Technical Publication

Field Automation Level

Assembly Catalog

FAL-5

Functional Description
Workshop Manual
Spare Parts Catalog
E531439/06E
Printed in Germany
© 2005 Copyright MTU Friedrichshafen GmbH
Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen
schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung,
Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken
und Online-Diensten.
Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen
Wartungs- und Bedienungspersonal zur Verfügung zu stellen.
Änderungen bleiben vorbehalten.

Printed in Germany
© 2005 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of
MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on
electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation.
Subject to alterations and amendments.

Imprimé en Allemagne
© 2005 Copyright MTU Friedrichshafen GmbH
Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU
Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches,
la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne.
Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à
l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite.
Modifications réservées.

Impreso en Alemania
© 2005 Copyright MTU Friedrichshafen GmbH
Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su
reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se
incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH.
El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del
personal de mantenimiento y de servicio.
Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania
© 2005 Copyright MTU Friedrichshafen GmbH
Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione,
alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici,
comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.
II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto
alla manutenzione e alla condotta.
Con riserva di modifiche.

Impresso na Alemanha
© 2005 Copyright MTU Friedrichshafen GmbH
A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a
autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento,
tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.
Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento
economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.
Salvo alterações.
Table of Contents 01

General Provisions ......................................................... 05

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
1.1 General conditions ....................................................... 07
1.2 Personnel and organizational requirements .................................. 08
1.3 Safety precautions when working on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
1.4 Auxiliary materials, fire prevention and environmental protection ................ 12
1.5 Standards for warning notices in the publication .............................. 14

Functional Description ...................................................... 15

2 PIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Peripheral Interface Modules (PIMs) ......................................... 17
2.2 Peripheral Interface Modules (PIMs) ......................................... 19
2.3 Peripheral Interface Modules (PIMs) ......................................... 21
2.4 Peripheral Interface Modules (PIMs) ......................................... 22
2.5 Overview of PIM printed circuit boards ...................................... 24
2.6 PIM – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 FIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Filter module 1 .......................................................... 31
3.2 FIM 1 – Technical data .................................................... 33
4 DIM – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Dimmer module 3 ........................................................ 35
4.2 DIM – Technical data ..................................................... 41
5 PSM – Purpose and Structure .................................................... 43
5.1 Power supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 PSM – Technical data ..................................................... 45
5.3 Power supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 PSM – Technical data ..................................................... 49
5.5 Mechanical installation of PIMs, FIMs, DIMs and PSMs ......................... 51
6 MPU 23 – Purpose and Structure ................................................. 53
6.1 Printed circuit board MPU 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2 MPU 23 – Technical data .................................................. 58
6.3 Printed circuit board MPU 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4 MPU 27 – Technical data .................................................. 63
7 CCB – Purpose and Structure .................................................... 65
7.1 Printed circuit board CCB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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02 Table of Contents

7.2 CCB 1 – Technical data ................................................... 66

8 SCB – Purpose and Structure .................................................... 67
8.1 Printed circuit board SCB 2 ................................................ 67
8.2 SCB 2 – Technical data ................................................... 68
8.3 Printed circuit board SCB 3 ................................................ 69
8.4 SCB 3 – Technical data ................................................... 72
8.5 Printed circuit board SCB 4 ................................................ 73
8.6 SCB 4 – Technical data ................................................... 74
9 COB – Purpose and Structure .................................................... 75
9.1 Printed circuit board COB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
9.2 COB 1 – Technical data ................................................... 77
9.3 Printed circuit board COB 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.4 COB 3 – Technical data ................................................... 81
10 PAB – Purpose and Structure .................................................... 83
10.1 Printed circuit board PAB 2 ................................................ 83
10.2 PAB 2 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11 FCB – Purpose and Structure .................................................... 87
11.1 Printed circuit board FCB 1 ................................................ 87
11.2 FCB 1 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12 COB – Purpose and Structure .................................................... 93
12.1 Printed circuit board COB 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.2 COB 17 – Technical data .................................................. 96
12.3 COB 5 – Technical data ................................................... 97
13 FCB – Purpose and Structure .................................................... 99
13.1 Display module FCB 2 .................................................... 99
13.2 FCB 2 – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14 AIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.1 Printed circuit board AIB 1 ................................................ 101
14.2 AIB 1 – Technical data .................................................... 106
14.3 Printed circuit board AIB 2 ................................................ 110
14.4 AIB 2 – Technical data .................................................... 114
14.5 Printed circuit board AIB 3 ................................................ 117
14.6 AIB 3 – Technical data .................................................... 120
14.7 Printed circuit board AIB 4 ................................................ 122
14.8 AIB 4 – Technical data .................................................... 125

