Woodward MicroNet TMR 5009 Digital Control System: Authoritative Guide to Hardware Installation and Configuration

MPU and Analog I/O Module (A3): Integrated with driver circuits for 4 speed sensor inputs, 8 analog inputs (4-20 mA), 4 analog outputs (4-20 mA), and 2 proportional actuator outputs. All calibrations are completed through software without potentiometers.

Discrete I/O module (A4): processes 24 discrete inputs (dry contacts) and 12 relay output commands. Input isolation is achieved through optocouplers.

Serial Input/Output Module (SIO, A5): Optional module, usually installed in the A and B cores. Provide additional serial communication ports (RS-232/422/485) to enhance communication redundancy and capability.

2.3 Terminal Module: On site Interface

Analog Terminal Modules (ATM-1, ATM-2): Installed on standard DIN rails. As the interface between on-site analog signals (speed, analog I/O, actuator) and analog I/O modules within three cores. Provide signal routing, summation, and isolation power supply (for proximity switch probes) functions.

Discrete terminal module (DTM-1 to DTM-4): used to connect on-site discrete wiring (contact input and relay output). Each DTM processes 6 contact inputs and 3 relay outputs. The relay output adopts a unique 6-relay fault-tolerant configuration, supporting latent fault detection (LFD), which can detect relay faults without affecting the output status.

2.4 Optional Components

Cabinet: Standard floor standing front door cabinet (compliant with NEMA 12/IP55), weighing approximately 272 kilograms. The control system can be installed as a whole inside the factory, providing integrated power interface board and wiring management.

OpView ™ Operator Interface (U3): A computer-based touchscreen workstation used as a touchscreen alarm and remote control panel.

Chapter 3: Detailed explanation of mechanical installation steps

3.1 Preparation before installation

Storage: The device should be stored in an environment with a temperature of -20 ° C to+70 ° C and a humidity of ≤ 90% (non condensing). When stored for a long time, the main power supply needs to be powered on at least once every 18 months.

Open box inspection: Carefully inspect all components (see Table 3-1) for damage. Systems with cabinets are shipped as a complete package, while those without cabinets are shipped as individual parts.

3.2 Installation process

Site selection: Choose a location that is dry, well ventilated, with an ambient temperature of 0-55 ° C (0-46 ° C inside the cabinet), and away from strong electromagnetic interference. Ensure good grounding.

Installation of cabinet (if equipped): Fix with standard floor brackets, introduce cables from the bottom, and reliably ground with ≥ 10 mm ² wires.

Installation of chassis: Install the main control chassis and power chassis on the panel or backplane at a specified distance (50-200 mm). Connect the two using the provided W1-B cable and ensure that the chassis is grounded.

Installation module: In the event of a power outage, insert each module (power supply, CPU, I/O, etc.) accurately into the corresponding slot of the main control chassis according to the slot identification (Figure 3-6), and tighten it with screws. Do not use brute force.

Install terminal module:

ATM: Installed on a well grounded DIN rail, and reliably grounded its "chassis ground" terminal using the accompanying grounding terminal (Misc A) and short wire (≤ 15 cm).

DTM: Master DTM (1,3) must be installed directly above Slave DTM (2,4). Ensure that the installation panel is reliably grounded.

Install OpView: Install according to the template (Figure 3-12) to ensure sufficient heat dissipation space is reserved.

Chapter 4: Electrical Installation and Wiring Specifications

4.1 General Principles

All on-site wiring must meet a temperature rating of at least 75 ° C.

Following EMC standards, analog and discrete I/O wiring must be separated from power lines.

Use shielded twisted pair cables to connect speed sensors, analog I/O, and communication ports. The shielding layer should be grounded at a single point at the control terminal and all intermediate terminal blocks, with an exposed wire length not exceeding 25 mm.

4.2 Power Wiring

Each main power supply must be equipped with an independent branch circuit protection (fuse or circuit breaker), with a rated value not exceeding 250% of the rated input current of the power supply (see Table 4-1). Slow melting protective devices must be used.

The input power wire diameter must meet the requirements in Table 4-1 (e.g. 10 mm ² or 8 AWG wire is required for a 24 Vdc power supply).

The three isolated 24 Vdc outputs (A, B, C) of the system must remain isolated and must not be short circuited externally, otherwise a short circuit at one point may cause the entire control system to lose power.

The leakage current exceeds 3.5 mA, therefore a protective earth (PE) connection is mandatory.

4.3 Detailed explanation of signal wiring

Speed sensor input: Supports passive magneto electric speed sensors (MPU) or active proximity switch probes (12/24 Vdc). MPU needs to install jumpers to enable three core detection; The proximity probe is provided with isolated power supply by ATM. Attention should be paid to frequency and voltage range limitations.