Eaton AIM User manual

Instructions for the
Analog Input Module
used with IMPACC Series III Networks
April 15, 1997 Page 1
THE ANALOG INPUT MODULE
The Analog Input Module (AIM) is a microprocessor-
based analog input data acquisition device designed for
use with IMPACC Series III networks. Its intended use is
to record energy consumption and other parameters by
monitoring signals from primary measurement devices
such as electric, gas and water utility meters, BTU and
steam flow meters, temperature and pressure sensors,
equipment runtime and any other devices having the
following signal types:
•General purpose current loops, 0-20 mA
•Pulse contacts up to 10 Hz
•Runtime contacts
A variety of values are computed and stored depending
on the sensor type. Refer to the IMPACC Series III
software manual.
AIM Circuit
Board
Cutler-Hammer IPONI
(Incom Product Operated
Network Interface)
Enclosure
Enclosure Cover
Figure 1 The Cutler-Hammer Analog Input Module
INSTALLATION
The AIM is designed to be installed, operated and
maintained by adequately trained people. Failure to
follow all guidelines, recommendations and instructions
may cause equipment damage and/or personal injury.
These instructions do not cover all details, variations, or
combinations of the equipment, its storage, delivery,
installation, check-out, safe operation or maintenance.
The installation must be in compliance with the National
Electric and all local codes or regulations, as well as
safety practices, for this class of equipment.
Only low voltage signals and 24VAC power are allowed
to enter the AIM enclosure. The AIM is designed to
accept sensor inputs of +/-10 volts or less. Any high
voltage terminations must be made outside of the AIM
enclosure in an electrical panel or junction box.
1) Parts List. Open the AIM shipping container and
remove all materials. Identify the items and quantities
listed below before continuing with the installation
1 - 10”x10”x4” NEMA 1 enclosure
1 - AIM Circuit Board
6 - 1/4” Hex Stand-off Screws
6 - 1/4” Nylon Screws
1 - Plastic Cover Plate
1 - 120 VAC/24VAC 24VA Plug-In Transformer
1 - 1.5A 250V Fuse (spare)
2 - Length of #12 AWG THHN Grounding Wire
4 - Crimp Eyelet
2 - 1/4” Screw with Nut
1 - IPONI module
1 - Phoenix Connector with Pre-wired Cable
2) Choosing a Location. The NEMA 1 enclosure is
designed for indoor installation only. The typical location
is on a wall in an electrical closet or mechanical room.
Ambient conditions must be between 32 and 125 Deg. F
and 20% to 80% RH, non-condensing. The AIM must
not be mounted inside electrical housings such as motor
control centers and switchgear.
Either locate the enclosure within 5 feet of a standard
120VAC receptacle, or install a receptacle within five
feet of the mounting location.
3) Securing the Enclosure. There are four holes
through the rear surface of the enclosure to allow wall
mounting. If mounting to a plywood surface, four #10 1”
wood screws are recommended. Use suitable hardware
for other surfaces to secure the enclosure.
The sides of the enclosure are lined with knockouts of
various sizes to facilitate conduit installation. Since all
terminations are made to the right edge of the circuit
board, the only usable knockouts are on the right side
and extreme right of the top and bottom. If further holes
are needed, remove the AIM circuit board before drilling
to prevent damage to the electrical components. All
wires and cable entering the AIM enclosure must have
proper strain relief and chafing protection.
4) Securing the AIM Circuit Board. Clear all debris
from the enclosure. Locate the hex stand offs riveted to
the inside of the enclosure. Line up the holes on the
stand offs with the holes in the AIM circuit board. Secure
the circuit board to the stand offs with the hex stand off
screws.

ANALOG INPUT MODULE
Page 2April 15, 1997
5) Grounding the Enclosure and Circuit Board.
Grounding is essential for proper operation and
protection of the AIM and safety of the user. Refer to
Figure 2 below for grounding connections.
Crimp
Eyelet
Case or
Conduit Ground
Crimp
Eyelet
s
AIM
Ground
Terminals
AIM
Circuit
Board 12 AWG
Stranded
20 feet
Max.
IPONI
Figure 2 Grounding Connections
Locate the hole drilled into the enclosure cover. Attach a
crimp eyelet on the inside of the cover using the 1/4”
screw and nut. Connect one of the grounding wires to
the crimp eyelet and crimp tight. Locate the hole drilled
on the upper right-hand wall inside the enclosure. Attach
the remaining crimp eyelets on the interior side of the
wall using a 1/4” screw and nut. Connect the grounding
wire attached to the enclosure door to one of the crimp
eyelets on the inside wall. Connect a grounding wire
from a free crimp eyelet on the inside wall to an
available ground terminal (terminals 41-72). Attach the
remaining crimp eyelet of the inside wall to a suitable
ground source, such as case ground for electrical
enclosures and conduit.
