transparent to the operation of the I/O bus. No
additional configuration is required.
The expander module has the same form factor as the I/O modules. It installs
in the I/O chassis. The I/O bus is available to the expander at the I/O backplane.
Redundant optical twist on connections are located on the front of the
expander. The expander module can be installed in either 4-pack / 6-pack or
maxPAC I/O racks in any location
Use of the same I/O modules in both the local and remote location. The DPU
configuration could include both local and remote I/O. A total of up to 60
modules to be supported by the DPU, either locally, remotely, or both. For bus
loading at the DPU end, each link counts as an I/O module.
The expander module includes a digital output to provide an indication of its
health. The expander module detects and reports an optical cable failure via a
DI.
The expander is available for use with the 4A, 4B and 4E DPUs

maxDNA Remote I/O

Functional Specifications
Expander has redundant optical cable pairs. One cable pair is
the active link. The inactive pair is continually tested. For
redundant DPU applications the test of the redundant link is
disabled, if not used.
For redundant DPU applications, any single failure of the
expander module or cable does not result in loss of remote
I/O. For single DPU applications, a cable failure does not
result in loss of remote I/O, but a momentary glitch (up to a
few seconds) will occur while the expander switches over to
the inactive cable. An indication of a cable failure is provided.
Redundant links are provided. For redundant DPU
applications, any single failure of the expander or cable does
not result in loss of operation, and the replacement of the
failed component may occur without loss of service. For
single DPU applications, a single cable failure does not result
in loss of operation.

I/O Modules

maxDNA ... Robust power plant grade I/O

Modules
P
S

P
S

P
S

P
S

P
S

P
S

MCBs

Realays

I/O

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

D
P
U

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

I/O

maxDNA I/O Modules

Rugged, high performance I/O modules provide signal
conditioning for signals from field devices connected to the
I/O terminations.
Analog Input

Digital Input (ac/dc)*

Part Number

Description

Part Number

Description

IOP301

Isolated analog input; 16 channels

IOP330

24 Vdc common input; 16 channels

IOP302

4-20mA common input; 16 channels

IOP334

24 Vdc isolated input; 16 channels

IOP303

3-wire RTD input; 8 channels

IOP331

48 Vdc common input; 16 channels

IOP304

Thermocouple/emf input; 16 channels

IOP332

120 Vac/dc isolated input; 16 channels

IOP305

Voltage common input; 16 channels

IOP333

240 Vac/Vdc isolated input; 16 channels

IOP306

Kit with sixteen 100 Ohm resistors

IOP350

Form C relay; 10 channels

IOP351

Form A/B relay; 16 channels

Analog Output

Bus Extender

Part Number

Description

Part Number

Description

IOP320

4-20 mA common output, 8 channels

IOP371

Optical bus extender

maxDNA I/O Modules

AI - IO
Modules

IOP301 Module specifications

24V(+)
24V(-)
1A

200

From backplane

1B

1
Rs

100

A/D

Rp

Xmitter

1D

2
24V

1E

1C

4-20 ma powered by system

1A

200

1B

1
Rs

+
Rp

Xmitter

100

1E
1C

4-20 ma powered externally

200

1A

Rs

Voltage
-

Temperature Sensitivity
Accuracy
Source Impedance Effect
Conversion method
Span
Calibration

+/-0.004% of reading/oC +/-1.5uv/oC RTI

+/-0.1% of reading at 25 oC
10 MOhm operational, 20K Ohms on loss of power
SigmA Delta oversampling. ADC per each two channel
4 to 20 mA, 0-2.4V
Self-calibration on power up. Periodically on line to
compensate for temperature effects
300 Ohms
1 Mohm
50 Volts
60db @ 50/60 Hz
500 Volts ac or peak ac
120db @ 50/60 Hz, 100 Ohm imbalance
1500 vac (field to logic)
500 vac (channel to channel)
400 mA

1B

1
+

16 Isolated input channels

15 bits plus sign
100 msec.

