NCM118586, Ver.
A Nexus OnCore™ Hardware Manual
2.4 MAO50 8-Channel Analog Output Module
2.4.1 Functional Description
The MAO50 8-Channel Analog Output Module is an intelligent data acquisition and
processing module. It contains a processor subsystem and an acquisition circuit specific
to the analog output function and can handle up to 8 analog outputs. All 8 analog outputs
can provide current output with signal range from 4-20mA or 0-20mA, and the last two
channels (channels 07 and 08) can also be configured for 1-5V dc output.
The module has two redundant intelligent I/O bus (iLink) connectors, which feed power
to the module, communicate with the controller, and receive process control commands
from the controller. Field signal wires connect to two 16-pin terminal blocks located on
the left side of the module. Operation status and diagnostics are provided via indicator
LEDs on the front of the module cover.
Figure 2.4-1. Module Front/Rear View
Figure 2.4-2. MAO50 Block Diagram
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2.4.2 Installation
2.4.2.1 Installing the Module
Refer to Figure 2.2-3 Nexus OnCore I/O Module Installation and follow the
steps shown below to install the MAO50 module:
1) Determine the module position for the MAO50 in the cabinet, with I/O bus
(iLink) cable installed.
2) Set the module address jumper per system design. Refer to
Configuration section 2.4.6 for details.
3) Connect the iLink bus cable with the module by its rear DB-9 connectors,
R net – Black, S net – White, and tighten the connector screws.
4) If I/O bus power is present, the module will be powered on. After a few
seconds, the module will go to normal operation.
5) Securely mount the module on the cabinet mounting pillars by its
mounting holes on each corner.
6) Align the module cover with the module base and push it in, until the
upper and lower tabs of the cover securely lock to the module base.
7) Configure the module on the HMI as necessary.
NOTE
The I/O module’s electrical circuit board (PCBA) grounding is provided
through the tinned PCB around board mounting holes. The cabinet’s
mounting pillar connects to the grounding bar through the grounding cables.
The mounting holes of the I/O module’s metal base are specially treated.
Tighten the mounting screws until the module is firmly grounded.
2.4.2.2 Removing the Module
Refer to Figure 2.2-4 Nexus OnCore I/O Module Removal and follow the
steps shown below to remove the MAO50 module：
1) Press the module cover upper and lower tabs simultaneously and remove
the cover from the module base.
2) Unscrew all four corner screws from the module base and remove the
module from the cabinet mounting pillars.
3) Loosen the I/O bus connector screws, which are located on the rear of
the module. Remove the I/O bus cable from the module’s R/S
connectors.
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NCM118586, Ver. A Nexus OnCore™ Hardware Manual
2.4.2.3 Terminal Wiring
Field signal wires connect to two 16-pin terminal blocks located on the left
side of the module. The MAO50 can provide the following types of analog
output:
Current output, 4-20mA
Voltage output, 1-5V dc (only available for channels 07 and 08)
Typical 1.5mm2 (#15 AWG or #16 AWG) wires (twisted shielded pair) are
used. For better shielding and to prevent external electromagnetic
interference, it is recommended that the field cable shield layer be stripped
near the module’s terminal block and connected to the module’s shield
terminal. Grounding bars are also provided adjacent to the cabinet entrance
of field cables for shield grounding.
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MAO50 (369B1842G5003)
Output + + CH07 － OUTPUT TYPE SETTING FOR CHANNEL
07
Load CH08 － OUTPUT TYPE SETTING FOR CHANNEL
Output - - 08
SHORTED － VOLTAGE
OPEN － CURRENT
JUMPER CH07/CH08
Shield S
Figure 2.4-3. MAO50 Wiring, Jumper Positions, and Cable Connections
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NCM118586, Ver. A Nexus OnCore™ Hardware Manual
MAO50 (369B1842G5005)
Output + + CH07 － OUTPUT TYPE SETTING FOR CHANNEL 07
CH08 － OUTPUT TYPE SETTING FOR CHANNEL 08
Load (Only the left two pins are for type setting)
Output - -
SHORTED － VOLTAGE
OPEN － CURRENT
JUMPER CH07/CH08
Shield S
Figure 2.4-4. MAO50 Wiring, Jumper Positions and Cable Connections
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2.4.3 Operation
2.4.3.1 Processor
Each I/O module contains a processor circuit which is common to all Nexus
OnCore I/O modules. The processor subsystem is based on ARM®
CortexTM-M3 System-on-Chip (SoC) technology, with high performance and
comprehensive hardware resources integrated into one single chip, including
RAM, flash memory, UART, timer, watchdog, DMA and GPIO. It contains the
following:
High performance CPU with integrated RAM and flash memory
Two independent half-duplex serial communication interfaces, up to
1Mbps I/O bus communication, plug and play for bus connection
Embedded I/O module temperature sensor
Three status and alarm LED indicators
Online upgradeability for bootloader/firmware via I/O bus (iLink)
NOTE
Upon power up, if there is valid firmware in the flash memory, the processor
will go to normal operation within 10 seconds. Otherwise, the processor will
remain in bootloader mode until valid firmware has been downloaded into the
flash memory.
