Ampcontrol iMAC2 User manual

IntegratedMonitoringandControlSystem
iMAC2UserManual
Version: 4 –October 2018
Designed and Manufactured in Australia by Ampcontrol Pty Ltd

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Ampcontrol Pty Ltd –ABN 28 000 915 542
iMAC System User Manual
iMAC2B009 V4 –10/18
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WARNING!
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Please share these warnings with other operators.
CAUTION!
The caution symbol highlights a potential risk of damage to
equipment.
Please share these cautions with other operators.
NOTE
The note symbol highlights key information.
Please share these notes with other operators.
ENVIRO
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impact on the surrounding fauna and/or flora.

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Ampcontrol Pty Ltd –ABN 28 000 915 542
iMAC System User Manual
iMAC2B009 V4 –10/18
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Copyright Notice
The Ampcontrol iMAC Integrated Monitoring and Control system described in this document is the property
of AMPCONTROL PTY LTD. It is furnished under a license agreement and is to be used only in
accordance with the terms of the agreement.
No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language or computer language, in any form or by any means, without prior
written permission of AMPCONTROL PTY LTD.
The iMAC signalling technique is protected by patent.
Disclaimer
While every effort has been made to assure the accuracy and clarity of this document, AMPCONTROL PTY
LTD assumes no liability resulting from any omissions in this document, or from misuse of the information
obtained herein. The information in this document has been carefully checked and is believed to be entirely
reliable with all of the necessary information included. AMPCONTROL PTY LTD reserves the right to make
changes to any products described herein to improve reliability, function, or design, and reserves the right to
revise this document and make changes from time to time in content hereof with no obligation to notify any
persons of revisions or changes. AMPCONTROL PTY LTD does not assume any liability arising out of the
application or any use of any product or circuit described herein; neither does it convey license under its
patent rights or the rights of others.
Before You Begin
Thank you for purchasing the Ampcontrol iMAC System.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: ampcontrolgroup.com

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Ampcontrol Pty Ltd –ABN 28 000 915 542
iMAC System User Manual
iMAC2B009 V4 –10/18
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TABLE OF CONTENTS
INTRODUCTION........................................................................................................7
Document Scope..............................................................................................7
Supplementary Documents ..............................................................................7
Definitions.........................................................................................................8
Fieldbus System Configurations.....................................................................10
SAFETY AND OTHER WARNINGS.........................................................................12
Safe Use of Equipment...................................................................................12
RECEIVING AND STORAGE...................................................................................13
Receiving........................................................................................................13
Inspection.......................................................................................................13
Storage after Delivery.....................................................................................13
Unpacking of Equipment.................................................................................13
iMAC SYSTEM OVERVIEW.....................................................................................14
Typical Installation..........................................................................................15
Application Software.......................................................................................16
iMAC Modules................................................................................................16
iMAC Address Range.....................................................................................17
Fault Finding Statistics....................................................................................17
Networking .....................................................................................................18
Local and Global Data....................................................................................19
Sequence Control...........................................................................................19
Emergency Stop SIL Qualification ..................................................................21
IECEx Certifications......................................................................................21
FIELDBUS SIGNALLING PROTOCOL.....................................................................23
iMAC2 SUPERVISORY CONTROLLER...................................................................24
Power Supply.................................................................................................25
Digital Inputs...................................................................................................25
Relay Outputs.................................................................................................26
Serial Communications Port ...........................................................................26
Ethernet Communications Port.......................................................................27
Fieldbus Ports ................................................................................................27
Memory..........................................................................................................27