Input Impedance - 4-20 mA input

- voltage input
Normal Mode Voltage
Normal Mode Rejection
Common Mode Voltage
Common Mode Rejection
Isolation

A/D

1D

No. of Channels
Resolution
Scan Rate

100

Input Power
(from 24V system supply)

A/D

Rp
2

1D
1E

Voltage input

1C

The module contains five jumpers per channel determine the type of input connected to the
channel.
Input Type
4-20 mA powered by System
4-20 mA powered externally
Voltage input

A
IN
IN
OUT

B
IN
IN
OUT

C
IN
OUT
OUT

D
IN
OUT
OUT

E
OUT
IN
IN

maxDNA I/O Modules

AI - IO
Modules

Redundant inputs must be configured

as voltage inputs with an external 100Ohm shunt resistor.

Twisted pair
(-)

4 wire
Transmitter

100
(+)
thermistor

Primary
IOP301
AI Module

(-)
(+)
Secondary
IOP301
AI Module

Twisted pair

(-)

(-)
24V
Supply

100

(+)

(+)
thermistor

2 wire
Transmitter

Primary
IOP301
AI Module

(-)
(+)
Secondary
IOP301
AI Module

The voltage that is developed across

each 100-Ohm shunt by the 4-20 mA
signal from the transmitter is wired to
the AI module using twisted pair cables.
A PTC thermistor between the
transmitter output and the 100-Ohm
shunt protects the 100-Ohm shunt
against over voltage and provides
additional resistance to increase the
transmitter load to 250 Ohms.
Kit IOP306 supplies 16 pairs of 100Ohm shunts and thermistors to support
two IOP301 analog input modules.

maxDNA I/O Modules

AI - IO
Modules

IOP302 / IOP305 Module Specifications

No. of Channels
Resolution
Scan Rate

Current Limit
200
A/D

100

24V(-)
From backplane
Fuse

Temperature Sensitivity
Accuracy
Source Impedance Effect
Conversion method
Span
Calibration
Input Impedance
Normal Mode Voltage
Normal Mode Rejection
Input Power
(from 24V system supply)

IOP302 - 16 nos. 4-20mA common input channels

IOP305 16 nos. voltage input channels.
15 bits plus sign
20 msec.
0.004% of reading/oC 1.5uv/oC RTI
0.1% of reading at 25oC
10 MOhm operational, 20K Ohms on loss of power
Sigma Delta oversampling. Single A/D per channel
4 to 20 mA, 1-2.4V.
Self-calibration on power up. Periodically on line to
compensate for temperature effects
IOP302, 300 Ohms; IOP305, 1mOhm
IOP302, 100 Volts; IOP305, 24 Volts
60db @ 50/60 Hz
125 mA

24V(+)

For current input, transmitter loop power is available to the module via
the backplane, providing individually fused 24V transmitter power for
each channel.
The electronic fuse protects the 24V loop power to the transmitter. A
200 Ohm thermistor in series with the input provides current limiting
for over voltage conditions up to 100 volts. The 24 volt supply is
available to the module from the backplane.

maxDNA I/O Modules

AI - IO
Modules
(+)
DCS 24V
Loop Supply
(-)
Twisted pair
(-)
Transmitter
2-wire

100
(+)
thermistor

Primary
IOP305
AI Module

(-)
(+)
Secondary
IOP 305
AI Module

The figure shows the recommended wiring for two redundant IOP305
analog input channels that share a common transmitter.

maxDNA I/O Modules

AI - IO
Modules
IOP303 Module Specifications

IOP304 Module Specifications

No. of Channels
Resolution
Scan Rate

8 Isolated 3-wire RTD input channels

15 bits plus sign
8 points converted in 1.6 seconds

No. of Channels
Resolution
Scan Rate

16 Isolated thermocouple input channels

15 bits plus sign
16 points converted in 1 seconds

Temperature Sensitivity
Accuracy
Input Multiplexer
Conversion method
Linearization

0.004% of reading/oC 1.5uv/oC RTI

0.15% of reading 0.5oC
Solid-state FET, optical isolation
Sigma Delta oversampling
Digital in DPU. RTD ranges may be randomly
mixed. Supports different configuration for each
channel
Self-calibration on power up. Periodically on line
to compensate for temperature effects.
5 Ohms each lead