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Table of Contents 03

15 BIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

15.1 Printed circuit board BIB 1 ................................................ 127
15.2 BIB 1 – Technical data .................................................... 130
15.3 Printed circuit board BIB 2 ................................................ 131
15.4 BIB 2 – Technical data .................................................... 134
16 BOB – Purpose and Structure .................................................... 137
16.1 Printed circuit board BOB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
16.2 BOB 1 – Technical data ................................................... 140
16.3 Printed circuit board BOB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
16.4 BOB 2 – Technical data ................................................... 144
16.5 Printed circuit board BOB 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
16.6 BOB 3 – Technical data ................................................... 148
17 EGB – Purpose and Structure .................................................... 149
17.1 Printed circuit board EGB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
17.2 EGB 1 – Technical data ................................................... 152
18 IIB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
18.1 Printed circuit board IIB 1 ................................................. 153
18.2 IIB 1 – Technical data ..................................................... 156
19 INB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
19.1 Printed circuit board INB 1 ................................................ 159
19.2 INB 1 – Technical data .................................................... 163
19.3 Printed circuit board INB 2 ................................................ 165
19.4 INB 2 – Technical data .................................................... 168
19.5 Printed circuit board INB 3 ................................................ 170
19.6 INB 3 – Technical data .................................................... 173
20 MFB – Purpose and Structure .................................................... 175
20.1 Printed circuit board MFB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
20.2 MFB 1 – Technical data ................................................... 179
20.3 Printed circuit board MFB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
20.4 MFB 2 – Technical data ................................................... 187
21 MOB – Purpose and Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
21.1 Printed circuit board MOB 1 ............................................... 191
21.2 MOB 1 – Technical data ................................................... 196
21.3 Printed circuit board MOB 2 ............................................... 198
21.4 MOB 2 – Technical data ................................................... 202

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04 Table of Contents

22 SAB – Purpose and Structure .................................................... 205

22.1 Printed circuit board SAB 1 ................................................ 205
22.2 SAB 1 – Technical data ................................................... 210
23 ROB – Purpose and Structure .................................................... 213
23.1 Printed circuit board ROB 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
23.2 ROB 1 – Technical data ................................................... 217

Workshop Manual .......................................................... 219

24 Malfunctions .................................................................. 221
24.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
24.1.1 Troubleshooting – LEDs on printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . 221
25 Work Descriptions ............................................................. 235
25.1 Power supply – Check .................................................... 235
25.2 Printed circuit board – Replacement ........................................ 236
25.3 Fuse – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
25.4 PIM – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
25.5 PIM – Replacement, screw-mounting ........................................ 239
25.6 Wiring – Repair .......................................................... 240

Appendix .................................................................. 241

26 Appendix ..................................................................... 243
26.1 Conversion tables ....................................................... 243
26.2 List of abbreviations ..................................................... 249
26.3 Index .................................................................. 252

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General Provisions 05

General Provisions

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06 General Provisions

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Safety 07

1 Safety

1.1 General conditions

General
In addition to the instructions in this publication, the applicable country-specific legislation and other compulsory
regulations regarding accident prevention must be observed. This engine is a state-of-the art product and conforms
with all applicable specifications and regulations. Nevertheless, persons and property may be at risk in the event of:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Non-compliance with the Safety Instructions
Correct use
The engine is intended exclusively for the application specified in the contract or defined at the time
of delivery. Any other use is considered improper use. The manufacturer will accept no liability for
any resultant damage. The responsibility is borne by the user alone.
Correct use also includes observation of and compliance with the maintenance specifications.
Modifications or Conversions
Modifications made by the customer to the engine may affect safety.
MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications or conversions.
Spare parts
Only genuine MTU spare parts must be used to replace components or assemblies. In the
event of any damage caused by the use of other spare parts, no liability nor warranty claims
vis-à-vis the engine manufacturer will be accepted.

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08 General Provisions

1.2 Personnel and organizational requirements

Personnel
Work on the engine must only be carried out by properly qualified and instructed personnel.
The specified legal minimum age must be observed.
Responsibilities of the operating, maintenance and repair personnel must be specified.
Organization
This publication must be issued to all personnel involved in operation, maintenance, repair or transportation.
It must be kept at hand near the engine and accessible at any time to all personnel involved
in operation, maintenance, repair or transportation.
The personnel must be instructed on engine operation and repair by means of this publication,
and in particular the safety instructions must be explained.
This is especially important for personnel who work on the engine only on an occasional basis.
Such personnel must be given instructions repeatedly.
Working clothes and protective equipment
Wear proper work clothing for all work.
Depending on the kind of work, use additional protective equipment, e.g. protective goggles, gloves, helmet, apron.
Work clothing must be tight fitting so that it does not catch on rotating or projecting components.
Do not wear jewelry (e.g. rings, chains etc.).