2.4.3.2 Physical Address
Each Nexus OnCore I/O module has its unique physical address within the
same iLink, and it can be set by the module’s address jumper. There are four
bits used to identify the module’s address, which means up to 16 addresses
can be configured (the first 14 addresses are valid). During module initiation,
the process system of the module will acquire a unique physical address. If
the address is the same as any other I/O modules within the I/O link,
communication between the module and controller will not be established
because of the address conflict. In such cases, the status LEDs of the I/O
module will indicate the problem. Refer to Diagnostics section 2.4.5 for
detailed information.
2.4.3.3 ID Line
The module’s electrical circuitry contains an ID part number which uniquely
identifies the module type. This allows the controller to confirm correct
matching between the target I/O module and the module’s firmware. Five bits
are used for module type, which means up to 32 module types can be
identified.
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2.4.3.4 Power Management
The Nexus OnCore I/O module includes power management on the 24V dc
input circuit. Transformers are used for module power isolation and to
prevent a short circuit between internal 24V and ground. The I/O module
continuously monitors internal operation power voltage. Any abnormal
condition will be reported to the controller and alarmed on the HMI screen.
2.4.3.5 Processor Temperature Monitoring
The processor contains a temperature sensor which measures actual
temperature on the electrical circuit board. The acquired data will be
transferred to the controller via the I/O link by the I/O module.
2.4.3.6 Analog Output Hardware
The MAO50 provides 8 analog outputs through its terminal blocks. Each
analog output section consists of an EMC section, V/I converter, 12-bit D/A
converter (DAC) and isolation circuit. All output channels are electrically
isolated from the processor and I/O bus.
24Vin - A
MAO50 AO Module
Isolation Power source
24Vin - B
Power
Source
iLink R
iLink Cable
*
DB9-R
V/I
EMC interface
Processor
Module D/A
isolation
Terminal Convertor iLink S
(8 outputs) (12 bit)
iLink Cable
DB9-S
Controller
Figure 2.4-5. MAO50 Hardware Block Diagram
NOTE
For the new MAO50 module (269B1842G5005), the V/I converter is
integrated into the DAC chip.
The first six channels (CH#01-CH#06) are current output type with signal
range from 4 to 20mA. The last two channels (CH#07 and CH#08) can be
configured as current or voltage output (0-5V). The load driven ability of
current output can be up to 1kΩ. There is one EMC section for each analog
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output channel to mitigate site interference and ensure output accuracy. For
each type of output configuration and wiring, refer to Configuration section
2.4.6 and Installation section 2.4.2.
Open-circuit detection is provided by the MAO50 for current type output.
Open-circuit is detected through an opto-coupler by reading back output
current. If the output circuit is open while the channel has current, an alarm
will be generated to indicate the channel open-circuit.
2.4.3.7 Status LEDs
Three LEDs are provided on the module’s front panel for operating status
and diagnostics display.
STAT COMR COMS
Figure 2.4-6. I/O Module Status Indicator (LEDs)
Color Label Description
Red STAT Module operation status indication
Green COMR Module communication status indication (iLink R)
Green COMS Module communication status indication (iLink S)
Table 2.4-1. MAO50 LED Indication
For detailed information about status LEDs, refer to Diagnostics section
2.4.5.
2.4.3.8 Connectors
The module has the following connectors:
Two DB-9 connectors (male) on the rear of the module to connect the
I/O bus (iLink) for I/O network connection, and 24V dc power supply.
Refer to NCM118585 Nexus OnCore™ System Manual for pin
definition of the connectors.