Temperature Sensitivity
Accuracy
Input Multiplexer
Conversion method
Linearization

0.004% of reading/oC 1.5uv/oC RTI

0.15% of reading 0.05oC
Solid-state FET, optical isolation
Sigma Delta oversampling
Digital in DPU. TC ranges may be randomly
mixed. Supports different configuration for each
channel
Self-calibration on power up. Periodically on line
to compensate for temperature effects
Digital in module
Performed each reading (1,000 0hm threshold)
Conversions disabled if common TC is connected
to redundant modules
Channel to Channel & field to logic isolation
0.3oC, 0.5oF
0.25oC
60db @ 50/60 Hz
120db @ 50/60 Hz, 100 Ohm imbalance
240V rms, 350V dc peak
125 mA

Calibration
Maximum Lead Resistance
Compensation
Backup
Isolation
Conformity Error
Normal Mode Rejection
Common Mode Rejection
Common Mode Voltage
Input Power
(from 24V system supply)

Conversions disabled if common RTD is

connected to redundant modules.
Channel to Channel & field to logic isolation
0. 0.3oC, 0.5oF
60db @ 50/60 Hz
120db @ 50/60Hz, 100 Ohm imbalance
240V rms, 350V dc peak
125 mA

Calibration
RJ Compensation
Open TC Detection
Backup
Isolation
Conformity Error
Reference Junction Error
Normal Mode Rejection
Common Mode Rejection
Common Mode Voltage
Input Power
(from 24V system supply)

Note: The IOP303 / IOP304 Modules can be configured in

Redundant mode

maxDNA I/O Modules

AO - IO
Modules

IOP320 Module Specifications

No. of Channels

8 nos. 4-20mA output channels

Resolution

12 bits

Isolation

Per channel field to logic isolation and per channel D/A

conversion

Scan Rate

8 msec.

Temperature Sensitivity

+/-0.004% of reading/oC +/-1.5uv/oC RTI

Accuracy

+/-0.1% of reading at 25oC

Span

4 to 20 mA.

Calibration

Self-calibration on power up with calibration jumper set

Load Impedance

0 - 800 Ohms

Input Power
(from 24V system supply)

175 mA

Note: The IOP320 Modules can be configured in Redundant

mode

maxDNA I/O Modules

24V/48V(-)

24V/48V(+)
Fuse disconnect

DI - IO
Modules
Signal
Conditioning
Circuit

To other channels

IOP330 / IOP331 Module specifications

No. of Channels
Rated Input Voltage
Input current per point
On-State Voltage
Isolation
User input to logic
Indicators
I/O Bus Address
Input Power
(from 24V system supply)

IOP 330 24V

IOP331 48V
16 Common inputs
16 Common Inputs
24 Volts nominal, 40 Volts
48 Volts nominal, 60 Volts
maximum
maximum
5 mA @ 24 Volts
5 mA @ 48 Volts
8.5 Volts
22 Volts
250 VAC continuous, 1,500 VAC for 1 minute
1 LED per point provides status indication.
LED provides power and communication indication.
LED provides loop power disconnect status
One address
50 mA

Note: The IOP330 / IOP331 Modules can be

configured in Redundant mode

I/O BUS
Interface
Circuit

maxDNA I/O Modules

IOP332 / IOP333 / IOP334 Module Specifications

DI - IO
Modules

IOP 332 120V

Rated Input
Input current per

120 Volts ac/dc nom.

180 Volts max
5 mA @ 120 Volts

IOP333 240V
240 Volts ac/dc nom.
280 Volts max
5 mA @ 240 Volts

IOP334 24V
24 Volts ac/dc nom.
40 Volts max
5 mA @ 24Volts

On-State Voltage
48 Volts dc
100 Volts
8.5 Volts
Isolation
60 VAC; 250 VAC continuous, 125 VAC 1500 VAC for 1 minute
User input to
logic
Isolation
continuous
Channel to
channel
Indicators
1 LED per point provides status indication
LED provides power and communication indication
LED provides the status of the loop power fuse disconnect
I/O Bus Address
One address
Input Power
50 mA
(from 24V
system supply)

