Barber-Colman MACO Series User manual

1640-IN-031-C-08 Page 1 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Table of Contents
MACO Series Controller Installation
Contents
1. General ............................................................................................... 4
1.1 CE EMC Compliance .................................................................... 5
1.2 Notes on EMC Shielding............................................................... 5
2. Installing & Wiring the T/C-Analog Board................................................ 23
3. Installing & Wiring the Communications Board ....................................... 30
4. Installing & Wiring the Data Handler Board............................................ 33
5. Installing & Wiring the Analog I/O Board................................................ 36
6. Installing & Wiring the High Speed Ana Sig Processor (Parison) Board. 41
6.1 Introduction ................................................................................. 41
6.2 Wiring of All Analog Inputs & Outputs ......................................... 41
6.2.1 Input/Output Specifications.................................................. 41
6.2.2 Analog Input/Output Wiring Guidelines................................ 42
6.2.3 Analog I/O Applications Wiring ............................................ 42
6.3 Wiring of DC Inputs & Outputs .................................................... 42
7. Installing & Wiring the Seq/Hydraulics Board......................................... 54
8. Installing & Wiring the Power Supply Board........................................... 56
9. Installing & Wiring AC Output Boards ..................................................... 61
10. Installing & Wiring DC Output Boards ..................................................... 66
11. Installing & Wiring Analog Output Boards ............................................... 72
12. Installing & Wiring AC Input Boards ........................................................ 77
13. Installing & Wiring DC Input Boards........................................................ 81
14. Installing & Wiring AC/DC Input Boards.................................................. 86
15. Wiring the 32 In/32 Out or 24 In/24 Out Digital I/O Boards ..................... 90
15.1 Introduction ................................................................................. 90
15.2 Specifications .............................................................................. 90
16. MACO Series Specifications ................................................................... 97
17. Application Guide for Sensors and Analog Signals............................... 102
17.1 General ..................................................................................... 102
17.2 Hydraulic Pressure Transducers............................................... 102
17.3 Position Transducers ................................................................ 102
17.4 Tachometer............................................................................... 102
17.5 Analog Outputs ......................................................................... 102
17.6 Extrusion/Parison Pressure Transducers.................................. 102
Figures Figure 1.0 12 Slot Enclosed Controller Dimensions....................................... 6
Figure 1.1 16 Slot Enclosed Controller Dimensions....................................... 7
Figure 1.2 12 Slot Open Frame Controller Dimensions ................................. 8
Figure 1.3 9 Slot Open Frame Controller Dimensions ................................... 9
Figure 1.4 7 Slot Open Frame Controller Dimensions ................................. 10
Figure 1.5 12 Slot Controller Board Locations (5 Slots of I/O) ..................... 11
Figure 1.6A 16 Slot Controller Board Locations (8 Slots of I/O) ..................... 12

