SAF SAFphire User manual

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Installation & Operating Procedures
PROGRAMMABLE LINER CONTROLLER
HARDWARE GUIDE
MANUAL VER. 2.8

06/05/13
SAFphire
Programmable Linear Controller
Hardware Guide
Manual Version 2.8

SAFphire Hardware Guide
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SAFphire Hardware Guide
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FOR YOUR SAFETY
Only qualified personnel should install this equipment, after
first reading and understanding all the information in this
manual. All instructions should be strictly adhered to. The user
should consult SAF or a SAF supplier for clarification of the
contents of this manual should any doubt or questions arise.
The installation of this equipment must be conducted in
accordance with all national, regional and local electrical codes.
All drawings and technical representations included in this
manual are for typical installations and should not in any way be
considered for specific applications or modifications. Consult
SAF Drives and Automation for supplemental instructions.
SAF Drives Inc. accepts no liability for any consequences
resulting from inappropriate, negligent or incorrect installation,
application or adjustment of this equipment.
The contents of this manual are believed to be correct at the
time of printing. In following with our commitment to the
ongoing development and improvement of our products SAF
reserves the right to change the specification of this product
and/or the content of this instruction manual without notice.

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SAFphire Hardware Guide
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Table of Contents
SAFphire Input/Output Cards
SAFphire Input/Output Cards..................................................................5
CA401 DIGITAL INPUT CARD ......................................................................11
MODELS..................................................................................................11
JUMPERS and SWITCHES ....................................................................11
TERMINALS ............................................................................................12
LEDS .......................................................................................................12
SPECIFICATIONS...................................................................................12
CA402 DIGITAL OUTPUT CARD ..................................................................14
MODELS..................................................................................................14
JUMPERS and SWITCHES ....................................................................14
TERMINALS ............................................................................................15
LEDS .......................................................................................................15
SPECIFICATIONS...................................................................................16
CA403 MULTIPLE I/O CARD.........................................................................17
MODELS..................................................................................................17
JUMPERS and SWITCHES ....................................................................17
TERMINALS ............................................................................................18
LEDS .......................................................................................................18
POTENTIOMETERS................................................................................19
SPECIFICATIONS...................................................................................19
CA404 ANALOG OUTPUT CARD .................................................................21
JUMPERS and SWITCHES ....................................................................21
TERMINALS ............................................................................................21
LEDS .......................................................................................................22
POTENTIOMETERS................................................................................22
SPECIFICATIONS...................................................................................22
CA406 SERIAL INTERFACE CARD..............................................................23
JUMPERS and SWITCHES ....................................................................23
TERMINALS ............................................................................................24

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LEDS .......................................................................................................25
SPECIFICATIONS...................................................................................26
CA407 DRIVE INTERFACE / ENCODER CARD...........................................27
JUMPERS and SWITCHES ....................................................................27
TERMINALS ............................................................................................28
LEDS .......................................................................................................29
POTENTIOMETERS................................................................................29
SPECIFICATIONS...................................................................................29
CA408 MULTIPROCESSOR CARD ..............................................................30
JUMPERS and SWITCHES ....................................................................30
TERMINALS ............................................................................................31
LEDS .......................................................................................................32
SPECIFICATIONS...................................................................................32
CA408-1 MULTIPROCESSOR CARD ...........................................................33
JUMPERS and SWITCHES ....................................................................33
TERMINALS ............................................................................................34
LEDS .......................................................................................................34
CHANGING THE BATTERY....................................................................34
SPECIFICATIONS...................................................................................34
CA409 FAULT RELAY CARD........................................................................36
TERMINALS ............................................................................................36
LEDS .......................................................................................................36
SPECIFICATIONS...................................................................................37
CA410 MODBUS PLUS INTERFACE CARD.................................................38
JUMPERS and SWITCHES ....................................................................38
TERMINALS ............................................................................................40
LEDS .......................................................................................................40
SPECIFICATIONS...................................................................................41
CA412 MULTIPLE ENCODER / ANALOG OUTPUT CARD..........................42
JUMPERS and SWITCHES ....................................................................42
LEDS .......................................................................................................44
POTENTIOMETERS................................................................................44