Input Voltage

Signal
Conditioning
Circuit

I/O BUS
Interface
Circuit

Note: The IOP332 / IOP333 / IOP334 Modules can be

configured in Redundant mode

maxDNA I/O Modules

DO - IO
Modules

IOP350 / IOP351 Module Specifications

Maximum Switching
Capacity
Number of Channels
Expected Relay Life
Output Configuration
Maximum Operating
Speed
Operating Time
Release Time
LED Indication
I/O Bus Address
Input Power
(from 24V system supply)

IOP 350 Form C

IOP351 Form A/B
5 amps @ 250 VAC
3 amps @ 30 VDC
0.3 amps @ 110 VDC
10
16
Mechanical @ 180cpm - 5X10^6
Electrical @ 20cpm (resistive load) 10^5
Either reset or fail in place through jumper settings
20cpm
15 msec. Maximum (excluding bounce)
5 msec. maximum (excluding bounce)
1 LED per point provides output status indication
active LED provides power and communication indication
One address
400 Ma

Note: The IOP350 / IOP351 Modules can be configured in Redundant

mode. In Redundant all Outputs shall be configured to Reset output.

maxDNA I/O Modules

I/O Module Features

Provides Rugged, High Performance Signal

Conditioning
ANSI C37.90a (IEEE 472) surge withstand
SAMA PMC 33.1 Electromagnetic
Susceptibility
IEC 801-2 Electromagnetic Compatibility
(electrostatic discharge)
SAMA PMC 31.1 field level vibration
Plug in with power on
Terminations with module or remote
Up to 40 modules per RPU cabinet (up to 5
rack assemblies of 8 modules each with
remote terminations)

maxNET

maxDNA Communications
requirements

MAXSTATIONS

Remote
Processing
Unit

Reliable
Secure
Fast
Flexible
Handles Burst Data
& Alarms

Solution is Switched Ethernet . . . maxNET

maxDNA - maxNET

MAXNET is the redundant Ethernet communications

network that supports communications between the
DPUs and the MAXSTATIONS.

maxDNA - maxNET
- maxNET uses the widely accepted Switched Fast Ethernet
standard. It runs 10 times faster (100 Mbps) then
conventional Ethernet. By employing intelligent switches
performance is enhanced so that all stations can access the
network at any time without the possibility of collision.
- Intelligent switches are employed at various locations in the
network to form a backbone for the system. The network can
be as simple as a star, but it is more likely to contain multiple
redundant switches at various locations.
- Each station is connected to a switch over a dedicated 10BaseT link. They do not share the link with any other stations.

maxDNA - maxNET
- maxNET uses the widely accepted Switched Fast Ethernet
standard. It runs 10 times faster (100 Mbps) than
conventional Ethernet. By employing intelligent switches
performance is enhanced so that all stations can access the
network at any time without the possibility of collision.
- Intelligent switches are employed at various locations in the
network to form a backbone for the system. The network can
be as simple as a star, but it is more likely to contain multiple
redundant switches at various locations.
- Each station is connected to a switch over a dedicated 10BaseT link. They do not share the link with any other stations.

maxNET How a Switch works

Learning Table
Port MAC Address
1 00-20-33-A5-3B
2 00-20-7C-DD-51
3 00-20-1F-47-13
4 00-20-D8-4E-FF

00-20-7C-DD-51

2
A
00-20-33-A5-3B

3
4
D

00-20-D8-4E-FF

C
00-20-1F-47-13

The switch knows the network

layout, it only forwards messages to
the proper port
Simultaneous conversations are
possible
Any pair of stations can talk directly
without interfering with other
conversations

maxNET Open network advantages

Based upon Switched Fast Ethernet

Ultra high speed (100 MBPS) redundant network
Proven industry standard
All the advantages of Ethernet without the
disadvantages
Utilizes intelligent switching

maxNET Switched Fast Ethernet is

proven technology
Multiple simultaneous conversations
Full-Duplex communications between switches
Similar to telephone system