1640-IN-031-C-08 Page 2 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figures (continued) Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O) ..................... 13
Figure 1.6C16 Slot Controller Board Locations (6 Slots of I/O) ..................... 14
Figure 1.6D9 Slot Controller Board Locations (3 Slots of I/O) ....................... 15
Figure 1.7 7Slot Controller Board Locations .................................................. 16
Figure 1.8 Multi-Chassis Installation ............................................................ 17
Figure 1.9 12 Slot Motherboard Bus Layout ................................................ 18
Figure 1.10 16 Slot Motherboard Bus Layout ................................................ 19
Figure 1.11 9 Slot Motherboard Bus Layout .................................................. 20
Figure 1.12 AC Power Connections for 9 Slot Controllers ............................. 21
Figure 1.13 AC Power Connections for 12 Slot Controllers ........................... 21
Figure 1.15 DC Power Connection for 7 Slot Controllers............................... 22
Figure 1.14 AC Power Connections for 16 Slot Controllers ........................... 22
Figure 2.0 Installing Resistors for Current Inputs ......................................... 24
Figure 2.1 A-60063-0XX or A-60133-0XX 12 Zone Temperature Board ..... 25
Figure 2.2 A-60063-1XX or A-60133-1XX 12 Zone Analog Input Board...... 26
Figure 2.3 A-60063-2XX or A-60133-2XX 6 Zone Analog Input / 6 Zone T/C
Input Board.................................................................................. 27
Figure 2.4 A-60063-3XX or A-60133-3XX 6 Zone T/C Input Board ............. 28
Figure 2.5 Wiring T/C Inputs using the T/C-Analog Card............................. 29
Figure 2.6 Wiring Analog Inputs using the T/C-Analog Card ....................... 29
Figure 3. A-60050 Communications Motherboard ..................................... 31
Figure 3.1 Wiring Communications Daughterboards ................................... 32
Figure 4.0 A-60010 Data Handler Board...................................................... 34
Figure 4.1 Wiring the DH Board (Overbraid in Conduit to Op Station)......... 35
Figure 4.2 Wiring the Data Handler Board (Overbraid to Op Station).......... 35
Figure 5.0 A-60051 Analog I/O Motherboard ............................................... 37
Figure 5.1 Analog I/O Wiring (Connector P2)............................................... 38
Figure 5.2 Analog I/O Wiring (Connector P3)............................................... 39
Figure 5.3 Wiring the Analog I/O Board ....................................................... 40
Figure 6.0 A-13815 High Speed Ana Sig Processor (Parison) Board.......... 43
Figure 6.1 High Speed Analog (Parison) Sensor Wiring.............................. 44
Figure 6.2 High Spd Ana (Parison) Card Pressure Transducer Wiring........ 45
Figure 6.3 High Spd Ana (Parison) Card DC Input and Output Wiring ........ 45
Figure 6.4 One-Head Time-Based Machine with B-C Servo Amp ............... 46
Figure 6.5 Two-Head Time-Based Machine with B-C Servo Amp ............... 47
Figure 6.6 Two-Head Position-Based Machine with B-C Servo Amp .......... 48
Figure 6.7 Two-Hd Position-Based Mach w/Pushout and B-C Servo Amp.. 49
Figure 6.8 Accumulator Machine (Velocity Control) with B-C Servo Amp.... 50
Figure 6.9 Two-Head Position-Based Machine with Moog Servo Amp ....... 51
Figure 6.10 Wiring the High Spd Ana (Parison) Board DC Inputs ................. 52
Figure 6.11 Wiring the High Spd Ana (Parison) Board DC Outputs............... 52
Figure 6.12 Wiring the High Spd Ana (Parison) Board Analog Inputs ........... 53
Figure 6.13 Wiring the High Spd Ana (Parison) Board Analog Outputs......... 53
Figure 7. A-60012 or A-60083 Seq/Hydr Board ......................................... 55
Figure 8.0 A-13395 Power Supply Board..................................................... 57
Figure 8.1 A-60045 Power Supply Board..................................................... 58
Figure 8.2 Wiring the Power Supply Board in 9 Slot Systems ..................... 59
Figure 8.3 Wiring the Power Supply Board in 12 Slot Systems ................... 59
Figure 8.4 Wiring the Power Supply Board in 16 Slot Systems ................... 60
Figure 9.0 A-13402 Standard Density AC Output Board ............................. 63
Figure 9.1 A-13904 High Density AC Output Board..................................... 64
Figure 9.2 AC Output Wiring ........................................................................ 65
Figure 10.0 A-60068 24 Output DC Out Board .............................................. 68
Figure 10.1 A-60107 16 Output DC Out Board .............................................. 69
Figure 10.2 DC Output Wiring ........................................................................ 70
Figure 10.3 Wiring the DC Output Board ....................................................... 71

1640-IN-031-C-08 Page 3 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figures (continued) Figure 11.0 Locating the Analog Output Boards ............................................ 73
Figure 11.1 A-60033 Analog Output Board.................................................... 74
Figure 11.2 Analog Output Wiring.................................................................. 75
Figure 11.3 Wiring the Analog Output Board ................................................. 76
Figure 12.0 A-13900 or A-60089 Standard Density AC Input Board ............. 78
Figure 12.1 High Density AC Input Board Assembly...................................... 79
Figure 12.2 AC Input Wiring ........................................................................... 80
Figure 13.0 A-60070 Standard Density DC Input Board ................................ 82
Figure 13.1 High Density DC Input Board Assembly ..................................... 83
Figure 13.2 DC Input Wiring........................................................................... 84
Figure 13.3 Wiring the DC Input Board .......................................................... 85
Figure 14. High Density AC/DC Input Board Assembly ............................... 88
Figure 14.1 A-13991-100 High Density DC/AC Input Board Assembly ......... 89
Figure 15.1 32 In/32 Out or 24 In/24 Out A-60150-x...................................... 91
Figure 15.2 32 In/32 Out or 24 In/24 Out Digital I/O Wiring ........................... 92
Figure 15.3 32 In/32 Out or 24 In/24 Out Sample Wiring............................... 93
Figure 16. Communications Cable Pinouts .................................................. 94
Figure 17. Communications Cable Part Numbers........................................ 95
Figure 18. Firmware Model Numbers........................................................... 96

