Johnson Controls MIOA Series User manual

Product Bulletin
Issue Date November 26, 2003
®
MIOA Series Modular Input/Output Assemblies
for Refrigeration, HVAC, and Building System Controllers
Modular Input/Output Assemblies (I/O Assemblies) are
built-up, configurable, circuit board assemblies that
provide analog or binary input points, output relays,
analog outputs, or a combination of inputs and
outputs.
I/O Assemblies provide network interface between the
controller and a variety of low voltage input sensor
devices and binary (On/Off) switches. The I/O
Assemblies also provide interface for On/Off circuit
control, analog device control, and electric
consumption metering.
I/O Assemblies consist of a Modular Input/Output Base
(I/O Base) with up to two Input Boards and two Output
Boards stacked on top of the I/O Base. See Table 3 for
the standard I/O Assemblies and component boards
that are available.
I/O Assemblies are designed for new installations, and
to replace existing Input/Output boards (I/O boards)
currently used with Johnson Controls/PENN®
Refrigeration System Controllers.
Figure 1: An MIOA Series Modular Input/Output
Assembly
Features and Benefits
TMatches the Footprint of
Existing Johnson
Controls/PENN I/O Boards
Allows for quick and easy changeout or
modification of existing I/O boards
TOptional Manual Override
Capacity of Output Relays Facilitates troubleshooting the system equipment controlled by the I/O Assembly
TAuto-Selects Either a
0-10 VDC or 4-20 mA
Analog Output Signal
Provides motor-speed control for a variety of
variable speed applications in Refrigeration,
Heating, Ventilating, and Air Conditioning
(HVAC), and Building Control Systems
TPulse-Inputs for Recording
Electric Consumption Allows for pulse-metering electric use or other control system pulse-metering applications
THigh Density of Inputs and
Outputs per I/O Assembly Provides more input sensor points, and output relay and analog control-points in less space
© 2003 Johnson Controls, Inc. 1
Code No. LIT-1201164 www.johnsoncontrols.com

Application
IMPORTANT: Use this MIOA Series Modular
Input/Output Assembly only as an operating control.
Where failure or malfunction of the I/O Assembly
could lead to personal injury or property damage to
the controlled equipment or other property,
additional precautions must be designed into the
system. Incorporate and maintain other devices such
as supervisory or alarm systems or safety or limit
controls intended to warn of, or protect against,
failure or malfunction of the I/O Assembly.
2MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers
Canadian Compliance Statement
This digital apparatus does not exceed the Class A
limits for radio noise emissions from digital apparatus
set out in the Radio Interference Regulations of the
Canadian Department of Communications.
FCC Compliance Statement
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference,
and (2) this device must accept any interference that
may cause undesired operation.
This equipment has been tested and found to comply
with the limits for a Class A digital device pursuant to
Part 15 of FCC rules. These limits are designed to
provide reasonable protection against harmful
interference when this equipment is operated in a
commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the
instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in
a residential area is likely to cause harmful
interference, in which case the user will be required to
correct the interference at his or her own expense.
Dimensions
4
(102)
5
(127)
Maximum
4-3/4
(121)
Maximum
9
(229)
Maximum 7
(178)
Minimum
Bottom of Snap-Track
Figure 2: Dimensions of a Typical Modular I/O Assembly, in. (mm)
Product Bulletin

Installation Considerations
The Johnson Controls/PENN Modular Input/Output
Board Assemblies (I/O Assemblies) are designed to
match the footprint of the existing input and output
boards used with Johnson Controls/PENN
Refrigeration System Controllers. The I/O Assemblies
are not position sensitive, but should be mounted
where they are readily accessible, and positioned to
allow adequate space for wire terminations on the side
of the I/O Assemblies.
Applying the Modular I/O Assembly
The I/O Assemblies are designed to operate in
conjunction with Johnson Controls/PENN Refrigeration
System or Convenience Store Controllers.
The I/O Assemblies provide the network interface
between the refrigeration system controller and all of
the system’s input devices, and all of the refrigeration,
building, or HVAC system control circuits managed by
the controller.
These I/O Assemblies match the footprints of the three
I/O boards currently installed with existing refrigeration
controllers, and may be configured as direct
replacements for the existing boards.