Switch 1

Switch 2

maxDNA - maxNET
The maxNET is the redundant communications network that
supports communications between Distributed Processing Units
(DPUs) and the WorkStation. Two Ethernet 10base-T ports are
provided to interface with the maxNET communication network.
All DPUs connect to redundant Ethernet switches. The backbone
of the maxNET operates at 100 Mbps.
All output actions use a check-before-execute technique for
greater security. In addition, there are continuous diagnostic
checks to insure error-free operation.
The message structure has been optimized to reduce
communication overhead and insure high information transfer
rates. Messages and transactions are completed immediately,
insuring immediate response to commands and requests.

maxDNA - maxNET

Features
Totally redundant communication paths
Efficient message structures
All stations have unlimited access without delay and
without the need for a traffic director
Built-in priorities for data gathering and handling
Guaranteed peer-to-peer transfer rates

maxDNA - maxNET
Buffered Switching
The switched hub employs a buffered stored-andforward architecture that permits packets to be routed
only to the network segment containing the destination
station. The switch examines each packet, determines the
destination, and then forwards that packet only to the port
required for that packet.
The switched hub also performs error checking to prevent
bad packets from being propagated throughout the network.
Every packet it receives is checked for validity before being
routed to the destination address.

maxDNA - maxNET
MAXNET Network Cables
The MAXNET network supports a number of physical layer
specifications including both electrical and fiber optic cables. A
summary of the cable limitations is provided below.
Electrical Cable
- The MAXNET Network supports two electrical network cable
types: 10BASE-T and 100BASE-TX. In either case, the cable used
is EIA Category 5 UTP (Unshielded Twisted Pair). Each cable
consists of four twisted pairs with RJ-45 connectors at each end.
10BASE-T
- The 10BASE-T cable is used to connect devices to a local switched
hub within 100meters.
100BASE-TX
The 100BASE-TX cable is used to interconnect two switched
hubs within 100meters.

maxDNA - maxNET
Fiber Optic Cable
Fiber optic cable is used to traverse a larger geographic area,
To provide electrical isolation between groups of equipment,
or when there is an electrically harsh environment. The MAXNET
network supports two fiber optic cable types: 10BASE-FL and
100BASE-FX. These are used primarily for long distance links and
for electrical isolation, usually between the Control Room
equipment (MAXSTATIONs) and the RPUs.
10BASE-FL
10BASE-FL uses 62.5/125-micron multimode fiber optic cable,
although it may require 100/140-micron cable for very long
distances (greater than about 3000 feet). All connectors are STtype connectors.
The typical implementation uses a fiber optic transceiver on one
end and a fiber optic transceiver or a fiber optic port on a switched
hub at the other end of the fiber optic cable.

maxDNA - maxNET
100BASE-FX
100BASE-FX uses 62.5/125-micron multimode fiber optic cable.
The connectors are all ST-type connectors. 100BASE-FX is
used to interconnect two switched hubs when the distance is
greater than 100 meters, the area to be traversed is an
electrically harsh environment, or for electrical isolation
between devices.
The typical implementation uses a fiber optic port on a
switched hub at each end of the fiber optic cable.
Each transceiver has a fiber optic transmit connector and a
fiber optic receive connector. It also has an RJ-45 connector for
the electrical cable. Although they are usually used in pairs,
one at each end of a fiber optic cable, some switched hubs
have fiber optic ports for 10BASE-FL or 100BASE-FX Cable.

maxDNA - maxNET

Model No.
CON064

FO

FO

FO

FO

Description
Ethernet 10/100 Base-fl 62.5 u, 4 fiber cable

Model No.
NWH101
NWH102
NWH121
NWH122
NWH131

Model No.
NWH151
NWH152
NWH153
NWH154
NWH155
NWH156

Description
Ethernet Switch , 12-10BT & 2-100BTX w/120 V PS
Ethernet Switch , 12-10BT & 2-100BTX w/240 V PS
Ethernet Switch , 24-10BT & 2-100BTX w/120 V PS
Ethernet Switch , 24-10BT & 2-100BTX w/240 V PS
Ethernet Switch , 24-10BT / 100BTX w/120 V PS
Ethernet Switch , 24-10BT / 100BTX w/240 V PS