1640-IN-031-C-08 Page 4 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
1. General
Thewiring guidelinesoutlinedin thismanual areto beused inadditionto all
applicable electrical and safety codes. Be sure to follow all requirements of
such codes as well as other recognized safety practices.
This controller must be installed in a suitable enclosure which will minimize or
prevent the accumulation of dust, dirt, or other particles which could build up and
clog ventilation slots. Periodic inspections must be scheduled to insure that slots
do not become clogged.
Cleaning of the control cabinet and the controller should be done using a vacuum
cleaner.Donot use compressed air asthiscouldforceparticles into the controller
and actually worsen conditions.
Airtemperaturewithintheenclosuremustnotexceed60°C(140°F).Thetempera-
ture will tend to be higher at the top of the enclosure so if possible, locate the
controller toward the middle or the lower portion. Allow adequate space for air to
flowaroundthecontroller.Itisstronglyrecommendedthatafullfourinchesormore
be maintained on all sides wherever possible. This space allows for wiring
installation and free flow of air to the bottom of the controller.
Severaldifferentchassistypesareavailable;12slotand16slotenclosedversions;
as well as 9 slot and 12 slot open versions. As of June 2001, the 12 slot enclosed
version is no longer available, but a (new) 7 slot open version (24 Vdc only) is
introduced.
Theleft side of the controller isfor analogvoltages fromthermocouples andother
sensors and the right side is for discrete Input and Output card signals (switching
voltages). The power supply card is the divider between the two types of signals.
A typical base control system requires approximately 1 kVA.
Note that this manual refers to wiring classifications in terms of "Class 1" and
"Class 2" which are classifications of the U.S. National Electrical Code (NEC).
Class 1 wiring is analogous to "Mains" and Class 2 is analogous to "SELV"
(separated extra low voltage).
Notealsothat thismanualreferstoACpowerwiringintermsof"L1"and"L2.""L1"
is analogous with "Live" and "L2" is analogous with "Neutral."
This Controller is intended for Panel Mounting
CAUTION:
DoNotOperateWithoutCoverin Place. Cover must be in place both for operator
safety and to insure proper cooling of internal components.
A.1

1640-IN-031-C-08 Page 5 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
1.1 CE EMC Compliance ThisMACOcontrolsystemisinfullcompliancewithCEEMCrequirementsaslong
asACinputboards,ACoutputboardsandanalogoutputboardsareexcluded.Use
of these boards will require additional EMC testing by the machine manufacturer.
Wiring guidelines to ensure the machine is CE EMC compliant are included with
eachboard described in this document. For additional wiring information,refer to
the following publications:
Recommended Guideline for Wiring & Grounding Machine Controls
Society of the Plastics Industry, Inc.
1275 K Street, N.W. – Suite 400
Washington, D.C. 20005
[phone]
IEEEGuidefortheInstallationofElectricalEquipmenttoMinimizeElectricalNoise
Inputs to Controllers from External Sources
(IEEE Std 518-1982)
1.2 Notes on EMC Shielding Nospecial EMC measures are required for signalcontrolorDC power wiring less
than3 meters inlength. Forsignalwiring inexcessof3 meters, routinginmetallic
conduit or an overbraid is required up to within 10 cm of the end point.
Forthisdocument,theterm"shield"appliestoaBRAIDEDshieldthatisgrounded
onlyatoneend. FOIL shields should NOT be used(theyofferpoorprotection that
is degraded further by using a drain wire to terminate the shield). Proper shield
termination must provide a peripheral clamping arrangement so that no internal
conductorsarevisible. Theterm"overbraid"appliestoaspecialtypeofshieldthat
isgroundedatBOTHends.Cablecanbepurchasedforthispurposeoroverbraid
can be added to existing cable. This type of shield affords protection to very high
frequencies,especiallywhensignificantmagneticfields(causedbyhighcurrents)
are present. As with braided shields, proper overbraid termination must provide a
peripheral clamping arrangement so that no internal conductors are visible.
Specific requirements for shields and overbraids are identified on the individual
figures within this document.
Where external power supplies are required, a CE recognized supply must be
used. Test results on CE power supplies have shown that they may emit noise
above 30 MHz. Install a ferrite bead suitable for power cord use at the output
terminals of the supply.
External supplies (and their ground distribution block) must be located within 30
cm of the bottom of the controller chassis.
If bond straps other than those supplied with this controller are used, they must
maintain a 5:1 length to width ratio.
Forinformationonobtainingferritebeads,bondstraps,shieldedcableoroverbraid,
contact the factory or your local sales representative.