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Safety 09

1.3 Safety precautions when working on the engine

Safety precautions when putting the equipment into operation
Prior to initial operation, the product must have been installed correctly and approved according to MTU specifications.
Before putting the device or the system into operation, always ensure
• that all maintenance and repair work is completed
• that all loose components have been removed from rotating parts
• that nobody is standing in the danger zone of moving engine components.
Immediately after putting the device or system into operation, make sure that all control and display
instruments as well as the signaling and alarm systems work properly.
Safety requirements for operators
Procedures for cases of emergency must be practised regularly.
The operator must be familiar with the controls and displays.
The operator must know the consequences of each operation to be carried out.
The operator must carry out the individual operations according to the documentation.
During operation, the displays and monitoring units must be permanently observed with regard to present
operating status, violation of limit values and warning or alarm messages.
The following steps must be taken if a malfunction of the system is recognized or reported by the system:
• notify the supervisory personnel in charge
• analyze the message
• if required, carry out emergency operations e.g. emergency engine stop.
Engine operation
When the engine is running, always wear ear protectors.
Ensure that the engine room is well ventilated.
Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable bonding agent.
Exhaust gases from combustion engines are poisonous. Inhalation of poisonous exhaust gases is a health
hazard. The exhaust pipework must be free of leaks and discharge the gases to atmosphere.
During engine operation, do not touch battery terminals, generator terminals or cables.
Inadequate protection of electrical components can lead to electric shocks and serious injuries.
When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.
Maintenance and repair
Strict adherence to the maintenance and repair schedule is an essential safety factor.
Never carry out maintenance and repair work with the engine running unless expressly instructed to do so.
Lock-out/tag-out the engine to preclude undesired starting. Disconnect the battery when electrical starters are fitted.
Close the main valve on the compressed-air system and vent the compressed air line when air starters are fitted. Post
the "Do Not Start" sign in the operating room or affix it to the controlling device! Persons not involved must keep clear.
Never attempt to rectify faults or carry out repairs if you do not have the necessary experience or special tools
required. Have maintenance and repair work carried out by qualified and authorized personnel only.
Use only proper, calibrated tools.
Do not work on engines or components which are only held by lifting equipment or crane. Always support by
suitable means which conform with the applicable regulations before commencing maintenance or repair work.
Before barring the engine, make sure that nobody is standing in the danger zone. After completing
work on the engine, check that all protective devices/safety guards have been installed and that
all tools and loose parts have been removed from the engine.
Fluids emerging under high pressure can penetrate clothing and skin and may cause serious injury. Before
starting work, relieve pressure in systems and H.P. lines which are to be opened.
Never bend a fuel line and do not install bent lines. Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage fuel lines during maintenance and repair work. To tighten the connections when installing
the lines, use the correct tightening torque and ensure that all retainers and dampers are installed correctly.

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10 General Provisions

Ensure that all fuel injection lines and pressurized oil lines have sufficient distance to other
components to avoid contact with them. Do not place fuel or oil lines near hot components,
except when necessary for design reasons during installation.
Elastomers (e.g. "Viton" sealing rings) are stable under normal operating conditions. The material decomposes
when exposed to fire or temperatures exceeding 300 °C. Hydrogen fluoride vapors are released in this
case. The resulting acid leads to serious burning if it contacts the skin. Do not touch elastomeric seals
if they have carbonized or resinous appearance. Wear protective gloves!
Take care with hot fluids in lines, pipes and chambers ⇒ Risk of injury!
Note cooling period for components which are heated for installation or removal ⇒ Risk of injury!
Never touch hot parts of the compressor and exhaust system ⇒ Risk of burning!
Take special care when removing ventilation or plugs from engine. In order to avoid discharge of
highly pressurized liquids, hold a cloth over the screw or plug. It is even more dangerous if the
engine has recently been shut down, as the liquids can still be hot.
Take special care when draining hot fluids. ⇒ Risk of injury!
When draining, collect fluids in a suitable container, mop up any spilt fluids or wipe or
soak them with a suitable bonding agent.
When changing the engine oil or working on the fuel system, ensure that the engine room is adequately ventilated.
When working high on the engine, always use suitable ladders and work platforms. Make
sure components are placed on stable surfaces.
In order to prevent back injuries when lifting heavy components adults, depending on age and sex,
should only lift weights between max. 10 kg and 30 kg, therefore:
• Use lifting gear or seek assistance.
• Ensure that all chains, hooks, slings, etc. are tested and authorized, are sufficiently strong and that
hooks are correctly positioned. Lifting eyes must not be unevenly loaded.
Welding work
Never carry out welding work on the engine or engine-mounted units.
Never use the engine as a ground connection. This prevents the welding current passing through
the engine resulting in burnt/scorched bearings, sliding surfaces and tooth flanks which may
lead to bearing seizure and/or other material damage.
Never route the welding lead over or near the wiring harnesses of MTU systems. The welding current may otherwise
induce an interference voltage in the wiring harnesses which could conceivably damage the electrical system.
The welding unit ground connection must not be more than 60 cm from the weld point.
If components (e.g. exhaust manifold) are to be welded, they must be removed from the engine.
It is not necessary to remove the connector and the connections when carrying out welding operation
on MTU electronics if the master switch for power supply is switched from "ON" to "OFF" and the wire
is disconnected from the negative and positive poles on the battery.
Hydraulic installation and removal
Only the hydraulic installation and removal equipment specified in the work schedule and
in the assembly instructions must be used.
The max. permissible push-on pressure specified for the equipment must not be exceeded.
The H.P. lines for hydraulic installation and removal are tested with 3800 bar.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the system to
be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle
into shaft end until correct sealing is achieved.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of the
component to be installed/removed. As long as the system is under pressure, there is the risk that the
component to be installed/removed may be suddenly released from the pressure connection.
Before use, the tools must be checked at regular intervals (crack test).