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Intrinsically Safe Battery.................................................................................27
Data Point Table.............................................................................................28
iMAC FIELDBUS MODULES....................................................................................29
Intrinsically Safe Barriers................................................................................29
Intrinsically Safe Remote Keypad...................................................................31
Digital Input Modules......................................................................................31
Analogue Input Modules.................................................................................31
Output Modules..............................................................................................32
Serial Interface Modules.................................................................................33
Specialty Modules ..........................................................................................34
Protection Modules.........................................................................................34
End-of-Line Modules ......................................................................................34
INSTALLATION........................................................................................................35
General Warnings...........................................................................................35
Mandatory Installation Practices.....................................................................36
Mechanical Arrangement................................................................................37
Electrical Connections....................................................................................37
COMMISSIONING AND CALIBRATION ..................................................................38
iMAC2 CONTROLLER OPERATION SUMMARY ..................................................39
iMAC2 Controller User Interface...................................................................40
System Menu ...............................................................................................41
iMAC2 Controller LEDs.................................................................................44
Selectors & DIP Switches.............................................................................44
SERVICE, MAINTENANCE & DISPOSAL..............................................................45
Equipment Service .......................................................................................45
Equipment Maintenance...............................................................................46
Disposal........................................................................................................46
iMAC2 CONTROLLER SPECIFICATIONS.............................................................47
EQUIPMENT LIST .................................................................................................49
iMAC2 Controllers & Accessories.................................................................49
Intrinsically Safe Barriers..............................................................................49
Intrinsically Safe Remote Keypads ...............................................................49
Digital Input Modules....................................................................................50
Analogue Input Modules...............................................................................50

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Output Modules............................................................................................51
Serial Interface Modules...............................................................................52
Specialty Modules ........................................................................................52
Protection Modules.......................................................................................52
EOL and MEOL Modules............................................................................53

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TABLE OF FIGURES
Figure 1.1: 2-Wire iMAC Fieldbus System Configuration 10
Figure 1.2: 3-Wire iMAC Fieldbus System Configuration 11
Figure 1.3: MLB Intrinsic Safety Barrier (Provides both 2-Wire and 3-Wire Terminal Connections) 11
Figure 4.1: Block Diagram of a Simple iMAC 2-Wire System 15
Figure 4.2: Tree Network of iMAC2 Controllers 18
Figure 4.3: Example of the use of Upstream Sequence Bits for Conveyor Sequence Control 20
Figure 4.4: Example of the use of Downstream Sequence Bits for Conveyor Sequence Control 20
Figure 4.5: An Implementation of Emergency Stops on a 2-Wire iMAC Fieldbus 21
Figure 5.1: Bipolar Pulse Width Modulated iMAC Fieldbus Signal 23
Figure 6.1: iMAC2 Controller (Front) 24
Figure 6.2: iMAC2 Controller (Right Side) 24
Figure 6.3: iMAC2 Controller (Rear) 24
Figure 6.4: iMAC2 Controller Terminal Layout 25
Figure 6.5: General Purpose Input Internal Circuitry 25
Figure 6.6: iMAC2 Controller’s Data Point Table 28
Figure 7.1: Utilisation of MLB and SLB Barriers in an Intrinsically Safe System 30
Figure 8.1: iMAC2 Controller Enclosure Dimensions 37
Figure 10.1: iMAC2 Controller Operational Interface (Front) 39
Figure 10.2: iMAC2 Controller Operational Interface (Right Side) 39
Figure 10.3: iMAC2 Controller Operational Interface (Left Side) 40
Figure 10.4: iMAC System Menu –Home Page 41
Figure 10.5: iMAC System Menu (Maintenance Page) 42
Figure 10.6: iMAC System Menu (Serial Communications Page) 43
Figure 10.7: iMAC System Menu (Version Page) 43