Depending on how the assembly is configured, an
I/O Assembly can:
• receive a variety of low-voltage analog and binary
signals from compatible input devices or binary
switches
• transmit analog and binary input signals to a
system controller for processing via RS485
network communications protocol
• receive binary and analog control signals from the
controller, which can activate (via the controller)
output relays on the I/O Assembly to provide
On/Off control of (low or line voltage) components
in a refrigeration system
• receive analog control signals from the system
controller and issue either 0.1-10 VDC or 4-20 mA
analog output signals to analog devices in the
refrigeration HVAC or building system, such as
condenser fan-speed controllers, variable-speed
compressor drives or damper position actuators
• do a combination of the functions listed above
Modular I/O Assembly: I/O Base and Component
Board Features
A complete I/O Assembly consists of a Modular I/O
Base (I/O Base), and up to two Input Boards and two
Output Boards that fit onto the I/O Base and connect
to it via a ribbon cable. See Figures 1, 2, 3, and 4.
A Modular I/O Base provides:
• an RS485 network communications connection
with jumper-selectable baud rate (9600 or 38400
baud) for communicating with the controller
• a communication interface with up to four (two
Input and two Output) daughter boards via Ribbon
Cable Connectors
• two analog signal output terminals that
automatically select either a 0.1-10 VDC or
4-20 mA output signal for controlling analog
devices in the system
• two digital input signal points for metering
electrical use
• four Light-Emitting Diode (LED) status and
diagnostic indicators. A green LED (DS1) indicates
Power-On. A yellow LED (DS2) provides
diagnostic flash codes. Two additional green
LEDs, Rx (DS3) and Tx (DS4), indicate network
communication activity between the I/O Assembly
and the controller.
• an eight-position DIP switch for setting the I/O
board (network communication) address
An Input Board provides:
• a green Power-On LED indicator
• an interface between a variety of compatible,
low-voltage analog and binary input devices and
the system controller
• eight input signal points. Each input point may be
set up to detect either passive or active input
devices, including 0.1-10 VDC input devices,
0-5 VDC input devices, or binary (On/Off)
switches. Also, up to six input points (per Input
Board) may be set to use 4-20 mA input devices.
Passive signal devices are typically two-wire
temperature sensors or binary (On/Off) switches. A
10 K Ohm Negative Temperature Coefficient (NTC)
Temperature Sensor is one type of passive sensor
device that may be connected to the Input Board.
Active signal devices are typically three-wire
transducers that use a power source to amplify the
sensed signal. The Johnson Controls/PENN P399
Series Pressure Transducer is an example of an active
device that may be connected to the Input Board.
MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers 3
Product Bulletin

An Output Board provides:
• four fused-protected, Form C, Single Pole, Double
Throw (SPDT) Output Relays with contacts rated
for 1.6 A at 24 to 240 VAC (400 VA maximum) for
controlling system circuits
• four red Relay Status LEDs for the output relays.
Each LED is set (independently by positioning the
associated Relay Output Jumper) to light when
the relay is energized or when it is de-energized.
• four control Override Switches, each with a
yellow Override Status LED indicator (only on
MO2-1C Model Output Boards). An override
switch allows you to override the control signal to
an output relay, and either energize or de-energize
the output relay until the override is reset to
normal operation.
Mod I/O Assembly Parameter and Addresses
Several parameters must be set so the I/O Assembly
can interface with the various input devices, and the
system controller. Also, a Board/Point Address must
be established for each input device and output relay
used on the assembly, in order for the controller to
recognize and process the input signals and generate
the proper output signals. These board/point
addresses are programmed into the controller at initial
setup.
Modular I/O Base Settings
An I/O Base provides for selection of the RS485
network-communication baud rate. Set the baud rate
by positioning the jumper on the pins of the Baud Rate
Selection Jumper Terminal (J11). See Figure 3.
The I/O Base provides two analog output signals for
controlling a system’s analog devices, such as fan
speed controllers and damper position actuators. The
analog outputs generate either a 0.1-10 VDC or
4-20 mA output signal. After the target devices are
wired to the Analog Output Terminal Block (J8) and
the I/O Assembly is powered, I/O Base automatically
detects the impedance of target devices and
generates the appropriate output signal to the target
device. See Figure 3 and Table 1.
Modular I/O Assembly Board Address
The I/O Assembly’s Board Address is established
using the Board Address DIP Switch (S1) on the I/O
Base. The DIP switch is a binary switch block. Each
switch in the switch block is assigned a number (1, 2,
4, 8, 16). The board address is equal to the sum of the
numbers of the switches that are in the up position.
See Figure 3.
The three switches on the left side of the eight-position
DIP switch block (numbered 32, 64 and 128) are
inactive and are not used to establish a board address.