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Safety 11

Working on electrical/electronic assemblies

Always obtain the permission of the person in charge before commencing maintenance and repair
work or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies. Any measures requiring a power
supply are expressly defined as such at the appropriate place in the manual.
Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery
acids to come in contact with skin or clothing. Wear protective goggles. Do not place tools on the
battery. Before connecting the cable to the battery, check battery polarity. Battery pole reversal may lead
to injury through the sudden discharge of acid or bursting of the battery body.
Do not damage wiring during removal work and when reinstalling wiring and ensure that during operation it is
not damaged by contact with sharp objects, by rubbing against other component or by a hot surface.
Do not secure wiring to fluid-carrying lines.
On completion of the maintenance and repair work, any cables which have become loose
must be correctly connected and secured.
On completion of all repair work, the component and system must be subjected to a function check.
Separate testing of the repaired component without system integration is insufficient.
If wires are installed beside mechanical components and there is a risk of chafing, use
cable clamps to properly support the wires.
For this purpose, no cable binders must be used as, during maintenance and / or repair work,
the binders can be removed but not installed a second time.
Spare parts shall be properly stored prior to replacement, i.e. particularly protected against moisture. Defective
electronic components and assemblies must be suitably packed when dispatched for repair, i.e. particularly
protected against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment
When working with laser equipment, always wear special laser-protection goggles.
Laser equipment can generate extremely intensive, concentrated radiation by the effect of stimulated emission
in the range of visible light or in the infrared or ultraviolet spectral range. The photochemical, thermal and
optomechanical effects of the laser can cause damage. The main danger is irreparable damage to the eyes.
Laser equipment must be fitted with the protective devices necessary for safe
operation according to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be used:
• Laser devices of classes 1, 2 or 3A,
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700 nm), a
maximum output of 5 mW, and in which the beam axis and surface are designed to prevent any risk to the eyes.
Operation of electrical equipment
When operating electrical equipment, certain components of this equipment are live.
Noncompliance with the warning instructions given for this equipment may result in
serious injury or damage to property.

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12 General Provisions

1.4 Auxiliary materials, fire prevention and environmental

protection
Fire prevention
Rectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -
therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants
lying around on the engine. Do not store combustible materials near the engine.
Do not carry out welding work on pipes and components carrying oil or fuel. Before
welding, clean with a noncombustible fluid.
When starting the engine with a foreign power source, connect the ground lead last and remove it first.
To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source
to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or
sounds indicating danger are drowned.
At all workplaces with a sound pressure level over 85 dB (A), always wear ear protectors
(protective wadding, plugs or capsules).
Environmental protection
Dispose of used fluids, lubricants, materials and filters in accordance with local regulations.
Manipulation of the injection control system can influence the engine performance and exhaust emissions.
As a result, compliance with environmental regulations may no longer be guaranteed.
Only fuels of the specified quality required to achieve emission limits must be used.
In Germany, the VAwS (= regulations governing the use of materials that may affect water quality) is applicable,
which means work must only be carried out by authorized specialist companies (MTU is such a company).
Auxiliary materials
Use only fluids and lubricants that have been tested and approved by MTU.
Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and
other chemical substances, follow the safety instructions applicable to the product. Take care when handling hot,
chilled or caustic materials. When using inflammable materials, avoid sparks, flames and do not smoke.
Lead
• When working with lead or lead-containing pastes, avoid direct contact to the skin and do not inhale lead vapors.
• Adopt suitable measures to avoid the formation of lead dust!
• Switch on fume extraction system.
• After coming into contact with lead or lead-containing materials, wash hands!
Acids and alkaline solutions
• When working with acids and alkalis, wear protective goggles or face mask, gloves and protective clothing.
• Immediately remove clothing wetted by acids and alkalis!
• Rinse injuries with plenty of water!
• Rinse eyes immediately with eyedrops or clean tap water.
Paints
• When painting anywhere other than in spray booths equipped with extractors, ensure good
ventilation. Make sure that adjacent work areas are not affected.
• No naked flames!
• No smoking.
• Observe fire prevention regulations!
• Wear masks providing protection against paint and solvent fumes.
Liquid oxygen
• Liquid oxygen is highly combustible.
• Liquid oxygen should only be stored in small quantities and in regulation containers (without fixed seals)!
• Do not bring liquid oxygen in contact with the body (hands), as this causes frostbite and possibly the loss of tissue.