Description
10BaseT to FL converter 120 VAC
10BaseT to FL converter 240 VAC
100BaseT to FL converter 120 VAC
100BaseT to FL converter 240 VAC
Mtg.shelf 120 VAC for 2 NWH101,
102, 121, 122 converters

Drawing Not To Scale

maxDNA - maxNET

Model No.
CEN405
CEN410
CEN425
CEN450
CEN500

FO

FO

FO

FO

Description
10/100 BaseT Ethernet pair cable, 5ft (PVC) category 5
10/100 BaseT Ethernet pair cable, 10ft (PVC) category 5
10/100 BaseT Ethernet pair cable, 25ft (PVC) category 5
10/100 BaseT Ethernet pair cable, 50ft (PVC) category 5
10/100 BaseT Ethernet pair cable, 100ft (PVC) category 5

maxSTATION

maxDNA - maxStation

MAXStation is the generic name Operator Station, Engineering Station, History Station or
MAXLink Station.
The software installed in the MAXStations assigns the Personality to the MAXStation.
MAXStation Personality is interchangeable with software.
MAXStations are Industry Standard Intel Computers.
MAXStation can also be installed as a Plant Information Network Station.

maxLINK

maxDNA - maxLink
MAXLink is a multifaceted interface module of MAXStation software that interfaces to
external devises.
MAXLink is a windows NT workstation.
MAXLinks support
- Serial transport
- Ethernet tranport
- Modbus+ transport
Currently MAXLink supports the following protocols
- Modplus through RS232 line
- AB PLCs: Micrologix, SLC500, SLC5/03, SLC5/04, 17774-PLC, PLC-2,
PLC-3, PLC-5/20, PLC-5/VME
The following Rocketport MAXLink serial port cards are to be used with the MAXLink
processor
- Model No. PMX033: Rocketport card (8 port)- max 2 / MAXLink processor
- Model No. PMX034: Rocketport card (16 port)- max 1 / MAXLink processor

maxSTATIONs
Softwares

maxDNA - maxStation Software

Model No. Description

Features

SFT 251

MAXVue
Runtime

SFT253

MAXTools

Create & maintain RPU hardware configuration

Create & maintain complete control configuration
programs and IO functions.
Useful standard Block Library.
Create & maintain System security
Off-line simulation and verification
Self documentation
On-line monitoring and help

Graphical View of process

System Diagnostics
Operations Control pop-ups, tuning, mode changes etc.
Alarms management / Alarm Filtering
Real Time trends, Trend Groups, XY Plots
Point details of all tagged DPU4E std. Objects
Print Alarm / log reports, screen prints etc.
Password protected security levels

maxDNA - maxStation Software

Model No.

Description

Features

Included in MAXVue
SFT253
Editor

Allows creation of virtually any display functionality

SFT255
SFT258

MAXStorian
(< 1000 pts.)
(> 1000 pts.)

Historical storage and retrieval functions of the system.

This information can be used in trending, reports, or
other long term, data intensive functions in the plant.

SFT254

MAXLink

Provides datalink interfaces to third-party systems.

SFT256

MAXCalcs

Application program that provides performance

calculations.
The software library provides the tools necessary for an
engineer to customize to the specifics of a given plant.

maxDNA - maxStation Software

Model No

Description

Features

Remote
MAXVue

Provides ability to monitor a MAX System from a

remote location by connecting to a selected
workstation via a modem or LAN connection.
PS: The workstation used as server must have
Remote MAXVue installed. The remote client
workstation must have atleast MAXVue Run Time
installed.