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iMAC System User Manual
iMAC2B009 V4 –10/18
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INTRODUCTION
Document Scope
This document is intended to provide an overview of the functionality of the iMAC System. It also serves as
a user manual for the general operation of the iMAC2 Controller.
This document is not intended to provide information on the operation of individual modules, instruction on
programming the iMAC2 Controller or modules, or how to access the Modbus communication registers.
Please refer to the relevant supplementary documents for this information.
Supplementary Documents
The iMAC2 System User Manual is intended to be read in conjunction with the following documents:
1.2.1 System Documentation
IMAC2B010 iMAC2 Controller Ethernet Communications Manual
IMAC2B011 iMAC2 Controller Web Interface Manual
IMAC2B015 iMAC2 Controller Ethernet-IP (CIP) Communications Manual
IMACB094 iMAC System Installation Requirements
IMACB153 iMAC Controller Serial Communications Manual
IMACB182 iMAC SIL Emergency Stop Qualification
IMACB005 iMAC Module Programming Manual
1.2.2 Module Documentation
IMACB003 iMAC RO4 Module Technical Datasheet
IMACB018 iMAC LPU Module Technical Datasheet
IMACB020 iMAC DI8 Module Technical Datasheet
IMACB045 iMAC IIM Module Technical Datasheet
IMACB046 iMAC DI4 Module Technical Datasheet
IMACB047 iMAC EOL/MEOL Module Technical Datasheet
IMACB060 iMAC LED4 Module Technical Datasheet
IMACB061 iMAC SSW Module Technical Datasheet
IMACB062 iMAC SQM Module Technical Datasheet
IMACB066 iMAC AIM Module Technical Datasheet
IMACB067 iMAC RTD1 Module Technical Datasheet
IMACB141 iMAC ARM Module Technical Datasheet
IMACB142 iMAC CRM Module Technical Datasheet
IMACB143 iMAC EMM Module Technical Datasheet
IMACB144 iMAC GRM Module Technical Datasheet
IMACB146 iMAC IRK Keypad Technical Datasheet
IMACB147 iMAC PIM Module Technical Datasheet
IMACB148 iMAC SIM-G Module Technical Datasheet
IMACB149 iMAC SIM-G2 Module Technical Datasheet
IMACB150 iMAC SIM-T Module Technical Datasheet
IMACB151 iMAC MLB Barrier Technical Datasheet
IMACB152 iMAC SLB Barrier Technical Datasheet
IMACB154 iMAC SIM-P Module Technical Datasheet
IMACB172 IMAC LIM Module Technical Datasheet

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Definitions
1.3.1 System Definitions
Term
Definition
2-Wire System
A 2-Wire iMAC system has a fieldbus that contains a Signal Line and a Common
Line. The Signal Line is fed through all of the emergency stop contacts and
terminated into the EOL module. In a 2-Wire System, all iMAC fieldbus modules
communicate over the Signal Line. This means that if an emergency stop is
activated, the Signal Line is broken and all modules downstream of the activated
emergency stop will lose communication with the iMAC2 Controller.
3-Wire System
A 3-Wire iMAC system has a fieldbus that contains a Signal Line, Monitoring Line
and a Common Line. The Signal Line is fed through all of the emergency stop
contacts and terminated into the EOL module. The Monitoring Line is terminated
into an MEOL module. In a 3-Wire System, all iMAC fieldbus modules communicate
over the Monitoring Line. The advantage of the 3-Wire System, over the 2-Wire
System, is that when the Signal Line is broken by an emergency stop,
communication with all modules is still possible via the Monitoring Line.
A-Line
The Signal Line in a 3-wire system.
AR
The Auxiliary Relay (AR) of the iMAC2 Controller. The operation of the AR can be
customised using the application (SLP) software.
B-Line
The Monitoring Line in a 3-wire system or the Signal Line in a 2-wire system.
C-Line
The Common Line for 3-wire and 2-wire systems
Common Line
The Common Line as the name suggests is the common return communications
line of the L1 fieldbus. The Common Line is used in both 2-Wire and 3-Wire
Systems.
CR
The Control Relay (CR) of the iMAC2 Controller. Provides emergency stop function
via End-Of-Line module monitoring.
Fieldbus
The iMAC Fieldbus is the communications backbone for the iMAC system. Can be
run as either a 2-Wire or 3-Wire System.
iMAC
Integrated Monitoring and Control
Monitoring
Line
The Monitoring Line forms part of the L1 fieldbus in a 3-Wire system and is
terminated into a MEOL module
In 3-Wire Systems, all the modules communicate over the Monitoring Line.
This allows communication to continue with all modules if an emergency stop is
activated, which opens the Signal Line. The Signal Line is fed through the
emergency stop contacts.
Multi-drop
The term multi-drop refers to a communications line that allows multiple
communicating devices to be connected to the same line.
Signal Line
The Signal Line forms part of the L1 fieldbus in both 2-Wire and 3-Wire systems.
The Signal Line is feed through the emergency stop contacts and is terminated into
the EOL module. In a 3-Wire System, the Signal Line is used only for tripping and
the modules communicate on the Monitoring Line. In a 2-Wire System, the Signal
Line is used for both tripping and communication.
SLP
Supervisory Logic Program. The Ampcontrol proprietary programming language for
the iMAC2 Controller's application software.
Application (SLP) software must be written, compiled and installed in order for the
iMAC2 Controller to perform intended operation.