1640-IN-031-C-08 Page 6 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.0 12 Slot Enclosed Controller Dimensions
19.0" (483mm) Ref.
18.312" (465.12mm)
Front View
1.37" (35mm) Approx.
13.562" (345mm)
Ref.
(4) .531"
(13.48mm)
(4) .281"
(7.14mm)
6-32 EMC
Bond Stud
1" (25.4mm)
Approx.
2" (50mm)
Approx.
10.500" (266.70mm)
Side View
8" (203mm)
Approx.
(with Cover)
Allow Approx. 2"
(51mm) Clearance
each Side
for Latches
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow (Fans)
Latch (2)
Dimensions are in inches
and (millimeters)

1640-IN-031-C-08 Page 7 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.1 16 Slot Enclosed Controller Dimensions
27.5" (697mm) Ref.
26.625" (676.28mm)
Front View
1.37" (35mm) Approx.
13.562" (345mm)
Ref.
(4) .531"
(13.48mm)
(4) .281"
7.14mm)
1" (25.4mm)
Approx.
2" (50mm)
Approx.
6-32 EMC
Bond Stud
10.500" (266.70mm)
Power Connection
Side View
8" (203mm)
Approx.
(with Cover)
Power Connection
6-32 EMC
Bond Stud
Allow Approx. 2"
(51mm) Clearance
each Side
for Latches
Allow Approx. 3-4" (75 - 100mm)
Clearance at Top and Bottom
for Air Flow (Fans)
Latch (2)
Dimensions are in inches
and (millimeters)

1640-IN-031-C-08 Page 8 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.2 12 Slot Open Frame Controller Dimensions
20.050 (509mm)
Reference
19.250 (489mm)
Front View
.531 (13.49mm) (4)
.281 (7.14mm) (4)
6-32 EMC
Bond Stud
1.705
(43mm)
8.750
(222.3mm)
Side View
Allow Approx. 2" (50mm)
Clearance each Side
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow
12.160
(106.4mm)
1.705
(43mm)
8.400
(213mm)
Dimensions are in inches
and (millimeters)
.400
(10mm)

1640-IN-031-C-08 Page 9 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.3 9 Slot Open Frame Controller Dimensions
16.415 (417mm)
Reference
15.665 (398mm)
Front View
.531 (13.49mm) (4)
.281 (7.14mm) (4)
6-32 EMC
Bond Stud
1.705
(43mm)
8.750
(222.3mm)
Side View
Allow Approx. 2" (50mm)
Clearance each Side
Allow Approx. 3-4" (75-100mm)
Clearance at Top and Bottom
for Air Flow
12.160
(106.4mm)
1.705
(43mm)
8.400
(213mm)
Dimensions are in inches
and (millimeters)
.400
(10mm)

1640-IN-031-C-08 Page 10 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Dimensions are in inches
and (millimeters)
Figure 1.4 7 Slot Open Frame Controller Dimensions
11.300
(287mm)8.750
(222.3mm)
14.000 (355.6mm)
14.800 (376mm)
Reference
Ø 0.281
(7.14mm)
0.500
(12.7mm)
1.275
(32.38mm)
0.400
(10mm)
Ø 0.531
13.49mm)
8.300
(210.8mm)
0.640
(16.2mm)