E531439/06E 05-09 © MTU

Safety 13

• No smoking, no naked flames, risk of explosion! Excessive oxygen in the air leads to explosive combustion.
• Do not store combustible substances, e.g. oils and greases, within 5 m of the working area!
• Under no circumstances should clothing be oily or greasy.
• Do not allow vapors to penetrate clothing! Oxygen enrichment in fabric can cause
working clothes to ignite suddenly!
• After working with liquid oxygen, do not smoke until clothing is free of vapors!
• Avoid all hard knocks and impacts when working with liquid oxygen.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers.
• Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and the loss of tissue.
• Wear protective clothing, including gloves, closed shoes and protective goggles!
• Ensure that the room is well ventilated. Nitrogen concentration exceeding 88% of
breathing air leads to suffocation.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Compressed air
Compressed air is air compressed at excess pressure and is stored in vessels from which it can be extracted.
The pressure at which the air is kept can be read off at pressure gauges which must be connected
to the compressed air vessels and the compressed air lines.
When working with compressed air, safety precautions must be constantly observed:
• Pay special attention to the pressure level in the compressed air network and pressure vessel!
• Devices and equipment connected must either be designed for this pressure or, if the permitted
pressure for the connected elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection. Hose
coupling and connections must be securely attached!
• Always wear protective goggles when blowing off tools or chips!
• The snout of the air nozzle should be provided with a protective disc (e.g. rubber disc), which prevents
air-borne particles being deflected and thereby prevents injury to eyes.
• First shut off compressed air lines before compressed air equipment is disconnected from the
supply line or before equipment or tools are exchanged!
• Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII
and B) out of containers, carries the risk of explosion!
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass)
for drying purposes or to check for leaks, results in a risk of shattering!
• Do not use compressed air to clean contaminated clothing whilst it is being worn.
Used oil
Used oil may contain health-threatening combustion residues.
Rub barrier cream into hands!
Wash hands after contact with used oil.

E531439/06E 05-09 © MTU

14 General Provisions

1.5 Standards for warning notices in the publication

In the event of immediate danger.
Consequences: Death or serious injury.
DANGER • Preventive measures
In the event of possibly dangerous situations.
Consequences: Death or serious injury.
WARNING • Preventive measures
In the event of dangerous situations.
Consequences: Slight injury or material damage.
CAUTION • Preventive measures

Note: This publication contains especially emphasized safety instructions in accordance with the American
standard ANSI Z535, which begin with one of the above signal words according to the degree of danger:

Warning notices
1. Read and become acquainted with all cautions and symbols before operating or repairing this product.
2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel!

E531439/06E 05-09 © MTU

Functional Description 15

Functional Description

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16 Functional Description

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PIM – Purpose and Structure 17

2 PIM – Purpose and Structure

2.1 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 23

Design of PIM 1

1 Module cassette 1
2 Basic module 1
3 Printed circuit board
PIM 1 comprises:
• Module cassette 1 (1) to accommodate one MPU 23 and one PIM printed circuit board.
• Basic module 1 (2) with printed circuit board COB 1-0X (3).
Slots and terminals

1 Slot 1
2 Slot 2
Slot 1 is reserved for the microprocessor board (MPU 23). All other slots may be
populated with PIM printed circuit boards.

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18 Functional Description

Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9.

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PIM – Purpose and Structure 19

2.2 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 23

Design of PIM 2

1 Module cassette 1
2 Module cassette 2
3 Basic module 2
4 Printed circuit board
PIM 2 comprises:
• Module cassette 1 (1) to accommodate one MPU 23 printed circuit board and one PIM printed circuit board.
• Module cassette 2 (2) to accommodate two PIM printed circuit boards.
• Basic module 2 (3) with printed circuit board COB 3-0X (4).

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20 Functional Description

Slots and terminals

1 Slot 1 3 Slot 3
2 Slot 2 4 Slot 4

Slot 1 is reserved for the microprocessor board (MPU 23). All other slots may be
populated with PIM printed circuit boards.
Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9.

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PIM – Purpose and Structure 21

2.3 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 27

Design of PIM 5

1 Module cassette 1
2 Basic module 1
PIM 5 comprises:
• Module cassette 1 (1) to accommodate one MPU 27 printed circuit board and one PIM printed circuit board.
• Basic module 1 (2) with printed circuit board COB 17-0X (3).
Slots and terminals

1 Slot 1
2 Slot 2
Slot 1 is reserved for the microprocessor board (MPU 27). All other slots may be
populated with PIM printed circuit boards.
Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9.

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22 Functional Description

2.4 Peripheral Interface Modules (PIMs)

PIMs for use with processor printed circuit board MPU 27

Design of PIM 3

1 Module cassette 1
2 Module cassette 2
3 Basic module 2
4 Printed circuit board
PIM 3 comprises:
• Module cassette 1 (1) to accommodate one MPU 27 printed circuit board and one PIM printed circuit board.
• Module cassette 2 (2) to accommodate two PIM printed circuit boards.
• Basic module 2 (3) with printed circuit board COB 5-0X (4).

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PIM – Purpose and Structure 23

Slots and terminals

1 Slot 1 3 Slot 3
2 Slot 2 4 Slot 4

Slot 1 is reserved for the microprocessor board (MPU 27). All other slots may be
populated with PIM printed circuit boards.
Example: The "n" in "n09" stands for the slot and "09" designates the terminal. "209" means: Slot 2, terminal 9.

