Emerson Machinery Health A6500 R Series User manual

Operating Manual
MHM-97877, Rev 5.07
June 2023
Machinery Health™ System
A6500-xR System Racks

Copyright
© 2023 by Emerson. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of Emerson.
Disclaimer
This manual is provided for informational purposes. EMERSON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Emerson shall not be liable for errors, omissions, or inconsistencies that may be contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is
subject to change without notice and does not represent a commitment on the part of Emerson. The information in this manual is
not all-inclusive and cannot cover all unique situations.
Patents
The product(s) described in this manual are covered under existing and pending patents.
Vermerk zur Installation der Messketten in explosionsgefährdeter Umgebung.
Soll die Messkette in explosionsgefährdeter Umgebung installiert werden, so ist auf die Einhaltung der in der
Gebrauchsanweisung enthaltenen Installationshinweise zu achten. Sollten dabei sprachliche Schwierigkeiten
auftreten, wenden Sie sich bitte an die Herstellerfirma, sie wird Ihnen eine Übersetzung der relevanten Artikel in der
Landessprache des Verwendungslandes zukommen lassen.
Nota fuq l−installazzjoni tal−ktajjen tal−kejl f’ambjent esplożiv
Jekk il−katina tal−kejl suppost li tigi installata f’ambjent esplożiv, hu importanti li ssegwi l−istruzzjonijiet pertinenti
tal−manwal.Jekk issib xi diffikultà bil−lingwa, jekk joghgbok ikkuntattja lill−manifattur biex tikseb traduzz-joni tal
−paragrafi rilevanti fil−lingwa mehtiega.
Anmärkning beträffande installation av mätkedjorna i explosionsfarlig miljö.
Ska mätkedjan installeras i explosionsfarlig miljö, måste de anvisningar följas som ges i instruktionsboken
beträffande installationen. Skulle därvid språkproblem uppstå, ber vi dig kontakta det tillverkande företaget som
då kommer att sända dig en översättning av de relevanta artiklarna på användningslandets språk.
Opomba za namestitev merilne verige v eksplozivno ogroženem okolju
Èe se merilna veriga namešèa v eksplozivno ogroženem okolju, je potrebno upoštevati namestitvena opozorila, ki
so v Navodilih za uporabo. Èe se pri tem pojavijo jezikovne težave, se posvetujte z izdelovalcem; poslali vam bodo
prevod ustreznih èlankov v jeziku države, kjer se naprava uporablja.
Záznam k inštalácii meracích reťazcov vo výbušnom prostredí
Ak má byť merací reťazec inštalovaný vo výbušnom prostredí, treba dbať na dodržiavanie pokynov k inštalácii,
uvedených v návode na použitie. V prípade, že by sa pritom vyskytli jazykové problémy, obráťte sa prosím na
výrobcu, ktorý Vám zašle preklad relevantných èlánkov v jazyku Vašej krajiny.
Nota referente à instalação de cadeias de agrimensor em ambientes potencialmente explosivos
Caso a cadeia de agrimensor deva ser instalada em um ambiente potencialmente explosivo, é imprescindível
observar e cumprir as indicações de instalação das instruções de serviço. Caso tenha dificuldades idiomáticas,
queira entrar em contato com a firma produtora, esta poderá enviar−lhe uma tradução dos capítulos mais
importantes no idioma do país onde o produto deverá ser empregado.
Wskazówka dotycząca instalacji łańcuchów mierniczych w otoczeniach zagrożonych eksplozją.
Jeżeli łańcuch mierniczy ma być zainstalowany w otoczeniu zagrożonym eksplozją, należy uwzględnić wskazówki
dotyczące instalacji, które są zawarte w instrukcji obsługi. Jeżeli w trakcie lektury wystąpią jakiekolwiek problemy
związane ze zrozumieniem tekstu, prosimy zwrócić się do producenta, który chętnie wykona tłumaczenie
wybranych części dokumentacji na język danego kraju.
2

Opmerking m.b.t. installatie van elektrische meet circuits in explosiegevaarlijke omgeving
Dient de installatie van elektrische meet circuits in een explosiegevaarlijke omgeving te geschieden, moet men
toezien dat de in de gebruikshandleiding opgenomen installatieinstructies worden nageleefd. Bij taalkundige
problemen gelieve contact op te nemen met de fabrikant, deze zal u vervolgens een vertaling in de taal van het
gebruiksland doen toekomen.