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SPECIFICATIONS...................................................................................45
CA413 SCANPORT INTERFACE CARD.......................................................46
JUMPERS and SWITCHES ....................................................................46
TERMINALS ............................................................................................46
LEDS .......................................................................................................46
SPECIFICATIONS...................................................................................47
CA414 SAF-LINK COMMUNICATIONS GATEWAY .....................................48
JUMPERS and SWITCHES ....................................................................48
TERMINALS ............................................................................................49
LEDS .......................................................................................................49
CHANGING THE BATTERY....................................................................49
SPECIFICATIONS...................................................................................49
CA415 ANALOG ISOLATION CARD.............................................................51
JUMPERS and SWITCHES ....................................................................51
TERMINALS ............................................................................................51
POTENTIOMETERS................................................................................51
SPECIFICATIONS...................................................................................52
CA416 POSITION INPUT CARD ...................................................................53
JUMPERS and SWITCHES ....................................................................53
TERMINALS ............................................................................................54
LEDS .......................................................................................................54
SPECIFICATIONS...................................................................................54
CA417 DDCS INTERFACE CARD.................................................................55
JUMPERS and SWITCHES ....................................................................55
TERMINALS ............................................................................................55
LEDS .......................................................................................................55
SPECIFICATIONS...................................................................................55
CA418 MULTIPROCESSOR CARD ..............................................................56
SWITCHES..............................................................................................56
JUMPERS................................................................................................58
TERMINALS ............................................................................................59
LEDS .......................................................................................................59

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SPECIFICATIONS...................................................................................59
CA419 DDCS INTERFACE CARD.................................................................60
JUMPERS and SWITCHES ....................................................................60
TERMINALS ............................................................................................60
LEDS .......................................................................................................60
SPECIFICATIONS...................................................................................60
CA451 MULTIPROCESSOR CARD ..............................................................61
JUMPERS and SWITCHES ....................................................................61
TERMINALS ............................................................................................63
LEDS .......................................................................................................64
SPECIFICATIONS...................................................................................65
CA452 MULTI CHANNEL ENCODER INPUT CARD ....................................65
JUMPERS and SWITCHES ....................................................................65
TERMINALS ............................................................................................65
LEDS .......................................................................................................66
SPECIFICATIONS...................................................................................66
CA453 MULTI CHANNEL ENCODER INPUT CARD ....................................66
JUMPERS and SWITCHES ....................................................................66
TERMINALS ............................................................................................66
LEDS .......................................................................................................67
SPECIFICATIONS...................................................................................67
CA454 DDCS INTERFACE CARD.................................................................67
JUMPERS and SWITCHES ....................................................................68
TERMINALS ............................................................................................68
LEDS .......................................................................................................68
SPECIFICATIONS...................................................................................68
CA460 MULTIPROCESSOR CARD ..............................................................68
JUMPERS and SWITCHES ....................................................................69
TERMINALS ............................................................................................70
LEDS .......................................................................................................70
SPECIFICATIONS...................................................................................71
DOWNLOADING/ANNUNCIATING OPTIONS ..............................................72

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BITBUS INTERFACE CARD..........................................................................77
REQUIREMENTS ....................................................................................77
HARDWARE INSTALLATION.................................................................77
JUMPER SETTINGS ...............................................................................77
RS232 TO BITBUS CONVERTOR ................................................................79
LEDs........................................................................................................79
CA406 DOWNLOAD CARD...........................................................................80
JUMPERS and SWITCHES ....................................................................80
TERMINALS ............................................................................................81
LEDS .......................................................................................................82
SPECIFICATIONS...................................................................................82
CABLE CONNECTIONS................................................................................83
BITBUS Cable.........................................................................................83
TERMINATION RESISTORS...................................................................83
BitBus WIRING LIMITS ..........................................................................83
RS232 CABLE.........................................................................................84
RS232 WIRING LIMITS...........................................................................84
CA407 to CA383 or CA384 CABLE........................................................84
DDCS MULTIPLEXER...................................................................................85
EXAMPLES .............................................................................................85
TERMINALS ............................................................................................86
SPECIFICATIONS...................................................................................87
RACK DIMENSION AND MOUNTING...........................................................88
8 SLOT RACK .........................................................................................88
17 SLOT RACK .......................................................................................88
POWER SUPPLY...........................................................................................90
LEDS .......................................................................................................90
SPECIFICATIONS...................................................................................90
HANDTERM OPERATION GUIDE.................................................................91
INTRODUCTION......................................................................................91
DISPLAY OVERVIEW .............................................................................91
OPERATING MODES..............................................................................92

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SYSTEM MAINTENANCE..............................................................................95
CA408 PROCESSOR CARD...................................................................95
CA414 SAF-Link CARD & CA408-1 PROCESSOR CARD ....................95
TECHNICAL SUPPORT.................................................................................96
CONTACT US..........................................................................................96