Input Board Settings
An Input Point Address is automatically established
for each input device wired to the I/O Assembly in
order for the controller to receive the input-device
signal.
The input point address corresponds to the A1 to A8
terminal positions on the lower input terminal block. On
I/O Assemblies with one input board, the point
addresses are 1 through 8. On I/O Assemblies with
two input boards, the addresses are 1 to 8 on the first
input board and 9 to 16 on the second input board.
The only setting required on the input board is the
Input Device Selection DIP Switch (S1). Position the
individual switches on the DIP switch block in the up
position for any compatible active input device. When
an NTC temperature sensor is connected to an input
terminal (A1 to A8), set the corresponding switch to
the down position (factory default position). See
Figure 4.
Output Board Point Settings
Each Output Board has four output relays with line
voltage contacts. The system-equipment control
circuits may be wired to either the Normally Open
(N.O.) or Normally Closed (N.C.) contacts on the
Form C, SPDT output relays. See Figure 4 and
Table 1.
The Output Point Address corresponds to the relay
on the output board. On I/O Assemblies with one
output board, the point addresses are 1 to 4. On I/O
Assemblies with two output boards, the addresses are
1 to 4 on the first output board (connected to J2
connector) and 5 to 8 on the second output board
(connected to the J4 connector). See Figure 4.
Position the Relay Output LED Jumpers. Each red
Output Relay Status LED may be set to light either
when the N.C. contacts are closed (and the relay coil
is de-energized) or when the N.O. contacts are closed
(and the coil is energized). When the LED Jumper is
installed on the upper two pins (position A), the red
LED lights when the relay is de-energized. When the
jumper is on the lower pins (position B, factory default
position), the LED lights when the relay is energized.
See Figure 4 and Table 2.
4MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers
Product Bulletin

On the MO2-1C model Output Board (only) each
output relay has a Relay Override Switch to override
the control signal to the relay and set the relay in a
fixed On or Off state. See Figure 4.
A lit yellow Override Status LED indicates the relay is
overridden. The first press of an Override Switch fixes
the corresponding relay in its present On or Off state.
A second press of the switch (within 10 seconds of first
press) fixes the relay in the opposite On or Off state.
(Additional presses with 10 seconds have no effect.)
After 10 seconds press the switch once to cancel
override and return the relay to normal control. A
flashing Override LED is an indication of an assembly
problem. See Figure 4 and Table 2.
BI1 COM BI2
128
64
32
16
8
4
2
1
POWER
TX
BAUD
MAIN BOARD
Low-Voltage Supply Power
Terminal Block (J5) Binary Input
Terminal Block (J7)
(For Electric Usage
Pulse Counter)
Green Power ON
LED (DS1) Baud Rate Selection
Jumper Terminal (J11)
Yellow
Diagnostic
LED (DS2)
Green RS485
Transmitting
LED (DS4)
Green RS485
Receiving
LED (DS3) Ribbon Cable Connectors
(Total of four, J1, J2, J3, J4)
Board Address
DIP Switch (S1)
RS485 Network Connection
Terminal Block (J6)
Analog Output
Terminal Block (J8)
Holes for Standoff Spacers to
Support Input or Output
(Total of 12) Boards
J1LOWER
J2UPPER
J3LOWER
J4UPPER
DS2
DS1
+ -
A
01 COM A02
DS3
9600/38400
J5
J6
DIAG S1
RX J7
J8
J11
DS4
6-32 Threaded Inserts
Attached to Mod I/O Base
(4 Total)
Figure 3: A Modular I/O Base
Relay 1 Relay 2 Relay 3 Relay 4
OverRide 1 OverRide 2 OverRide 3 OverRide 4
NC COM NO NC COM NO NC COM NO NC COM NO
F1 F2 F3 F4
K1 K2 K3 K4
A
B
A
BA
BA
B
Power
Override
Switch*
(One of four)
Line Fuse
5 A 240 VAC
(One of four)
Red Relay
Status LED
(One of four)
Mounting
Holes
(Two of four)
Yellow Override
Status LED*
(One of four)
Output Relay
Terminal
Block
(One of four)
Relay
LED Jumper
(One of four)
Output
Green
Power-ON
LED
Ribbon Cable
Connector
Analog Input Board
Ribbon Cable
Connector
Input Sensors
Terminal Block
Input
Device
Selection
DIP Switch
Green
Power-ON
LED
Power
Input Board Output Board
J1 J2 J4J3
*Override LEDs and Switches on
MO2-1C Model Output Boards only
Mounting
Holes
(Two of four)
(MI2-1C Model)
Figure 4: An Input Board and an (MO2-1 Model) Output Board with Optional Relay Override Switches
MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers 5
Product Bulletin

Terminal Designations and Functions
Table 1 lists the terminals available on the
I/O Assemblies, terminal designations, point
addresses, functions provided by the terminals, and
the electrical ratings for each terminal block. See
Figures 3 and 4.