Pastaba dėl matavimo grandinės įrengimo sprogimo atžvilgiu pavojingoje aplinkoje
Jei matavimo grandinė turi būti įrengta sprogimo atžvilgiu pavojingoje aplinkoje, privaloma laikytis vartotojo
instrukcijoje pateiktų įrengimo nurodymų. Jei kiltų sunkumų dėl kalbos, prašome kreiptis į gamintojo įmonę, kuri
pateiks Jums reikiamo skyriaus vertimą į vartotojo valstybės kalbą.
Nota sull’installazione delle catene per misurazione in ambienti a rischio di esplosioni
Nel caso in cui si debbano installare le catene per misurazione in ambienti a rischio di esplosioni, è necessario
attenersi alle avvertenze per l’installazione contenute nelle istruzioni d’uso. Per difficoltà di carattere linguistico,
rivolgetevi alla ditta produttrice. Quest’ultima Vi farà pervenire una traduzione degli articoli rilevanti nella lingua
del paese d’impiego.
Megjegyzės a mėrőláncok robbanásveszėlyes környezetben törtėnő szerelėsėhez.
Ha a mėrőláncot robbanásveszėlyes környezetben kell felszerelni, akkor ügyeljen a Használati útmutatóban közölt
szerelėsi utasítások betartására. Amennyiben nyelvi nehėzsėgek merülnek fel, szíveskedjen a gyártó céghez
fordulni, amely elküldni Önnek a felhasználó ország nyelvėre lefordított, erre vonatkozó cikket.
Remarque concernant l’installation des chaînes de mesure dans un environnement présentant un risque
d’explosion
Si la chaîne de mesure doit être installée dans un environnement présentant un risque d’explosion, il est impératif
de veiller à respecter les consignes d’installation contenues dans les instructions de service. S’il devait ce faisant
surgir des problèmes linguistiques, veuillez vous adresser à la société fabricante: elle vous fera parvenir une
traduction des articles significatifs dans la langue du pays de mise en oeuvre.
Huomautus mittausketjun asentamisesta räjähdysalttiissa ympäristössä
Jos mittausketju tulee asentaa räjähdysalttiissa ympäristössä, on käyttöohjeessa annettuja asennusohjeita
noudatettava. Jos käyttöohjeessa käytetty kieli aiheuttaa ongelmia, kääntykää valmistajayrityksen puoleen. Se
toimittaa käyttöönne tarvittavat artikkelit käyttömaan vir alliselle kielelle käännettynä.
Juhend mõõdukettide ülespanemiseks plahvatusohtlikus piirkonnas.
Kui panna üles mõõdukettid plahvatusohtlikkus piirkonnas, nii tuleb jälgida kasutusjuhendis sisaldatud
instalationimärkmeid. Juhul kui tekkivad raskused keelega, siis pöörduge palun tootja poole. Tootja saadab
emakeelse tõlge vastavalt artiklile ning maale.
Notas sobre la instalación de cadenas de medición en un entorno potencialmente explosivo.
Si ha de instalar la cadena de medición en un entorno potencialmente explosivo, deberá respetar las indicaciones
sobre la instalación, contenidas en el manual de uso. Si surgieran dificultades lingüísticas, póngase en contacto con
la empresa fabricante, que le facilitará una traducción del artículo en la lengua del país donde se emplee.
Note on the installation of the measuring chains in an explosive environment
If the measuring chain is supposed to be installed in an explosive environment, it is important to follow the
pertinent installation instructions in the manual. Should you encounter difficulties with the language, please
contact the manufacturer to obtain a translation of the relevant paragraphs into the language required.
3

Σημεíωση για τηυ εγκατáσταση αλuσíδωυ μέτρησης σε περιβáλλου, στο oπoío uπàρΧει κíυδuυoς έκρηξης
Εáυ η αλuσυδα μέτρησης πρóκειται υα εγκατασταΘεí σε περιβáλλoυ, στo oπoío uπáρΧει κíυδuυoς έκρηξης, πρέπει υα
τηρηΘoúυ oπωσδńπoτε oι oδηγíες εγκατáστασης πoυ περιλαμβáυoυται στις oδηγíες Χρńσης. Εáυ υπáρξouυ
γλωσσικές δuσκoλíες καταυóησης, παρακαλoúμε υα απεuΘuυΘεíτε στηυ κατασκεuáστρια εταιρεíα, η oπoíα Θα
ϕρoυτíσει για τηυ απoστoλń μιας μετáϕρασης τωυ σΧετικωυ áρΘρωυ στη γλωσσα της Χωρας Χρńσης.