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24 Functional Description

2.5 Overview of PIM printed circuit boards

MPU printed circuit boards (microprocessor systems)

Printed circuit board Function

MPU 23 • Single-chip processor with main and data memory

• 1 CAN interface as per ISO 11 898
• 1 slot for CCB 1, SCB 2 or SCB 4
• Power supply for PIM printed circuit boards

MPU 27 • Single-chip processor with main and data memory

• 2 CAN interface as per ISO 11 898
• Connector for FCB 2
• Power supply for PIM printed circuit boards

MPU 23 extension boards

Printed circuit board Function

CCB 1 • 1 additional CAN interface as per ISO 11 898

SCB 2 • 1 additional RS422 interface

SCB 4 • 1 additional RS232 interface

MPU 27 extension boards

Printed circuit board Function

FCB 2 • Display module

Connection printed circuit boards (motherboards)

Printed circuit board Function

COB 1-0X* • Connection printed circuit board between PIM 1

terminals and printed circuit board MPU 23 and
the printed circuit board in the second slot
• Used for processor printed circuit board MPU 23

COB 3-0X* • Connection printed circuit board between PIM 2

terminals and printed circuit board MPU 23 and
the three printed circuit boards in slots 2, 3 and 4
• Used for processor printed circuit board MPU 23

COB 17-0X* • Connection printed circuit board between PIM 5

terminals and printed circuit board MPU 27 and
the printed circuit board in the second slot
• Used for processor printed circuit board MPU 27

COB 5-0X* • Connection printed circuit board between PIM 3

terminals and printed circuit board MPU 27 and
the three printed circuit boards in slots 2, 3 and 4
• Used for processor printed circuit board MPU 27

* 0X stands for the latest version of the printed circuit board (e.g. COB 3-03).
All printed circuit board versions are downward-compatible.

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PIM – Purpose and Structure 25

PIM printed circuit boards

Printed circuit board Function

AIB 1-0X* • 4 analog measuring channels to acquire

resistance, voltage and current signals

AIB 2-0X* • 2 analog input channels to acquire voltage and

current signals
• 2 analog output channels to output voltage and
current signals

AIB 3-0X* • 8 analog input channels to acquire current signals

AIB 4-0X* • 4 electrically isolated analog input channels to

acquire current signals (external power supply)

BIB 1-0X* • 8 electrically isolated binary inputs (external power

supply)
• Cable damage monitoring

BIB 2-0X* • 8 electrically isolated binary inputs (internal power

supply)
• Cable damage monitoring

BOB 1-0X* • 4 independent relay outputs (changeover contacts)

• Cable damage monitoring

BOB 1-0X/A* • 4 independent relay outputs (changeover contacts)

without cable damage monitoring

BOB 2-0X* • 14 transistor output stages (positive-switching)

BOB 3-0X* • 14 transistor output stages (positive-switching)

EGB 1-0X* • 8 analog input channels to acquire voltage signals

(for NiCr-Ni temperature sensor)

FCB 1-0X* • Display of alarms and fault codes

FCB 1-0X/A* • 2 transistor output stages (positive-switching)
• 2 transistor output stages (ground-switching)
• 2 independent relay outputs (changeover contacts)

IIB 1-0X* • 4 analog voltage outputs for instrument control

(0 VDC - 10 VDC)
• 4 electrically isolated binary inputs

INB 1-0X* • 4 outputs for instrument control (2 bipolar outputs

and 2 unipolar outputs)
• Dimmer (external power supply)
Produced and supplied as spare part only. INB 2-0X
used in new configurations.

INB 2-0X* • 4 outputs for instrument control (each output

bipolar or unipolar)
• Dimmer (internal power supply)

INB 3-0X* • 7 current outputs to control instruments (4 mA -

20 mA)
• 1 frequency output to control an instrument (0 Hz
- 1500 Hz)
• Use in conjunction with MPU 27 and MPU 29 only!

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26 Functional Description

Printed circuit board Function

MFB 1-0X* • 2 electrically isolated inputs for analog speed

signals with hysteresis control or 2 electrically
isolated inputs for binary speed signals or binary
signals (status interrogation) (only one speed
acquisition variant possible, either analog or
binary)
• Power supply (24 VDC) for electronic transmitters
or sensors
• 2 independent relay outputs (changeover contacts)

MFB 2-0X* • 2 analog input channels to acquire potentiometers

• 3 electrically isolated binary inputs (external power
supply)
• 5 transistor output stages (positive-switching) with
internal power supply (24 VDC)
• Power supply (24 VDC) for electronic transmitters
or sensors
• Use in conjunction with MPU 29 only!

MOB 1-0X* • 4 electrically isolated transistor output stages to

control two DC motors or dynamic/static control
of solenoid valves (for proportional valves or
positive/ground-switching valves), full step motors
only and in conjunction with printed circuit board
SMB 2-0X
• Use with MPU 23 only

MOB 2-0X* • 4 electrically isolated transistor output stages to

control two DC motors or dynamic/static control
of solenoid valves (for proportional valves or
positive/ground-switching valves)
• 2 current feedback channels
• Use with MPU 27 only

PAB 2-0X* • PIM node address and baud rate programming

SAB 1-0X* • 1 electrically isolated CAN interface as per

ISO 11 898
• 3 independent relays to output binary information
• 1 electrically isolated transistor output stage
(positive-switching)
• 1 electrically isolated binary input with cable
damage monitoring

SCB 3-0X* • 2 electrically isolated interfaces as per RS422 or

RS232 standard

ROB 1-0X* • 5 relay inputs with change-over switch, one of

which with 4 inputs (OR function)
• 1 relay input with four change-over switches
This printed circuit board is not bus-compatible and
can only be used in special PIMs with a suitable
motherboard. It cannot be used in type 1 and 2 PIMs
nor in type 5 and 3 PIMs.