1640-IN-031-C-08 Page 11 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.5 12 Slot Controller Board Locations (5 Slots of I/O)
Mother Board
Temperature #1
Slot #2
Slot #3
Data Handler
Slot #5
Sequence/Hydraulics
Slot #12
Slot #11
Slot #10
Slot # 9
Slot # 8
Power Supply
Optional:
Slot #1:
Slot #4:
Slot #5:
Slot #6:
Slot #7:
Temp (T/C-Ana) Bd #1 (or Parison)
Data Handler Bd
Analog I/O
Sequence/Hydraulics Bd
Power Supply Bd (See Note)
Standard:
Slot #2:
Slot #3:
Slot #8:
Slot #9:
Slot #10:
Slot #11:
Slot #12:
Temp (T/C-Ana) Bd #2 (or Parison)
Communications Bd
Output Bd #1
Output Bd #2 or Input Bd #4
Output Bd #3 or Input Bd #3
Output Bd #4 or Input Bd #2
Input Bd #1Note: In 11 or 12-slot controllers, primary power is
connected directly to the power supply board.
Note:Whencountingboardsinmulti-racksystems(for
switchsettings,RLD/screenprogramming)counteach
control rack separately.
Note: Analog output boards (if used) follow the last
digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
B.1
IMPORTANT:
EMC Critical Item

1640-IN-031-C-08 Page 12 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.6A 16 Slot Controller Board Locations (8 Slots of I/O)
Optional:
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Slot #10
Slot #9
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Data Handler
Power Supply
Mother Board
See Wiring
Detail Below
Slot #1:
Slot #5:
Slot #7:
Slot #8:
Temperature (T/C-Analog) Bd #1
Sequence/Hydraulics Bd
Data Handler Bd
Power Supply Bd
Analog I/O Bd #1 in Slot #3.
2nd Seq Bd in Slot #6.
Start in Slot #2 with remaining Temperature
Bds (5 max.), followed by Comm Bd.,
followed by all Parison Bds (2 max.).
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Output Bd #5
Output Bd #6 or Input Bd #3
Input Bd #2
Input Bd #1
Slot # 2,
3,4 & 6:
Slot # 9:
Slot #10:
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Standard:
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen pro-
gramming)counteachcontrolrackseparately.
Energize CR 605
and
Energize CR 607
(if Hi Density I/O)
Note:Analogoutputboards(ifused)followthe
last digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
B.1
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
Top
E24-1261
Viewed from side
of Controller
E24-1134-005
IMPORTANT:
EMC Critical Item

1640-IN-031-C-08 Page 13 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.6B 16 Slot Controller Board Locations (7 Slots of I/O)
Optional:
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Slot #10
Power Supply
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Slot #7
Data Handler
Mother Board
See Wiring
Detail Below
Slot #1:
Slot #5:
Slot #8:
Slot #9:
Temperature (T/C-Analog) Bd #1
Sequence/Hydraulics Bd
Data Handler Bd
Power Supply Bd
Analog I/O Bd #1 in Slot #3. Analog I/O Bd #2
in Slot #7 (requires 2nd Seq Bd in Slot #6).
Start in Slot #2 with remaining Temperature
Bds (6 max.), followed by Comm Bd., fol-
lowed by all Parison Bds (2 max.).
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Output Bd #5 or Input Bd #3
Output Bd #6 or Input Bd #2
Input Bd #1
Slot # 2, 3,
4, 6 & 7:
Slot #10:
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Standard:
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen pro-
gramming)counteachcontrolrackseparately.
Energize CR 604
and
Energize CR 607
(if Hi Density I/O)
Note:Analogoutputboards(ifused)followthe
last digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
B.1
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
Top
E24-1261
Viewed from side
of Controller
E24-1134-005
IMPORTANT:
EMC Critical Item