Info vedrørende installation af målekæderne i eksplosionstruede omgivelser
Hvis målekæden skal installeres i eksplosionstruede omgivelser, skal installationsanvisningerne i brugsanvisningen
følges. Hvis der i denne forbindelse opstår sproglige problemer, bedes De henvende Dem til produktionsfirmaet,
som så vil sørge for, at De modtager en oversætelse af den relevante artikel på Deres sprog.
Poznámka k instalaci mĕřicích řetězců v prostředí s nebezpečím výbuchu.
Když má být měřicí řetězec (sestávající z čidla a konvertoru) instalován v prostŕedí s nebezpečím výbuchu, tak je
třeba respektovat instalační pokyny, které jsou součástí návodu k upotřebení. Kdyby při tom došlo k jazykovým
potížím, tak prosíme kontaktujte výrobní firmu, která Vám relevantní článek zašle v jazyku krajiny použití.
Piezīme par mērīšanas ķēžu instalēšanu sprādziena bīstamās zonās.
Ja mērīšanas ķēde jāuzstāda sprādzienbīstamā zonâ, ir jāievēro lietošanas instrukcijā dotie instalēšanas norādījumi.
Ja rodas kādas valodas grūtības, lūdzu griezieties pie izgatavotāja firmas, kas Jums nosūtīs nozīmīgâko nodaļu
tulkojumus lietotāja valsts valodā.
Emerson
epro GmbH
Jöbkesweg 3
48599 Gronau
Germany
T [phone]
F [phone]
www.Emerson.com
4

Contents
Chapter 1 General.......................................................................................................................... 7
1.1 Using this manual.............................................................................................................................7
1.2 Symbols............................................................................................................................................7
1.3 Liability and guarantee..................................................................................................................... 8
1.4 Incoming goods inspection.............................................................................................................. 8
1.5 Technical support.............................................................................................................................8
1.6 Storage and transport.......................................................................................................................9
1.7 Disposal of the device.......................................................................................................................9
1.8 China RoHS Compliance................................................................................................................... 9
1.9 CCC Certification – AMS 6500 ATG................................................................................................. 10
1.10 Installation awareness.................................................................................................................. 10
Chapter 2 Safety instructions....................................................................................................... 11
2.1 Using the device............................................................................................................................. 11
2.2 Owner's responsibility.....................................................................................................................11
2.3 Radio interference..........................................................................................................................12
2.4 ESD safety...................................................................................................................................... 12
Chapter 3 Application and Design................................................................................................ 13
3.1 Application.....................................................................................................................................13
3.1.1 A6500-SR System Rack................................................................................................................13
3.1.2 A6500-RR System Rack for redundant Relay Cards...................................................................... 14
3.1.3 A6500-FR System Rack with front terminal connectors ...............................................................14
3.2 Design............................................................................................................................................16
3.2.1 A6500-SR System Rack................................................................................................................16
3.2.2 A6500-RR System Rack for redundant Relay Cards...................................................................... 18
3.2.3 A6500-FR System Rack with front terminal connectors............................................................... 20
Chapter 4 Installation and Mounting............................................................................................25
4.1 CSA - General safety....................................................................................................................... 25
4.2 Mount the System Rack – A6500-SR and A6500-RR........................................................................26
4.2.1 AMS 6500 ATG Fan Kit for A6500-SR............................................................................................27
4.3 Mount the system rack – A6500-FR................................................................................................ 28
4.3.1 AMS 6500 ATG Fan Kit for A6500-FR............................................................................................31
4.4 Required installation space including cables and ventilation...........................................................33
4.5 EMC-compliant installation and grounding example.......................................................................34
4.6 Connect I/O signals.........................................................................................................................35
4.6.1 Power supply...............................................................................................................................45
4.6.2 Connecting sensors to the System Rack.......................................................................................48
4.7 Slide switch settings — digital inputs and key-signals ..................................................................... 68
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4.7.1 Digital inputs...............................................................................................................................69
4.7.2 Key-signal....................................................................................................................................71