6) Wiring Connections and Features. Figure 3
shows the wiring connections (other than grounding
connections) and major features of the AIM. Wiring
connections include 24VAC power, channel input
terminals 1-32, channel ground terminals 41-72,
auxiliary terminals and communication connections.
Channel grounds are electrically common (non-
isolated). Auxiliary terminals are as indicated below:
40
37
39
38
36
35
33
34
80
77
79
78
76
75
73
74
+8 VDC
+8 VDC
+8 VDC
+24 VDC
+24 VDC
+24 VDC
Contact 1B
Contact 2B
+8 VDC
+8 VDC
+8 VDC
+24 VDC
+24 VDC
+24 VDC
Contact 1A
Contact 2A
Other features include a 1.5A 250V fuse (5mm x
20mm), LED indicators and system test pushbutton.
Aux.
Terminals
Network
Connection
24VAC
Connector
Channel 1
Channel 32
Logic
Power
24VDC
Power
Status
System Test
1.5A
250V
Fuse
Channel
Input
Terminals
(upper)
IPONI Ribbon
Cable Connector
IPONI 3-Pin
Connector
Shield
Newtork
8VDC
Power
Channel
Ground
Terminals
(lower)
3
2
1
Figure 3 Wiring Connections and Features
7) Communication Connections. Power must be
disconnected from the AIM before making
communication connections. Failure to disconnect
power may result in electrical shock and/or damage to
the AIM and IPONI.
As shown in Figure 4 there are two connections from the
IPONI to the AIM, and a network connection to the AIM.
Plug the 3-terminal Phoenix connector with pre-wired
cable into the IPONI and plug the other end of the cable
into the 3-pin connector at the bottom left corner of the
AIM. Plug the DB9 ribbon cable connector into the AIM.
Connect the network communication wires to the
network connector at the bottom right corner of the AIM
as shown. The shield is “floating”, or not grounded at the
AIM.
Network
Connection
IPONI Ribbon
Cable Connector
(DB9)
3-Pin
Connector
Green Phoenix
Connector with
Pre-wired Cable
Network
Shield
IPONI AIM Circuit
Board
Floating Shield
Network
3
2
1
Figure 4 Communication Connections

ANALOG INPUT MODULE
April 15, 1997 Page 3
8) Securing the Cover Plate. Before securing the
cover plate, check grounding and communication
connections.
Adjust the two cables from the IPONI so that they fit
under the cover plate. Line up the holes in the top of the
stand off screws used to secure the circuit board with
the holes in the plastic cover plate. Use the 1/4” nylon
screws to secure the cover plate. Do not overtighten.
9) Connecting Power. The AIM is powered by a UL-
listed, 24VAC, class 2, plug-in transformer rated at
24VA. Plug the transformer into any standard 120VAC
wall outlet. Attach the transformer connector to the
24VAC connector on the AIM to the left of the fuse
brackets on the upper right corner of the circuit board.
Note that the connector is keyed to fit in only one
direction.
Once power has been applied, the LEDs indicating
‘Logic Power’, ‘8VDC Power’ and ‘24VDC Power’ should
illuminate. Under normal operation the ‘Status’ LED will
flash about once a second. If a malfunction has
occurred, the ‘Status’ LED will remain lit. If the LEDs do
not illuminate in this fashion, refer to Step 12.
10) Connecting Sensors. Disconnect power from the
AIM before installing any sensor wiring. Failure to
disconnect power may result in electrical shock and/or
damage to the AIM.
The maximum allowable voltage to any channel input is
10 Volts. 24VDC power is available to power 4-20 mA
current loops. 8VDC power is available to monitor pulse
or runtime contacts. Refer to the specific sensor type
below for wiring diagrams.
Cable shields may be terminated at the AIM channel
ground terminals or at the sensor. In either case, shields
must be terminated at only one end.
4-20 mA Current Loop Sensors
Figure 5 shows wiring connections for general purpose,
0-20 mA or 4-20 mA current loops. Sensors with this
signal output can be purchased from many
manufacturers to measure virtually any parameter,
including temperature, humidity, pressure and flow. The
AIM is equipped with a set of voltage source terminals
that provide 24VDC loop power, or these sensors can be
powered by an external source as shown in Figure 3. In
all cases, current loops must be grounded at the AIM.