Two 16-pin removable terminal blocks on the left side of the module for
field signal wiring
One programming port (JTAG) on the front of the module’s electrical
circuit board for embedded processor programming and tuning
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2.4.4 Specifications
Specification
Item
369B1842G5003 (Legacy) 369B1842G5005
Number of Channels 8
Analog Output 4-20mA，1-5V dc (only channels 07 and 08)
Load Capacity (current
Max. 1kΩ
output)
Load Capacity (voltage
Min. 500kΩ Min. 200kΩ
output)
D/A Resolution 12 bit
Frame Rate Refresh all channels within 1ms
System dependent scan rate for control purposes
Accuracy 0.2% of full scale over the full operating temperature range
Interference Resistance CMRR ≥ 120dB@250VAC
Channel to ground ≥500VAC@50/60Hz
Isolation
Channel to system ≥1500VAC@50/60Hz
Power Supply Dual redundant 24V dc (±10%)
Power Consumption Typical 1W, max 6.5W Typical 1.55W, max 6.55W
Heat Dissipation Typical 1W, max 5.7W Typical 1.45W, max 5.75W
Physical
Size 209mm x 129.5mm x 51mm (height x width x depth)
Weight 450g
Operating Temperature -20 - 70ºC (-4 - 158ºF)
Storage Temperature -40 - 85ºC (-40 - 185ºF)
Operating Relative Humidity 5-95% (non-condensing)
Table 2.4-2. MAO50 Specifications
2.4.5 Diagnostics
The MAO50 module performs the following self-diagnostic tests:
1) A power up self-test that includes RAM and flash memory. In case of fault
detection, the module will remain in initialization state, the onboard program will
be halted, and no command will be transmitted.
2) Module’s physical address conflict detection. When an address conflict is
detected, the module will remain offline.
3) I/O link communication check. If any I/O link communication fails, an alarm will be
generated and sent to the controller by the redundant I/O link.
4) Continuous monitoring of the internal power supplies for correct operation. An
alarm will be generated if the power voltage is less than 20V dc.
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5) Continuous monitoring of AO circuit. An alarm will be generated if either SPI
communication is lost or AO power supply fails.
6) Open-circuit detection on current output mode.
NOTE
Open-circuit detection is only available when the channel has current output.
Details of the individual diagnostics are available from the OptimumC application on the
HMI. The diagnostic signals can be individually latched, and then reset if they become
healthy.
LEDs are provided on the module cover for module’s status indication.
STAT COMR COMS Description
Solid on Solid on Solid on Module initiating
If all LEDs remain on for long time, the module’s
firmware may be invalid, or the CPU has failed.
Off Flashing Flashing Normal operation
Flashing Solid on Solid on Module physical address invalid or conflict exists
Flashing Off/Flashing Off/Flashing Internal alarms exist or both I/O communication loss
Per flashing frequency of STAT:
LED flash in turn = In bootloader mode
Flashing Flashing Flashing
LED flash simultaneously = In firmware mode, internal
alarms exist (exclude communication failure)
Flashing Off Flashing iLink R failure, or other internal alarms exist
Flashing Flashing Off iLink S failure, or other internal alarms exist
Table 2.4-3. I/O Module LEDs
Normally, when the module is powered on, all three LEDs will be on as the module
initiates. After a few seconds, initiation will be complete, and the processor will start to
run. Depending on the module status, the STAT light will be off or flashing, and the other
two LEDs will stay off until communication between the module and the controller is
established.
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2.4.6 Configuration
2.4.6.1 Physical Address Setting
The module’s physical address within the I/O bus can be set by the address
switch. Refer to Table 2.4-4 for all available physical addresses and settings.
Table 2.4-4. I/O Module Address Setting
If the OptimumC software version is earlier than V2.6.1.2, the module
addresses 12 and 13 are reserved.
2.4.6.2 Parameter Configuration
Configure the module’s parameters in the controller’s configuration prior to
using the MAO50 module.
NOTE
The following information is extracted from the Nexus OnCore configuration
application. Only hardware related parameters are listed here. Refer to the
Engineer Software Manual and the Function Block Manual for specific
information and detailed operation instructions.
To configure the MAO50 module in SysCfg, click on “Device”, “Link”,
“Module” and “Channel”. Refer to the Engineer Software Manual for detailed
operation instructions.
NOTES
1) For virtual device type, choose “NEXUS”.
2) Insert one “Link” for each I/O link (iLink). It will be mapped as a “Station”
in the controller.