4.8 Communication............................................................................................................................. 75
4.8.1 Bus line interconnection of two System Racks............................................................................. 76
4.8.2 A6500-FR – Ethernet connection.................................................................................................77
4.9 Sensor raw signal............................................................................................................................78
4.10 Connection of current outputs..................................................................................................... 83
4.11 Digital outputs and Relay Card......................................................................................................83
4.12 A6500-RR - external inputs........................................................................................................... 85
4.13 A6500-FR - external inputs........................................................................................................... 86
4.14 Commission the System Rack.......................................................................................................86
Chapter 5 Hazardous location installation....................................................................................87
5.1 General installation requirements...................................................................................................87
5.2 Field housing requirements............................................................................................................ 87
5.3 Connection requirements...............................................................................................................89
5.4 CSA - Special conditions of safe use................................................................................................ 89
5.5 Technical data, explosion protection.............................................................................................. 90
5.6 Control drawing – A6500-SR and A6500-RR................................................................................... 92
5.7 Control drawing – A6500-FR...........................................................................................................97
5.8 Revision history............................................................................................................................ 102
Chapter 6 Maintenance..............................................................................................................103
Chapter 7 Replace the System Rack............................................................................................ 105
Chapter 8 Technical data............................................................................................................107
8.1 Power supply................................................................................................................................107
8.2 Slot distribution............................................................................................................................107
8.3 Mechanical design and environmental conditions........................................................................ 107
Chapter 9 Certificates.................................................................................................................111
Contents Operating Manual
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vi MHM-97877, Rev. 5.07

1 General
1.1 Using this manual
This manual contains information concerning the use of the device.
Read the operating manual completely prior to starting installation and operating the
device. Comply with all safety instructions.
This operating manual applies for A6500-xR System Racks with hardware revision listed in
Table 1-1. See type plate for revision level.
Table 1-1: Hardware revision
A6500-SR System Rack 03, 04, 05, 06, 07
A6500-RR System Rack for redundant Relay Cards 00, 01, 02, 03
A6500-FR Small System Rack with front connectors 02, 03, 04
Include the operating manual when transferring the device to third parties.
Note
When requesting technical support, please indicate type and serial number from the type
plate.
Table 1-2 shows a list of documents that are referred to in this operating manual.
Table 1-2: Referenced documents
MHM-97873 Operating Manual A6500-UM Universal Measurement Card
MHM-97874 Operating Manual A6500-TP Temperature Process Card
MHM-97876 Operating Manual A6500-RC Relay Card
MHM-97875 Operating Manual A6500-CC Com Card
MHM-97878 Operating Manual A6500-LC LVDT Converter
1.2 Symbols
Note
This symbol marks passages that contain important information.
CAUTION
This symbol marks operations that can lead to malfunctions or faulty measurements, but
will not damage the device.
DANGER
A danger indicates actions that can lead to property damage or personal injury.
Operating Manual General
MHM-97877 June 2023
MHM-97877, Rev. 5.07 7

According to IEC 61010, this symbol means that this device must be
operated with DC voltage.
According to IEC 61010, this symbol means that the documentation of
the device must completely be read and understood before installing and
commissioning of the device. Observe all safety related instructions in this
document.
1.3 Liability and guarantee
Emerson is not liable for damages that occur due to improper use. Proper use also includes
the knowledge of, and compliance with, this document.
Customer changes to the device that have not been expressly approved by Emerson will
result in the loss of guarantee.
Due to continuous research and further development, Emerson reserves the right to
change technical specifications without notice.
1.4 Incoming goods inspection
Check the content of the shipment to ensure that it is complete, visibly inspect the goods
to determine if the device has been damaged during transport. The following parts are
included in the scope of delivery and must be contained in the shipment:
•Backplane mounted in a rack
•Cage clamps – only A6500-SR and A6500-RR
•Short Ethernet cable (approximately 0.5 m) for A6500-CC connection - only A6500-FR
•Operating manual on CD
If the contents are incomplete, or if you observe any defects, file a complaint with the
carrier immediately. Inform the responsible Emerson sales organization so your device can
be replaced. In this case, attach a tag with customer name and the observed defect.
1.5 Technical support
You may need to ship this product for return, replacement, or repair to an Emerson
Product Service Center. Before shipping this product, contact Emerson Product Support to
obtain a Return Materials Authorization (RMA) number and receive additional instructions.