AIM
Terminal
Blocks
32
31
30
29
11
10
9
8
7
6
5
4
3
2
1
24 VDC
Loop
Power
Channel Inputs
Channel Ground and
Shield Terminations
4-20mA Sensor
Powered by the AIM
4-20mA Sensor Powered by
an External Power Supply
External Power Supply
+
-
+
+
-
-
37
36
35
77
76
75
Figure 5 General Purpose Sensor Wiring
Pulse and Runtime Contact Sensors
Figure 6 shows the typical installation for pulse and
runtime contact sensors. Dry or isolated contacts must
be powered by a voltage source. Two voltages are
available at the AIM auxiliary terminals, 8VDC and
24VDC. If the 8VDC power is used, no resistor is
required. If the 24VDC power is used, install a 1,000
Ohm resistor in series with the dry contact to drop the
voltage down below 10 Volts.
Notes: 1) Input impedance is 499 ohms.
2) Pulse rates cannot exceed 10 pulses per
second, or 10Hz
3) Runtime contacts may be either normally
open or normally closed. The IMPACC
Series III software must be configured
accordingly.
There is enough power on the auxiliary terminals to
drive all 32 inputs using the method shown in Figure 6.
If the 24VDC loop power is used, the total maximum
power draw off of the 8VDC and 24VDC power terminals
combined cannot exceed 16VA.

ANALOG INPUT MODULE
Page 4April 15, 1997
AIM
Terminal
Blocks
32
31
30
29
11
10
9
8
7
6
5
4
3
2
1
8 VDC
Loop
Power
Channel Inputs
Channel Ground and
Shield Terminations
Pulse
Contact
or
Runtime
Contact
40
39
38 80
79
78
Figure 6 Pulse and Runtime Contact Sensor Wiring
11) Cable Recommendations. Note that these are
only recommendations. For some situations only a
certain type of cable may be used. before selecting
specific cables, consult local and National Electric
codes.
Analog sensors should use a 22 AWG twisted-pair
(stranded conductor), foil shielded cable with a drain
wire. Multiple sensors can be connected through a multi-
pair cable. Consult the sensor’s manufacturer for limits
on cable lengths. Generally 500 feet is acceptable.
Contact closure and runtime sensors should use a 22
AWG twisted-pair (stranded conductor), foil shielded
cable with a drain wire. Multiple sensors can be
connected through a multi-pair cable. Cable runs in
general should not exceed 1000 feet.
12) Trouble Shooting. Under normal operating
conditions the LEDs indicating ‘Logic Power’, ‘8VDC
Power’ and ‘24VDC Power’ will remain lit. The ‘Status’
LED will flash about once a second. If a malfunction has
occurred, the ‘Status’ LED will either remain lit or remain
un-lit. This typically indicates a sensor profile error, or in
rare cases, a clock or memory error. If the Status LED is
not flashing normally, perform the following steps in the
order given below until it begins flashing normally.
A) Attempt communication using IMPACC. If
communication is possible, download the sensor
profile and reset the date and time.
B) Disconnect power from the AIM for 5 seconds and
then re-connect. Proceed to step A.
C) Disconnect power from the AIM. Hold down the
‘System Test’ pushbutton as power is re-connected.
This clears the memory of the AIM. Disconnect
power again from the AIM, wait 5 seconds and then
re-connect without holding down the pushbutton.
Proceed to step A.
If none of these steps corrects the problem, please call
the Advanced Products Support Center at the number
below.
SPECIFICATIONS
32 input channels, non-isolated, ±10 Volts maximum
499 Ohm input impedance
Capacitor backed-up RAM
Current input 0-20 mA DC
accuracy ±0.02 ma from 0.2 to 20 mA
(excludes sensor error)
resolution 0.01 mA
Pulse input Form “A” contact closure
10 Hz maximum, 50% duty cycle
10ms de-bounce
Runtime input Form “A” contact closure
Power 120VAC/24VAC UL listed transformer
Supply 24VA
Power 8VA including IPONI
Consumption
Auxiliary 8VDC and 24VDC
Power 16VA total, maximum
Operating 32-125°F (0-50°C)
Environment 20-80% RH non-condensing
Enclosure NEMA 1
12”H x 10”W x 6”D
Mounting Holes:
Catalog No. AIM
Style No. 4D13140G01
For product support please call the
Advanced Products Support Center:
1-800-809-2772 or 412-494-3750
10”
8”
8”10”