* 0X stands for the latest version of the printed circuit board (e.g. AIB 1-02).
All printed circuit board versions are downward-compatible.

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PIM – Purpose and Structure 27

2.6 PIM – Technical data

Technical data of PIMs (screw terminals)

Term Unit Value

Installation position As desired

Operating voltage VDC 24, -50 %

to +30 %
Residual
ripple less
than 5 %,
as per
STANAG
1008

Power consumption Less than

PIM 1 or PIM 2 with MPU 23 A 0.2 (depend-
ing on
printed
circuit
boards
used)

Connecting-cable cross section mm2 Max.

2 x 2.5 solid
or
Max. 2
x 1.5
stranded
with
sleeve as
per DIN
64228

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ± 1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting Hz 2 - 25:

Xpp = ±
1.6 mm
25 - 100:
a=±4g

EMC specification

Ambient temperature °C -30 - +70

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28 Functional Description

Term Unit Value

Storage temperature °C -35 - +85

Rel. humidity % 0 - 97,

non-con-
densing

Color Blue (RAL

5015)

Material Fiber-
glass-rein-
forced
polycar-
bonate

PIM 1

Dimensions (H x W x D) mm 75 x 70 x
90

Number of terminals 32

Weight kg Approx.
0.3 (pop-
ulated)

PIM 2

Dimensions (H x W x D) mm 75 x 140 x
90

Number of terminals 64

Weight kg Approx.
0.6 (pop-
ulated)

Technical data of PIMs (spring terminals)

Term Unit Value

Installation position As desired

Operating voltage VDC 24, -50 %

to +30 %
Residual
ripple less
than 5 %,
as per
STANAG
1008

Power consumption

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PIM – Purpose and Structure 29

Term Unit Value

PIM 1 or PIM 2 with MPU 23 A Less than

0.2 (depend-
ing on
printed
circuit
boards
used)

PIM 5 or PIM 3 with MPU 27 A Less

than 0.35
(depend-
ing on
printed
circuit
boards
used)

Connecting-cable cross section mm2 Per

terminal:
2 x -2.5

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ± 1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting Hz 2 - 25:

Xpp = ±
1.6 mm
25 - 100:
a=±4g

EMC specification

Ambient temperature °C -30 - +70

Storage temperature °C -35 - +85

Rel. humidity % 0 - 97,

non-con-
densing

Color Blue (RAL

5015)

Material Fiber-
glass-rein-
forced
polycar-
bonate

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30 Functional Description

Term Unit Value

PIM 1

Dimensions (H x W x D) mm 75 x 70 x
90

Number of terminals 32

Weight kg Approx.
0.3 (pop-
ulated)

PIM 2

Dimensions (H x W x D) mm 75 x 140 x
90

Number of terminals 64

Weight kg Approx.
0.6 (pop-
ulated)

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FIM – Purpose and Structure 31

3 FIM – Purpose and Structure

3.1 Filter module 1

Purpose and structure

Design

1 Basic module 3
2 Printed circuit board FIB 1

Use
• Smoothing external operating voltages
• Overvoltage protection
• Overcurrent protection (self-restoring fuses)
• Reverse-battery protection
• EMC filter
Terminals

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32 Functional Description

The operating voltage is supplied (filter input) via terminals 101 to 116. The filtered operating
voltage is available at terminals 201 to 216 (filter output).

1 Self-restoring fuse

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FIM – Purpose and Structure 33

3.2 FIM 1 – Technical data

Technical data of FIM 1

Term Unit Value

Dimensions (H x W x D) mm 60 x 70 x
90

Weight kg 0.3

Installation position As desired

Input voltage VDC 12 - 36

Output current A ≤ 6 at an
ambient
tempera-
ture of up
to 45 °C
≤ 4 at an
ambient
tempera-
ture of up
to 70 °C

Filter power consumption Less than

0.05 A (at
24 VDC)

Connecting-cable cross section mm2 2 x -

2.5 per
terminal

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting 2 - 25:

Xpp = ±1.6
mm
25 - 100:
a = ±4 g

EMC specification

Ambient temperature °C -30 - +70

Storage temperature °C -35 - +85

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34 Functional Description

Term Unit Value

Rel. humidity 0 % -
97 %,
non-con-
densing

Color Blue (RAL

5015)

Material Fiber-
glass-rein-
forced
polycar-
bonate

Number of terminals 32

Reverse-battery protection Yes

Overcurrent protection Yes (self-

restoring
fuses)

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DIM – Purpose and Structure 35

4 DIM – Purpose and Structure

4.1 Dimmer module 3

Purpose and structure

Design

1 Basic module 3
2 Printed circuit board DIM 3–01

Use
DIM 3 supplies a pulse-width-modulated 24 V output signal to supply background
illumination of dimmable instruments with power.
• PWM output signal (3 - 100 %), positive-switching (High side)
• Total output current at all terminals max. 2 A
• Input filter
• Various setpoint signal inputs:
• PWM input signal (e.g. from printed circuit board INB 2, which can control up to 10 DIM 3s in parallel)
• Potentiometer (5 kΩ)
• Analog voltage 7 0 28 V
• Analog voltage 0 - 10 V
• Adjustable basic brightness
• Wide input voltage range, controlled (typ. 17 - 29 V)
• Low power loss

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36 Functional Description

Terminals

The supply voltage is supplied via terminals 101 and 102 (+24 VDC) and 103 and 104 (ground). 8 outputs are available
for lamp control at terminals 201 to 216. The dimming voltage is set by varying assignment at terminals 107 to 116.