Product Support
Emerson provides a variety of ways to reach your Product Support team to get the answers
you need when you need them:
Phone Toll free 800.833.8314 (U.S. and Canada)
+1.512.832.3774 (Latin America)
+63.2702.1111 (Asia Pacific, Europe, and Middle East)
General Operating Manual
June 2023 MHM-97877
8 MHM-97877, Rev. 5.07

Email [email protected]
Web http://www.emerson.com/en-us/contact-us
To search for documentation, visit http://www.emerson.com.
To view toll free numbers for specific countries, visit http://www.emersonprocess.com/
technicalsupport.
Note
If the equipment has been exposed to a hazardous substance, a Material Safety Data Sheet
(MSDS) must be included with the returned materials. An MSDS is required by law to be
available to people exposed to specific hazardous substances.
1.6 Storage and transport
Store and transport the device only in its original packaging. Technical data specifies the
environmental conditions for storage and transport.
Related information
Technical data
Power supply
Slot distribution
Mechanical design and environmental conditions
1.7 Disposal of the device
Provided that no repurchase or disposal agreement exists, recycle the following
components at appropriate facilities:
•Recyclable metal
•Plastic elements
Sort the remaining components for disposal, based on their condition. National laws or
provisions on waste disposal and protection of the environment apply.
Note
Environmental hazards! Electrical waste and electronic components are subject to
treatment as special waste and may only be disposed by approved specialized companies.
1.8 China RoHS Compliance
Our products manufactured later than June 30, 2016 and those which are sold in the
People's Republic of China are marked with one of the following two logos to indicate the
Environmental Friendly Use Period in which it can be used safely under normal operating
conditions.
Products without below mentioned marking are either manufactured before June 30 or
are non-electrical equipment products (EEP).
Operating Manual General
MHM-97877 June 2023
MHM-97877, Rev. 5.07 9

Circling arrow symbol with "e": The product contains no hazardous substances over
the Maximum Concentration Value and it has an indefinite Environmental Friendly
Use Period.
Circling arrow symbol with a number: This product contains certain hazardous
substances over the Maximum Concentration Value and it can be used safely under
normal operating conditions for the number of years indicated in the symbol. The
names and contents of hazardous substances can be found in the folder "China
RoHS Compliance Certificates" on the documentation CD or DVD enclosed with the
product.
1.9 CCC Certification – AMS 6500 ATG
With the announcement of the Chinese market regulation authority SAMR (State
Administration for Market Regulation), a Compulsory Product Certification (CCC
certification) is mandatory for many explosion protection products. This explosion proof
(“Ex”) product complies to the CCC obligation and is certified (certification number:
2020322304002386).
This China Compulsory Certificate mark (CCC), is a compulsory safety mark for
many products imported, sold, or used in the Chinese market and indicates that the
product is certified in accordance to GB/T 3836.1-2021, GB/T 3836.3-2021, and
GB/T 3836.8-2021. If the product label is to small to contain the CCC certification
mark, it is sufficient to have the mark printed on the minimum package and in the
attached document.
1.10 Installation awareness
Note
When planning a measurement, observe the following items:
•Consider environmental conditions which might have an influence on the
measurement such as temperature, humidity, substances aggressive to the sensor,
and pollution.
•Always use a stiff and vibration-free sensor holder.
•Define a suitable measuring range, not larger than necessary, in consultation with the
operator of the plant.
•Define the trip limit in consultation with the operator of the plant.
•Take measurement deviations into account when defining the trip limit.
•Use a sensor that meets the requirements of the defined measuring range.
•Ensure an EMC-compatible installation including the use of proper cables.
•Ensure proper function of the measurement before activating the measurement for
regular operation.
General Operating Manual
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10 MHM-97877, Rev. 5.07

2 Safety instructions
To ensure safe operation, carefully observe all instructions in this manual.
The correct and safe use of this device requires that operating and service personnel both
understand and comply with general safety guidelines and observe the special safety
comments listed in this manual. Where necessary, safety-sensitive points on the device
are marked.
DANGER
Because the device is electrical equipment, commissioning and service must be performed
only by trained and authorized personnel. Maintenance must be carried out only by
trained, specialized, and experienced personnel.
2.1 Using the device
Install and use the device as specified in this document.