Table 1: Terminals, Point Addresses, Functions, and Electrical Ratings
Board Terminal
Block Name
(and Label)
Terminal
Label
Point Address
(Automatically
Assigned) Function and Electrical Rating
Low Voltage
Power
(J5)
AC1
CT
AC2 N/A
Apply low-voltage supply power to power the I/O Base
and the connected component boards.
24 VAC, 50 or 60 Hz, Class 2, 30 VA Minimum, or
20 VAC, 60 Hz, Class 2, Center Tap 30 VA Minimum
RS485
Network
(J6)
+
-
See the Modular I/O
Assembly Board
Address section.
These terminals receive/transmit the RS485 Network
signal. Maintain polarity between network devices.
Differential + or – 5 VDC
Binary Input
(J7)
BI1
COM
BI2 N/A
Connect electrical consumption metering devices to
these terminals.
Dry Contacts: Do not apply any power to these
terminals.
Modular
I/O Base
Analog
Output
(J8)
AO1
COM
AO2
Analog Output 1
Analog Output 2
These terminals supply analog output signals to the
connected analog control devices in the system.
4-20 mA or 0.1-10 VDC output
Do not apply any power to these terminals.
A1 to A8 Input Points 1 to 8 on first board (or 9 to 16
on second board)
Apply low-voltage analog input signals at these
terminals. Wire the signal output from passive or active
input devices to these terminals.
4-20 mA or 0.1-10 VDC, 10 VDC Maximum
Lower Ten
Terminals
(J2) +5V N/A
These terminals supply 5 VDC power for active analog
input devices.
Total output limited to 65 mA.
Do not apply any power to these terminals.
COM N/A These terminals provide common/reference for
passive and active analog input signal devices.
Input
Board
Upper Ten
Terminals
(J2) +15V N/A
These terminals supply 15 VDC power for active analog
input devices.
Total output limited to 120 mA. (A Maximum of six
4-20 mA input devices may be connected to these
terminals.)
Do not apply any power to these terminals.
J1 NC
COM
NO
Output Point 1 on first
board (or 5 on second
board)
J2 NC
COM
NO
Output Point 2 on first
board (or 6 on second
board)
J3 NC
COM
NO
Output Point 3 on first
board (or 7 on second
board)
Output
Board
J4 NC COM
NO
Output Point 4 on first
board (or 8 on second
board)
These terminals switch the target/connected
Equipment-control circuit ON and OFF according to the
criteria programmed on the system controller.
Contact Rating: 1.6 A Pilot Duty, 240 VAC Maximum
Voltage (per relay):
400 VA Pilot Duty, 240 VAC (Maximum Voltage)
200 VA Pilot Duty, 120 VAC
40 VA Pilot Duty, 24 VAC
Each Relay COM terminal has a 240 VAC, 5 A fuse.
6MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers
Product Bulletin

Table 2: Modular I/O Assembly LED Names, Designations, and Indications
Modular
Component
Board LED Name
LED
Designation on
the Circuit
Board
Indication and Troubleshooting
Override
Status LEDs
(Yellow)
M02-IC only
Override (1 to 4)
Continuously lit (non-blinking) LED means the Override is On.
Blinking Override 1 LED means bad ROM.
Blinking Override 2 LED means bad RAM.
All four Override LEDs blinking means the Output Board address
has changed since power was applied. Check ribbon cable
connections and reset board by cycling power to I/O Base.
Power ON
LED (Green) Power LED On indicates power to the Output Board. If LED is Off: Check
for Power to I/O Base. Check Ribbon Cable connections between
Output Board and I/O Base.
Output
Board
Output
Relay Status
LEDs (Red) Relay (1 to 4)
The LED lights when the relay is energized if the jumper is installed
on the lower two pins (factory default Position B).
The LED lights when the relay is de-energized if the jumper is
installed on the upper two pins (Position A).