1640-IN-031-C-08 Page 14 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.6C 16 Slot Controller Board Locations (6 Slots of I/O)
Optional:
Slot #16
Slot #15
Slot #14
Slot #13
Slot #12
Slot #11
Power Supply
Slot #9
Slot #1
Slot #2
Slot #3
Slot #4
Sequence/Hydraulics
Slot #6
Slot #7
Data Handler
Mother Board
See Wiring
Detail Below
Analog I/O Bd #1 in Slot #3.
2nd Seq Bd in Slot #6.
Start in Slot #2 with remaining Temperature
Bds (5 max.), followed by Comm Bd.,
followed by all Parison Bds (2 max.).
Output Bd #1
Output Bd #2
Output Bd #3
Output Bd #4
Input Bd #2
Input Bd #1
Slot #2, 3,
4, 6, 7 & 9:
Slot #11:
Slot #12:
Slot #13:
Slot #14:
Slot #15:
Slot #16:
Standard:
Slot #1:
Slot #5:
Slot #8:
Slot #10:
Temperature (T/C-Analog) Bd #1
Sequence/Hydraulics Bd
Data Handler Bd
Power Supply Bd
Note: When counting boards in multi-rack
systems (for switch settings, RLD/screen pro-
gramming)counteachcontrolrackseparately.
Energize CR 606
and
Energize CR 607
(if Hi Density I/O)
Note:Analogoutputboards(ifused)followthe
last digital output board.
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
B.1
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
Top
E24-1261
Viewed from side
of Controller
E24-1134-005
IMPORTANT:
EMC Critical Item

1640-IN-031-C-08 Page 15 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.6D 9 Slot Controller Board Locations (3 Slots of I/O)
Note:Whencountingboardsinmulti-racksystems(for
switchsettings,RLD/screenprogramming)counteach
control rack separately.
Slot #1
Slot #2
Data Handler
Slot #4
Sequence/Hydraulics
Slot #9
Slot #8
Slot #7
Power Supply
Mother Board
Slot 1: Temperature (T/C-Analog)
Slot 2: Temperature,CommunicationsorAnalogI/O
Slot 3: Communications or Analog I/O
Slot 4: Data Handler (only)
Slot 5: Sequence/Hydraulics (only)
Slot 6: Power Supply (only)
Slot 7: Input Bd #1
Slot 8: Output Bd #2
Slot 9: Output Bd #1
Energize CR 605
and
Energize CR 607
(if Hi Density I/O)
3 Slots of I/O
See Wiring
Detail Below
CAUTION:
Controller MUST be operated with Cover in place! Wires and Boards carry High
Voltage which may cause Severe Shock or Electrocution. When inserting or
removing Boards, make certain ALL power is OFF. When removing boards, use
card pullers at top and bottom of board. Pull board out approximately 1" and use
insulated screwdriver to "pop" connector free.
B.1
IMPORTANT:
EMC Critical Item
Earth (Safety Ground)
No Connection
L2 Vac IN
No Connection
L1 Vac IN
Top
E24-1261
Viewed from side
of Controller
E24-1134-005

1640-IN-031-C-08 Page 16 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.7 7 Slot Controller Board Locations
Sequence/Hydraulics
Slot #2*
Data Handler
Slot #4
Slot #7
Slot #6
Power Supply & Communications
*If process control/line graphs is
specified in sequence options, this
slot must have Analog I/O card.
Note:Whencountingboardsinmulti-racksystems(for
switchsettings,RLD/screenprogramming)counteach
control rack separately.
Slot 1: Sequence/Hydraulics (only)
Slot 2: Analog I/O*, T/C-Analog or Parison/Motion
Slot 3: Data Handler (only)
Slot 4: T/C-Analog or Parison/Motion
Slot 5: Power Supply & Communications (only)
Slot 6: Combo I/O or Analog Output
Slot 7: Combo I/O or Analog Output

1640-IN-031-C-08 Page 17 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.8 Multi-Chassis Installation
Controller 4
(Secondary)
Controller 3
(Secondary)
Controller 2
(Secondary)
Controller 1
(Primary)
Controllers in a multi-rack configuration can be any combination of 7 Slot, 9 Slot,
11 Slot, 12 Slot or 16 Slot Chassis. Controller 1 is the "primary" controller.
Controllers 2, 3 and 4 are "secondary" controllers.
Secondary controllers must contain a power supply board, a data handler board
and a sequence/hydraulics board. Additional board requirements will depend on
the application.
Controllers are interconnected by the connections to each data handler board.
Controller addresses are determined by Switch S2 on each data handler board.
The last controller of the installation must have its line terminating resistors
jumpered to the "in" position (J19 and J20). All other controllers must have these
resistors jumpered to the "out" position.
Wire each controller separately, but to the same source distribution and ground
distribution.
Data Handler
Board 1 Data Handler
Board n Data Handler
Board n Data Handler Board (last)
J19
J20
3
3
1
1
Out
In
Out
In
P14
Data +
Data -
ISO5V
ISOC0M
1
J19
J20
3
3
1
1
Out
In
Out
In
P14
Data +
Data -
ISO5V
ISOC0M
1
J19
J20
3
3
1
1
Out
In
Out
In
P14
Data +
Data -
ISO5V
ISOC0M
1
J19
J20
3
3
1
1
Out
In
Out
In
P14
Data +
Data -
ISO5V
ISOC0M
1
To Operator
Station
Switch S2
(Data Handler Board)
O
F
F
ROCKER DOWN
1 2 3 4 5 6 7 8
Single Rack
Ctlr 1
Ctlr 2
Ctlr 3
Ctlr 4
Switch S2
Sw1 Sw2
Off
On
Off
On
Off
Off
Off
On
On
Off
Sw3
Off
Off
Off
Off
On
(See Operator
Station Wiring Detail)
EMC Terminal
Block EMC Terminal
Block EMC Terminal Block EMC Terminal Block
10 ft. (3.3m)
maximium 10 ft. (3.3m)
maximium 10 ft. (3.3m)
maximium
(Overbraid) (Overbraid) (Overbraid)