If the device is used in a manner not specified by the manufacturer, the functions and
protection provided by the device may be impaired.
2.2 Owner's responsibility
If there is a reason to suspect that hazard-free operation, and thus, adequate machine
protection is no longer possible, take the device out of operation and safeguard it from
unintentional operation. This is the case:
•if the device shows visible damage.
•if the device no longer works.
•after any kind of overload that has exceeded the permissible limits (such as those
detailed in chapter "Technical data," section "Environmental conditions").
DANGER
If device tests have to be completed during operation or if the device has to be replaced or
decommissioned, it will impair the machine protection and may cause the machine to
shut down. Make sure to deactivate machine protection before starting such work, and
reactivate it after work has been completed.
Related information
Technical data
Power supply
Slot distribution
Mechanical design and environmental conditions
Operating Manual Safety instructions
MHM-97877 June 2023
MHM-97877, Rev. 5.07 11

2.3 Radio interference
The device is carefully shielded and tested to be technically immune to radio interference
and complies with current standards. However, if you operate this device together with
other peripheral devices that are not properly shielded against radio interference,
disturbances and radio interferences may occur.
2.4 ESD safety
DANGER
Internal components can be damaged or destroyed due to electrostatic discharge (ESD)
during the handling of the device.
Take suitable precautions before handling the device to prevent electrostatic discharges
through the electronics. Such measures might include, for example, wearing an ESD
bracelet. Transport and storage of electronic components may only be made in ESD-safe
packaging.
Handle the device with particular care during dry meteorological conditions with relative
humidity below 30% as electrostatic discharges can appear more frequently.
Safety instructions Operating Manual
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3 Application and Design
3.1 Application
Different System Racks are part of the AMS 6500 ATG system. See Table 3-1.
Table 3-1: System Racks
System Rack Description
A6500-SR 11 slots for A6500-UM Universal Measurement Cards or A6500-TP
Temperature Process Cards
One slot for an A6500-RC Relay Card
Two slots for A6500-CC Com Cards
A6500-RR Nine slots for A6500-UM Universal Measurement Cards or A6500-TP
Temperature Process Cards
Two slots for A6500-RC Relay Cards
Two slots for A6500-CC Com Cards
A6500-FR Six slots for A6500-UM Universal Measurement Cards or A6500-TP
Temperature Process Cards
One slot for an A6500-RC Relay Card
One slot for an A6500-CC Com Card
3.1.1 A6500-SR System Rack
The A6500-SR System Rack is part of the AMS 6500 ATG system. It is a 19" rack (84HP
width and 3RU height). The System Rack allows you to install up to 11 protection cards
(two channel A6500-UM Universal Measuring Card and/or four channel A6500-TP
Temperature Process Card), one A6500-RC Relay Card, and one A6500-CC Com Card –
two Com Cards for redundant communication.
The rear of the System Rack is equipped with screw terminal connectors to connect input
and output signals, with D-Sub connectors to provide sensor raw signals, and slide
switches to configure key signals and binary inputs.
Each of the 11 slots for protection cards has four eight-pole screw terminal connectors for
connecting several sensor types (eddy current sensors, piezoelectric sensors, seismic
sensors, RTDs, etc.), binary inputs, binary outputs (function outputs), current outputs, and
pulse outputs. The available number of measuring channels and all other functions
depend on the installed cards.
The function outputs of the protection cards are connected by the backplane of the
System Rack to the relay card. The changeover contacts of the 16 output relays are
connected to the six eight-pole screw terminal connectors of the Relay Card slot.
The Com Card is required to configure the installed protection cards and provides data
using Modbus TCP/IP, Modbus RTU, and OPC UA.
Operating Manual Application and Design
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MHM-97877, Rev. 5.07 13

You can extend the system with a second System Rack to a 6RU system. In this case, the
Com Card(s) of the first rack are used for both System Racks.
3.1.2 A6500-RR System Rack for redundant Relay Cards
The A6500-RR System Rack for redundant Relay Cards allows you to install two A6500-RC
Relay Cards. The inputs of the Relay Cards are connected in parallel to use redundancy. Up
to 12 external signals can be connected to the Relay Cards to logically combine them with
the internal signals. Because of the second Relay Card, the number of slots for installing
protection cards (A6500-UM Universal Measuring Card and/or A6500-TP Temperature
Process Card) is limited to nine. All other function and connections of the A6500-RR are
identical with the A6500-SR.