SAFphire Hardware Guide
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CA401 Digital Input Card
The CA401 is a 16 channel digital input card. The inputs may be 24 VDC
or 120 VAC depending on the model of the card. The 16 inputs are made
up of two groups of 8 inputs. Each group has its own neutral.
MODELS
B - 24 Volt DC input
D - 120 Volt AC input
JUMPERS and SWITCHES
SB1 - CARD ADDRESS
The address of the CA401 is determined by four dip switches of SB1
labeled A0, A1, A2, and A3. The other four dip switches are unused. Their
position has no effect on card operation. The four switches labeled A0 -
A3 form a four bit binary address in the range 0 to 15. A0 is the least
significant bit. A3 is the most significant bit. When a switch is in the ON
position it adds a 0 to the board address. When a switch is not in the ON
position it adds the value shown below to the board address.
A0 1
A1 2
A2 4
A3 8
When using more than 1 CA401 card in the same rack, each card must
have an unique address as set by the card address switches.
Typical address settings are shown below
JP1
JP1 allows the user to give up input 16 and use it as a latching input.
When JP1 is in the AG position, activating input 16 latches the data and
deactivating input 16 makes new data valid. When JP1 is in the AH
position, input 16 is simply the sixteenth input.

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TERMINALS
CA401
DIGITAL
INPUT CARD
SAF
BUS
STATUS
INPUTS
ACTIVE INPUTS
1 2 3 4 5 6 7 8
- -
9
10
11
12 13 14 15 16
- -
1
2
3
4 5 6 7
8
9
10
11
12 13
14 15 16
NA
Neutral for inputs
1 to 8
1
Input 1
2
Input 2
3
Input 3
4
Input 4
5
Input 5
6
Input 6
7
Input 7
8
Input 8
NA
Neutral for inputs
1 to 8
NB
Neutral for inputs
9 to 16
9
Input 9
10
Input 10
11
Input 11
12
Input 12
13
Input 13
14
Input 14
15
Input 15
16
Input 16 /Latching
Input (see Jumper
JP1)
NB
Neutral for inputs
9 to 16
Note: Terminals labeled NA are connected internally. Terminals labeled
NB are connected internally.
LEDS
The LEDs labeled 1 to 16 will be ON when the voltage between the
corresponding Input terminal and its neutral is above the INPUT
THRESHOLD VOLTAGE for the model of card being used.
The SAF BUS STATUS LED will be flashing once per second when the
card is being accessed by the SAFphire processor card. This LED will not
change states when the card is not being accessed.
SPECIFICATIONS

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MODEL B (24 VDC inputs)
Maximum Input
Voltage
30 VDC
Input Threshold
Voltage
12 VDC
Input Current
2 mA
Input Filter Delay
.1 msec
Isolation
optical 1.5 kV
MODEL D (120 VAC inputs)
Maximum Input
Voltage
140 VAC 50/60
Hz
Input Threshold
Voltage
70 VAC 50/60 Hz
Input Current
2 mA
Input Filter Delay
10 msec
Isolation
optical 1.5 kV
Current Draw per Card (both Models)
5 VDC
160 mA
+15 VDC
0 mA
-15 VDC
0 mA

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CA402 Digital Output Card
The CA402 is a 16 channel digital output card. The outputs are rated at
24 VDC or 120 VAC depending on the model of the card. The 16 outputs
are made up of two groups of 8 outputs. Each group has its own output
voltage source.
MODELS
B - 24 Volt DC output
D - 120 Volt AC output
JUMPERS and SWITCHES
SB1 - CARD ADDRESS
The address of the CA402 is determined by four dip switches of SB1
labeled A0, A1, A2, and A3. The other four dip switches are unused. Their
position has no effect on card operation. The four switches labeled A0 -
A3 form a four bit binary address in the range 0 to 15. A0 is the least
significant bit. A3 is the most significant bit. When a switch is in the ON
position, it adds a 0 to the board address. When a switch is not in the ON
position it adds the value shown below to the board address.
A0 1
A1 2
A2 4
A3 8
When using more than 1 CA402 card in the same rack, each card must
have an unique address as set by the card address switches.
Typical address settings are shown below

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TERMINALS
1
Output 1
2
Output 2
3
Output 3
4
Output 4 +
5
Output Voltage Source for
Outputs 1 to 8
6
Output 5
7
Output 6
8
Output 7
9
Output 8
10
Output Voltage Source for
Outputs 1 to 8
11
Output 9
12
Output 10
13
Output 11
14
Output 12
15
Output Voltage Source for
Outputs 9 to 16
16
Output 13
17
Output 14
18
Output 15
19
Output 16
20
Output Voltage Source for
Outputs 9 to 16
Note: Terminals 5 and 10 are connected internally. Terminals 15 and 20
are connected internally.
LEDS
The LEDs labeled 1 to 16 will be ON when the corresponding output is
ON.
The SAF BUS STATUS LED will be flashing once per second when the
card is being accessed by the SAFphire processor card. This LED will not
change states when the card is not being accessed.