1640-IN-031-C-08 Page 18 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
Figure 1.9 12 Slot Motherboard Bus Layout
A-13394
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11 Slot 12
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11 Slot 12
DC POWER
ANALOG DATA BUS
CONTROL DATA BUS
COMM. DATA BUS LOGIC BUS
POWER BUS
FAN1
FAN2
P167
DC POWER BUS POWER BUS FAN 1 FAN 2
PIN
NUMBER
P1
P2
P3
P4
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
ANALOG
DATA BUS CONTROL
DATA BUS COMMUNICATIONS DATA BUS LOGIC DATA BUS
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth Ground at P167)
PIN
NUMBER PIN NUMBER PIN NUMBER
PIN
NUMBER PIN NUMBER PIN NUMBER PIN NUMBER
P5
P6
P7
P8
P9
P10
P157
P158
P159
P160
P161
P162
P163
P164
P165
P166
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
F1/F2 COM
+20V
TACH2
+20V
F1/F2 COM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[0]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[0]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
+20 V
+20 V
F1/F2 COM
F1/F2 COM
SLOTS
7 & 8
ONLY

1640-IN-031-C-08 Page 19 of 104
MACO Series Controller Installation
Eurotherm/Barber-Colman
Figure 1.10 16 Slot Motherboard Bus Layout
A-13887 A-13888
A-13887 A-13888
DC POWER BUS POWER BUS FAN 1 FAN 2
PIN
NUMBER
P1
P2
P3
P4
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
ANALOG
DATA BUS CONTROL
DATA BUS COMMUNICATIONS DATA BUS LOGIC DATA BUS
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth
Ground at P184)
PIN
NUMBER PIN NUMBER PIN NUMBER
PIN
NUMBER PIN NUMBER PIN NUMBER PIN NUMBER
P5
P6
P7
P8
P9
P10
P174
P175
P176
P177
P178
P179
P180
P181
P182
P183
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
F1/F2 COM
+20V
TACH2
+20V
F1/F2 COM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
CNTL_SLOT[8]
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
/COMM_SELECT[8]
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
+20 V
-20 V
F1/F2 COM
F1/F2 COM
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 1 Slot 2 Slot 3
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 1 Slot 2 Slot 3
DC POWER
ANALOG DATA
BUS 1
CONTROL DATA BUS
COMM. DATA BUS LOGIC BUS
POWER BUS
FAN1
FAN2
P184
Slot 4 Slot 5 Slot 6 Slot 7
Slot 4 Slot 5 Slot 6 Slot 7
LOGIC BUS
POWER BUS
FAN1
DC POWER
FAN 1
PIN
NUMBER
P177
P178
P179
P180
P181
F1/F2 COM
+20V
TACH1
+20V
F1/F2 COM
ANALOG DATA
BUS 2