Note
A6500-CC Com Cards with firmware version 2.xx support the A6500-RR System Rack.
3.1.3 A6500-FR System Rack with front terminal connectors
The A6500-FR System Rack with front terminal connectors allows you to mount the
system rack in boxes or cabinets with no space for connecting cables at the rear. Because
of the smaller size than the A6500-SR and A6500-RR 19" racks, the number of slots for
installing protection cards (A6500-UM Universal Measuring Card and/or A6500-TP
Temperature Process Card) is limited to six. The A6500-FR is designed for one A6500-RC
Relay Card and one A6500-CC Com Card. The scope of functions is slightly limited
compared to the A6500-SR and A6500-RR System Racks (see Table 3-2)
Note
A6500-CC Com Cards with firmware version 2.xx support the A6500-FR System Rack.
Table 3-2: System Racks - overview differences
Functions / connections A6500-SR A6500-RR A6500-FR
Redundant communication x x -
Redundant A6500-RC Relay Cards - x -
Connection of external alarm signals
to the A6500-RC
- x (12 signals) x (6 signals)
Connection of a second system rack
to the A6500-CC Com Card(s)
x x -
Number of slots for A6500-UM and/or
A6500-TP
11 9 6
Number of slots for A6500-CC 2 2 1
Number of slots for A6500-RC 1 2 1
Sensor raw through D-Sub connectors x x x
Modbus RTU x x x
Modbus TCP/IP x x x
OPC UA x x x
Cable termination side rear rear front
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Table 3-2: System Racks - overview differences (continued)
Functions / connections A6500-SR A6500-RR A6500-FR
Dimensions 3RU/84HP 3RU/84HP 6RU/50HP
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3.2 Design
3.2.1 A6500-SR System Rack
Figure 3-1 and Figure 3-2 show the structure of the A6500-SR System Rack backplane.
Figure 3-1: A6500-SR front view
A. Slots 1 to 11 for Universal Measurement Cards and Temperature Process Cards
B. Slot for the Relay Card
C. Slots for Com Cards (one card or two cards for redundant communication)
Left slot: recommended for single card communication and primary card of redundant
communication
Right slot: recommended for secondary card of the redundant communication
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Figure 3-2: A6500-SR rear view
A. Redundant power supply (+24 V DC).
B. Slide switches for slots 1 to 11 to assign digital inputs and activate the pulse pull-up
voltage.
C. D-Sub connectors for the sensor raw signals. One connector for four raw signals (two
cards with two channels each).
D. D-Sub connectors for communication in a two-rack system, and 6-pole screw terminal
connectors for Modbus RTU communication.1
E. Screw terminal connectors to connect the 16 output relays of the Relay Card.1
F. Screw terminal connectors to connect to input and output signals of Universal
Measuring Cards and Temperature Process Cards.1
1Pictured push-in spring cage connectors are an optional accessory.
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3.2.2 A6500-RR System Rack for redundant Relay Cards
Figure 3-3 and Figure 3-4 show the structure of the backplane with redundant relays.
Figure 3-3: A6500-RR front view
A. Slots 1 to 9 for Universal Measurement Cards and Temperature Process Cards
B. Slots for two Relay Cards, separated by a 2HP blind plate
C. Slots for Com Cards (one card or two cards for redundant communication)
Left slot: recommended for single card communication and primary card of redundant
communication
Right slot: recommended for secondary card of the redundant communication
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Figure 3-4: A6500-RR rear view
A. Redundant power supply (+24 V DC).
B. Screw terminal connectors to connect external signals to the Relay Card.2
C. Slide switches for slots 1 to 9 to assign digital inputs and activate the pulse pull-up
voltage.
D. D-Sub connectors for the sensor raw signals. One connector for four raw signals (two
cards with two channels each).
E. D-Sub connectors for communication in a two-rack system, and 6-pole screw terminal
connectors for Modbus RTU communication.2
F. Screw terminal connectors to connect the 16 output relays of each Relay Card.2
G. Screw terminal connectors to connect to input and output signals of Universal
Measuring Cards and Temperature Process Cards.2
2Pictured push-in spring cage connectors are an optional accessory.
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3.2.3 A6500-FR System Rack with front terminal connectors
Figure 3-5 and Figure 3-6 show the structure of the backplane with front terminal
connectors.
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