SFT257

MAXApps

Toolkit for application development that allows

programmers to build custom applications.
PS: Prerequisite to use MAXApps development
tools is MS C++ Prof. Edition 5.0 (SFT232) and MS
VB Prof. Edition 5.0 (SFT233).

SFT262

MAXOPC
Server

Open interface of MAXSystem.

Method of exchanging real time data with PC
based clients using MS OS.
MAXOPC reads values from either DPU4E or
MAXStorian.

Software
Backplane

maxDNA - maxStation
Modular Architecture
Plug and Play System Additions
Can Grow as Your Needs Change

MAXVue

MAXTools MAXStorian MAXCalcs

MAXAPP

Software Backplane

MAXLinks Virtual DPU

PLC

DPU 4E

maxDNA - maxStation
Software Backplane
The Software Backplane is the maxDNA distributed communications
infrastructure software. An instance of this software resides on each
maxSTATION and is responsible for transferring client data requests to
the provider, which in turn provides the data to the client. The services
include the following:
Connect
Register
Subscribe
Read
Write
The software Backplane consists of a number of modules:
- MAXrrs - Registration and Routing (RRS)
- MAX1000 Local Status Server (LSS)
- MAX1000 + Plus Transport Daemon

maxDNA - maxStation

MAXrrs - Registration and Routing (RRS)

This is the core of the software backplane, This program is responsible
for connecting clients with providers of information. Providers register
information on the software backplane. Clients read, write and
subscribe to that information through the software backplane.
MAX1000 Local Status Server (LSS)
This program provides a number of housekeeping functions. These
include storage for other processes (such as the last display and
selected point for MAXVue) as well as a set of simulation functions.
MAX1000 + Plus Transport Daemon
No a Daemon is not something evil. It is a program that performs a
background function, the word coming from the UNIX realm. The
transport daemon is aware of other MAXSTATIONS or Ethernet
connected devices. It is made aware by a special broadcast that is
performed by other transport daemons.

maxDNA - maxStation
Module

Description

Win/NT Local Status Server

Keep and present information about all relevant processes running in the Win/NT
environment through the Software Backplane

Registration & Routing, IPC

Registration & Routing handles receiving and transmitting of messages.

Event Merge

Collects events from all sources and makes the data available to other applications

Transport Daemon

Used for inter-station communications

Test SBP

Test program for testing the Software Backplane.

Timesync

Handle time synchronization with the workstation (under Win/NT.)

maxDNA - maxStation
SBP
Connectivity
SBP
Requestor
Process(s)

Local
Status
Server

Future SBP
Requestors
of Services

Registration
& Routing
Function Provider

Software Backplane
Interface to
Requestors/Providers

Timesync
Provider

Future
Providers of
New Services

MAXNET communications
available on LAN to
external Units

DPU4E
Operating
System SBP

Figure shows the components of the Software Backplane, and their relationship
to the Requestors, such as MAXVUE, and to external providers, such as the
DPU4E.

maxDNA - maxStation
SBP Function Processing Flow
Diagram
Software Backplane Requestor
Function
Calls

Callback
s

Software Backplane Interface (Functional Library Calls in Requestor / Provider Processes)

Send to via Interprocess Communications

Software Backplane Provider

Provider
Function Calls

Provider
Callbacks

Figure shows the functions of the SBP.

1- The SBP Client, or Requestor, calls to the SBP for a particular service.
2- The SBP queries the Provider, which has registered that service.
3- The registered Provider issues a callback to the SBP, saying Here it is
The SBP issues a callback to the Requestor, saying Here it is

End of Section ?

maxDNA - Special Features

Special Features
1 ms built in SOE
Redundant and shared I/Os
Address independent signals
Signal identification by user friendly tagnames
Isolation of power supply (system, transmitter)
Visualisation of I/O & Dpu status from HMI
240 Vac/dc output modules
Dpu replacement is simple
Use of fibre optics
No EPROM Programming
Card failure negligible (SMT for card)

maxDNA - Special Features

Special Features
Remote maxVIEW
On line incremental downloading
On line card replacement
Direct conectivity of Dpu to maxNET
Signal exchange to other systems through maxLINK