Input Board Power ON
LED (Green) Power LED On indicates power to the Input Board. If LED is Off:
Check for Power to I/O Base. Check Ribbon Cable connections
between Input Board and I/O Base.
Power ON
LED (Green) DS1/POWER LED On indicates power to the I/O Base. If LED is Off: Check J5 Terminal Block for low-voltage supply power.
Diagnostics
LED
(Yellow) DS2/DIAG
Flash Codes:
1 Flash: +5VDC or +15VDC output is out of specification.
Possible Input Device (Transmitter/Transducer) failure.
2 Flashes: Communication failure between the Modular I/O Base
and an Input or Output Board. Check cables.
3 Flashes: RS485 network communication error. Occurs when the
Board Address or Communication Baud rate is changed.
4, 5, 6, or 8 Flashes: Transient Input/Output data-corruption error.
7 Flashes: RS485 communication error. Occurs when Modular I/O
Assembly has not received a command directed to any
output board relays for more than 1 minute.
RS485
Receiving
LED (Green) DS3/Rx Flashing LED indicates I/O Assembly is receiving RS485 Network
communication signals.
Modular I/O
Base
RS485
Transmitting
LED (Green) DS4/Tx Flashing LED indicates I/O Assembly is transmitting RS485 Network
communication signals.
Repairs and Replacement
Except for the four fuses on the Output Boards, the I/O
Assemblies and the component boards from which
they are built do not have any field repairable parts. Do
not attempt to repair a modular I/O Base or any of the
Input or Output Boards. If an I/O Base or component
board fails, the I/O Base or component board must be
replaced.
Contact your Johnson Controls/PENN sales
representative to order a new I/O Base or component
board.
Ordering Information
Refer to Table 3 and contact your authorized
Johnson Controls sales representative to order
I/O Assemblies and their component boards.
MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers 7
Product Bulletin

Table 3: Order Selection Table
Product Code Number Product Description Weight
MIOA1010-1C Modular I/O Assembly with two Input Boards side-by-side
(16 analog input points) (3-1/2 x 5 x 9in) 0.85 lb (0.39 kg)
MIOA1100-1C Modular I/O Assembly with two Input Boards stacked
(16 analog input points), (3-1/2 x 5 x 7 in.) 0.85 lb (0.39 kg)
MIOA0202-1C Modular I/O Assembly with two Output Boards with relay override
function (8 output relay points) 0.95 lb (0.43 kg)
MIOA0303-1C Modular I/O Assembly with two Output Boards
without the relay override function (8 output relays) 0.95 lb (0.43 kg)
MIOA1212-1C Modular I/O Assembly with two Input Boards and two Output Boards
(16 analog input points and 8 output relay points) 1.43 lb (0.65 kg)
MIOA0000-1C Modular I/O Base (only) 0.37 lb (0.17 kg)
MI1-1C Input Board (only) (8 analog input points) 0.24 lb (0.11 kg)
MO2-1C Output Board (only) (4 output relay points with the relay override function) 0.29 lb (0.13 kg)
MO3-1C Output Board (only) (4 output relay points without the relay override
function) 0.28 lb (0.13 kg)
Technical Specifications
Product MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System
Controllers
Power Requirements 24 VAC (50 or 60 Hz) 30 VA minimum, Class 2 Transformer, or
20 VAC (Center-Tapped) (60 Hz) 30 VA minimum, Class 2 Transformer
Output Relay Contacts
Electrical Ratings 1.6 A Pilot Duty, 240 VAC Maximum Voltage (per relay):
400 VA Pilot Duty, 240 VAC
200 VA Pilot Duty, 120 VAC
40 VA Pilot Duty, 24 VAC
Output Fuse Rating GMA 5 A, 240 VAC
Agency Listings FCC, CFR 47, Part 15, Class A; DOC
UL Listed, File E152562, CCN’s PAZX (US) and PAZX7 (Canada)
Ambient Storage and
Operating Conditions -40 to 140°F (-40 to 60°C)
5-95% RH noncondensing
Dimensions (H x W x D) 3-1/2 x 5 x 9 in. (90 x 127 x 230 mm) Maximum
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, contact Application Engineering at [phone]. Johnson Controls, Inc. shall not be liable for damages resulting from
misapplication or misuse of its products.
8MIOA Series Modular Input/Output Assemblies for Refrigeration, HVAC, and Building System Controllers
Controls Group
507 E. Michigan Street
P.O. Box 423 Published in U.S.A.
Milwaukee, WI 53201 www.johnsoncontrols.com
Product Bulletin