1640-IN-031-C-08 Page 20 of 104
Eurotherm/Barber-Colman
MACO Series Controller Installation
DC POWER BUS POWER BUS
PIN
NUMBER
P1
P2
P3
P4
+5 Vdc Common
+5 Vdc
+5 Vdc Common
+5 Vdc
ANALOG
DATA BUS CONTROL
DATA BUS COMMUNICATIONS DATA BUS LOGIC DATA BUS
+5 Vdc Common
Not Used
28 Vac ØA
28 Vac ØB
Not Used
Guard (tied to Earth
Ground at P184)
PIN
NUMBER
PIN
NUMBER PIN NUMBER PIN NUMBER PIN NUMBER
P5
P6
P7
P8
P9
P10
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
3
2
ANLG_ADDR[0]
ANLG_ADDR[1]
ANLG_ADDR[2]
ANLG_ADDR[3]
ANLG_ADDR[4]
ANLG_ADDR[5]
ANLG_ADDR[6]
ANLG_ADDR[7]
ANLG_ADDR[8]
ANLG_ADDR[9]
ANLG_ADDR[10]
/CNTL FAULT
ANLG_DATA[0]
ANLG_DATA[1]
ANLG_DATA[2]
ANLG_DATA[3]
ANLG_DATA[4]
ANLG_DATA[5]
ANLG_DATA[6]
ANLG_DATA[7]
ANLG_R/W
/DPR SELECT
SYSTEM CLOCK
/SYSTEM RESET
ANLG_SPARE[1]
ANLG_SPARE[2]
ANLG_SPARE[3]
ANLG_SPARE[4]
ANLG_SPARE[5]
ANLG_SPARE[6]
ANLG_SPARE[7]
ANLG_SPARE[8]
CNTL_SLICE[0]
CNTL_SLICE[1]
/CNTL FAULT
/CNTL_BUSY
CNTL_ADDR[0]
CNTL_ADDR[1]
CNTL_ADDR[2]
CNTL_ADDR[3]
CNTL_ADDR[4]
/CNTL_RAM
/CNTL_RD
/CNTL_WR
CNTL_DATA[0]
CNTL_DATA[1]
CNTL_DATA[2]
CNTL_DATA[3]
CNTL_DATA[4]
CNTL_DATA[5]
CNTL_DATA[6]
CNTL_DATA[7]
SYSTEM CLOCK
/SYSTEM RESET
/POWER DOWN
CNTL_SLOT[X]
CNTL_SLOT[1]
CNTL_SLOT[2]
CNTL_SLOT[3]
CNTL_SLOT[4]
CNTL_SLOT[5]
CNTL_SLOT[6]
CNTL_SLOT[7]
CNTL_SLOT[8]
COMM_SLICE[0]
COMM_SLICE[1]
/COMM_FAULT
/COMM_BUSY
COMM_ADDR[0]
COMM_ADDR[1]
COMM_ADDR[2]
COMM_ADDR[3]
COMM_ADDR[4]
/COMM_RAM
/COMM_RD
/COMM_WR
COMM_DATA[0]
COMM_DATA[1]
COMM_DATA[2]
COMM_DATA[3]
COMM_DATA[4]
COMM_DATA[5]
COMM_DATA[6]
COMM_DATA[7]
SYSTEM CLOCK
/COMM RESET
/POWER DOWN
/COMM_SELECT[X]
/COMM_SELECT[1]
/COMM_SELECT[2]
/COMM_SELECT[3]
/COMM_SELECT[4]
/COMM_SELECT[5]
/COMM_SELECT[6]
/COMM_SELECT[7]
/CO
MM
S
ELE
C
T
[8]
/LGC_SELECT[X]
/SYSTEM RESET
5V POWER
/POWER DOWN
COMMON
COMMON
LGC_ADDR[0]
LGC_ADDR[1]
LGC_ADDR[2]
LGC_DATA[0]
LGC_DATA[1]
LGC_DATA[2]
LGC_DATA[3]
LGC_DATA[4]
LGC_DATA[5]
LGC_DATA[6]
LGC_DATA[7]
LGC_R/W
/CNTL FAULT
SYSTEM CLOCK
SPARE_BUS[1]
SPARE_BUS[2]
SPARE_BUS[3]
SPARE_BUS[4]
SPARE_BUS[5]
SPARE_BUS[6]
TACH 1
TACH 2
+20 V
-20 V
F1/F2 COM
F1/F2 COM
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9
Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9
DC POWER
ANALOG DATA
BUS 1
CONTROL DATA BUS
COMM. DATA BUS
POWER BUS
FAN1
FAN2
P184
LOGIC BUS
ANALOG DATA
BUS 2
Figure 1.11 9 Slot Motherboard Bus Layout