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1) Add a module to the controller’s configuration. Insert an I/O module within
designated “station”. Select “AO50” for the module’s device type.
2) Configure the module’s parameters within the device’s property window.
Parameter Description Choices
Module’s physical address within the
Address 0-13
I/O link
Request 20, 40, 80, 200, 480, 1000,
Controller’s scan rate for the module
Interval units are ms
Engineering description for the Text description, manually key
Description
module in
Table 2.4-5. MAO50 Hardware-Related Parameters
Figure 2.4-7. MAO50 Module Parameter Setting
3) Configure each channel of the module. Refer to Figure 2.4-8. Double-
click each row of the module’s output list to configure the I/O points.
Figure 2.4-8. MAO50 Module Output Channel Parameter Setting
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Each MAO50 output channel maps an XAO function block. The following
parameters are required for hardware related configuration:
Parameter Description Choices
Determined by the module’s
parameter setting and the channel
Addr Signal HW address
position within the signal list, read
only
Cvt Conversion type 0=Output AD value
AD value for upper limit of
MaxAD 4095 = 20mA (5V dc)
measurement range
AD value for lower limit of 0 = 0mA (0V dc)
MinAD
measurement range 819 = 4mA (1V dc)
Table 2.4-6. Hardware-Related Configuration Parameters
NOTE
Output signal range 0-20mA (0-5V dc) corresponds to AD range (0-4095).
Configure MaxAD/MinAD to 1/0 to disable alarm for unused channels.
2.4.6.3 Failsafe Configuration
The MAO50 module is configurable to allow the user to select a failsafe
condition upon loss of control (communication with both controllers is lost).
When configured for failsafe, the output will go to the failsafe state within two
frame cycles upon loss of communication with both controllers. If the MAO50
loses communication with the active controller for 2 frames, the module will
respond to the standby controller output commands. If the MAO50 then loses
communication with the standby controller, the module will go to the failsafe
state within 2 frames. Follow the procedure shown below to enable the
failsafe configuration in SysCfg.
1) Connect to the DPU and upload its configuration. Double-click the
MAO50 module to pop up its Device Property dialog box. Select the
“Enable Output Channel Failsafe Configuration” checkbox.
Figure 2.4-9. MAO50 Module Failsafe Setting – Step 1
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2) Go to the “Outputs” sheet of the MAO50 module. Select the “SetVal”
option in the “FailsafeType” column and input a specified failsafe value
(0-100%) in the “FailsafeValue(%)” column. Failsafe is configurable for
each row (channel). For channels that do not need the failsafe function,
select the “HoldLastVal” option in the “FailsafeType” column.
Figure 2.4-10. MAO50 Module Failsafe Setting – Step 2
3) Right-click “Nexus I/O” and then click “Apply New Configuration” on the
popup menu to download the Pcode to the MAO50 module.
Figure 2.4-11. MAO50 Module Failsafe Setting – Step 3
NOTES
1) Failsafe is applicable for the MAO50 module with the ST type chip. It is
not applicable for the old MAO50 module with the TI type chip.
2) The MAO50 module needs to upgrade its firmware to OptimumC
v2.7.0sp2 or above to enable the failsafe function.
2.4.7 Alarms
Alarm ID Alarm Description Possible Cause Solution
32－39 AO Channel [ ] unhealthy Open-circuit for current Check loop
for current source open output: connection.
369B1842G5003 >
2.8mA.
369B1842G5005 > 1mA.
40 Channel 1-8 I/O power DC-DC failure. Replace I/O module.
supply voltage low Module DC power Check cabinet DC
supply failure. power supply module.
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Alarm ID Alarm Description Possible Cause Solution
41, 42 The power A(B) of system DC-DC failure. Replace I/O module.
(24V) has failed Module DC power Check cabinet DC
supply failure. power supply module.
48-55 Channel [ ] DAC SPI Module HW failure. Replace I/O module.
communication lost
Table 2.4-7. MAO50 Specific Alarms
For Nexus OnCore I/O Module Common Alarms, refer to Table 2.2-9.
2.4.8 Ordering Information
Module
Item Code Description Remark
Name
MAO50 Analog Output Module 8 Legacy item
369B1842G5003 MAO50
Channels
MAO50 Analog Output Module 8
369B1842G5005 MAO50
Channels
Table 2.4-8. MAO50 Ordering Information
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