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1.3.2 Module Definitions
Term
Definition
AIM
Analogue Input Module that connects to the iMAC L1 fieldbus. There are two types
available, a 0-10V model and a 4-20mA model.
ARM
Auxiliary Relay Module that connects to the iMAC L1 fieldbus. Provides a relay
output that mimics the operation of the iMAC2 Controller's AR. Note: requires
specific application (SLP) software for operation.
CRM
Control Relay Module that connects to the iMAC L1 fieldbus. Provides a relay
output that mimics the operation of the iMAC2 Controller's CR. Note: requires
specific application (SLP) software for operation.
DI4
Digital Input Module (4x digital inputs) that connects to the iMAC L1 fieldbus.
Provides remote monitoring of four voltage free contacts.
DI8
Digital Input Module (8x digital inputs) that connects to the iMAC L1 fieldbus.
Provides remote monitoring of eight voltage free contacts.
EMM
End of line Monitoring Module that connects to the iMAC L1 fieldbus. Provides a
changeover relay output that de-energises if the Signal Line is unhealthy.
EOL
End Of Line Module that terminates the Signal Line of the iMAC L1 fieldbus.
GRM
General Relay Module that connects to the iMAC L1 fieldbus. Provides an output
relay that can be remotely controlled by the iMAC2 Controller.
IIM
Input and Indication Module that connects to the iMAC L1 fieldbus. Provides five
voltage free contact inputs and four LED outputs for indication.
IRK
iMAC Remote Keypad that connects to the iMAC L1 fieldbus. Allows the user to
operate the iMAC2 Controller's interface remotely.
LED4
LED Output Module that connects to the iMAC L1 fieldbus. Provides four LED
outputs for indication.
LIM
LED Indication Module which interfaces directly to the iMAC Fieldbus, providing a
highly configurable remote indication module.
LPU
Lightning Protection Unit Module that connects to the iMAC L1 fieldbus. Provides
surge protection for a multi-dropped iMAC module.
MEOL
Monitoring End Of Line Module that terminates the Monitoring Line of the iMAC L1
fieldbus in a 3-Wire System.
MLB
Master Line Barrier is an intrinsically safe barrier required for I.S. applications. It
connects between the iMAC2 Controller and hazardous area L1 fieldbus.
RO4
Relay Output Module (4x relays) that connects to the iMAC L1 fieldbus. Provides
four relay outputs that can be remotely controlled by the iMAC2 Controller, or linked
to follow the states of an iMAC input module.
RTD1
Resistance Temperature Device Module that connects to the iMAC L1 fieldbus.
Provides a remote temperature input using a PT100 RTD sensor.
SIM-G
Serial Interface Module (GasGuard) that connects to the iMAC L1 fieldbus. This
module provides an interface between an Ampcontrol GasGaurd Controller and the
iMAC L1 fieldbus.
SIM-G2
Serial Interface Module (GasGuard x2) that connects to the iMAC L1 fieldbus. This
module provides an interface between two Ampcontrol GasGaurd Controllers and
the iMAC L1 fieldbus.
SIM-P
Serial Interface Module (Programmable) that connects to the iMAC L1 fieldbus.
This module provides an interface between a Modbus RTU RS485 slave device
and the iMAC L1 fieldbus.