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SPECIFICATIONS
MODEL B (24 VDC Outputs)
Maximum Output
Current
100 mA
Maximum Output
Voltage
200 V RMS
Minimum Output Voltage
Frequency
DC
Isolation
optical 2.5 kV
MODEL D (120 VAC Outputs)
Maximum Output
Current
300 mA RMS 5 A peak
(20 msec)
Maximum Output
Voltage
280 V RMS 500 V peak
Minimum Output Voltage
Frequency
47 Hz
Isolation
optical 2.5 kV
Current Draw per Card (both Models)
5 VDC
150 mA
+15 VDC
0 mA
-15 VDC
0 mA

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CA403 Multiple I/O Card
The CA403 is a multiple input / output card with 3 12 bit bipolar analog
inputs, 4 digital inputs, 2 12 bit bipolar analog outputs, 2 digital form C
relay outputs and 1 +10 Volt fixed output. The digital inputs may be 24
VDC or 120 VAC depending on the model of the card. The 4 digital inputs
are made up of two groups of 2 inputs. Each group has its own neutral.
MODELS
B - 24 Volt DC input
D - 120 Volt AC input
JUMPERS and SWITCHES
SB3 - CARD ADDRESS
The address of the CA403 is determined by four dip switches of SB3
labeled A0, A1, A2, and A3. The other four dip switches are unused. Their
position has no effect on card operation. The four switches labeled A0 -
A3 form a four bit binary address in the range 0 to 15. A0 is the least
significant bit. A3 is the most significant bit. When a switch is in the ON
position, it adds a 0 to the board address. When a switch is not in the ON
position it adds the value shown below to the board address.
A0 1
A1 2
A2 4
A3 8
When using more than 1 CA403 card in the same rack, each card must
have an unique address as set by the card address switches.
Typical address settings are shown below

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TERMINALS
1
Analog Input 1
2
Common
3
Analog Input 2
4
Common
5
Analog Input 3
6
Common
7
Analog Output 1
8
Common
9
Analog Output 2
10
Common
11
+10 V Reference
12
Common
13
Logical Output 1 Toggle
14
Logical Output 1 Normally
Closed
15
Logical Output 1 Normally
Open
16
Logical Output 2 Toggle
17
Logical Output 2 Normally
Open
18
Logical Output 2 Normally
Open
19
Neutral for A1 and A2 Inputs
20
Logical Input A1
21
Logical Input A2
22
Logical Input B1
23
Logical Input B2
24
Neutral for B1 and B2 Inputs
LEDS
The LEDs labeled I/P A1, I/P A2, I/P B1, and I/P B2 will be ON when the
voltage between the corresponding Logical Input terminal and its neutral
is above the INPUT THRESHOLD VOLTAGE for the model of card being
used.
The LEDs labeled O/P 1 and O/P 2 will be on when the corresponding
Logical Output is ON.

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POTENTIOMETERS
RV1 - RV10 These pots are factory calibrated and should not need user
adjustment
SPECIFICATIONS
Model B Digital Inputs
Maximum Input Voltage
30 VDC
Input Threshold Voltage
12 VDC
Input Current
2 mA
Input Filter Delay
1 msec
Isolation
optical 1.5 kV
Model D Digital Inputs
Maximum Input Voltage
140 VAC 50/60
Hz
Input Threshold Voltage
70 VAC
Input Current
2 mA
Input Filter Delay
10 msec
Isolation
optical 1.5 kV
Digital Outputs (both models)
Maximum Output
Current
1 A resistive load
Maximum Output
Voltage Source
200 V RMS
Isolation
mechanically 1 kV
Analog Outputs (both models)
Maximum Output
Voltage
+/- 11.7 V
Maximum Output
Current
40 mA (short
circuit proof)
Resolution
12 bit
Isolation
none
Analog Inputs (both models)
Maximum Input Voltage
+/- 11.7 V
Maximum Input Current
250 uA
Resolution
12 bit
Isolation
none
10 Volt Reference (both models)
Maximum Output
Current
25 mA
Accuracy
+/- .02%
Isolation
none