1 Self-restoring fuse 2 Control unit

Circuitry for dimming voltage setting

Possible connection for dimming voltage setting.

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DIM – Purpose and Structure 37

Connection is only established at terminals 107 to 116 respectively.

1 Control unit

1 Control unit

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38 Functional Description

1 Control unit

1 Control unit

1 Control unit

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DIM – Purpose and Structure 39

1 Control unit

1 Control unit

1 Control unit

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40 Functional Description

1 Control unit

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DIM – Purpose and Structure 41

4.2 DIM – Technical data

Technical data of DIM 3

Term Unit Value

Dimensions (H x W x D) mm 60 x 70 x
90

Weight kg 0.3

Installation position As desired

Input voltage VDC 17 - 29

Output current A ≤2

Filter power consumption W <1

Connecting-cable cross section mm2 2 x -

2.5 per
terminal

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting Hz 2 - 25:

Xpp = ±1.6
mm
25 - 100:
a = ±4 g

EMC specification

Ambient temperature °C -30 - +70

Storage temperature °C -35 - +85

Rel. humidity % 0 - 97,

non-con-
densing

Color Blue (RAL

5015)

Material Fiber-
glass-rein-
forced
polycar-
bonate

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42 Functional Description

Term Unit Value

Number of terminals 32

Reverse-battery protection Yes

Overcurrent protection Yes (self-

restoring
fuses)

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PSM – Purpose and Structure 43

5 PSM – Purpose and Structure

5.1 Power supply modules

Purpose and structure of PSM 3–01

Design

1 Basic module 3
2 Printed circuit board PSM 3–01
3 Printed circuit board

Use
• Input filter
• Electrical isolation of output voltages
• Self-restoring fuse
• Outputs 6 x 5 VDC (each 50 mA)
• Outputs 8 x 10 VDC (each 50 mA)

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44 Functional Description

Terminals

1 Slot 1
2 Slot 2
The primary voltage (supply voltage) is supplied via terminals 101 and 102 (+V) and 103 (ground). The controlled
output voltages are available at terminals 105 to 116 (+5 V voltage) and 201 to 216 (+10 V voltage) .

1 Self-restoring fuse

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PSM – Purpose and Structure 45

5.2 PSM – Technical data

Technical data of PSM 3-01

Term Unit Value

Dimensions (H x W x D) mm 60 x 70 x
90

Weight kg 0.3

Installation position As desired

Input voltage VDC 12 - 36

Output current mA ≤ 50 per 5

V output
≤ 50 per
10 V
output

Output voltage VDC 6x5 ±2

%
8x1 ±2
%

Connecting-cable cross section mm2 2 x -

2.5 per
terminal

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting Hz 2 - 25:

Xpp = ±1.6
mm
25 - 100:
a = ±4 g

EMC specification

Ambient temperature °C -30 - +70

Storage temperature °C -35 - +85

Rel. humidity % 0 - 97,

non-con-
densing

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46 Functional Description

Term Unit Value

Color Blue (RAL

5015)

Material Fiber-
glass-rein-
forced
polycar-
bonate

Number of terminals 32

Reverse-battery protection Yes

Overcurrent protection Yes (self-

restoring
fuses)

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PSM – Purpose and Structure 47

5.3 Power supply modules

Purpose and structure of PSM 3-01/A

Design

1 Basic module 3
2 Printed circuit board PSM 3-01/A
3 Printed circuit board

Use
• Input filter
• Electrical isolation of output voltages
• Self-restoring fuse
• Outputs +15 VDC and −15 VDC
Terminals

The primary voltage (supply voltage) is supplied via terminals 101 and 102 (+V) and 103 (ground).
The controlled output voltages are available at the terminals 105 and 107 (GND), 201 and 203 (+15
V voltage) and 106, 108, 202, 204 and others (−15 V voltage).

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48 Functional Description

1 Self-restoring fuse

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PSM – Purpose and Structure 49

5.4 PSM – Technical data

Technical data of PSM 3-01/A

Term Unit Value

Dimensions (H x W x D) mm 60 x 70 x
90

Weight kg 0.3

Installation position As desired

Input voltage VDC 12 - 36

Output current mA ≤ 50 per

output

Output voltage VDC 2 x +15 ± 2

%
2 x −15 ± 2
%

Connecting-cable cross section mm2 2 x -

2.5 per
terminal

Degree of protection IP 20 as
per DIN
40 050

Shock 10g , 11
ms

Vibrostability

Top-hat rail mounting Hz 2 - 13.2:

Xpp = ±1
mm
13.2 - 100:
a = ± 0.7 g

Screw mounting Hz 2 - 25:

Xpp = ±1.6
mm
25 - 100:
a = ±4 g

EMC specification

Ambient temperature °C -30 - +70

Storage temperature °C -35 - +85

Rel. humidity % 0 - 97,

non-con-
densing

Color Blue (RAL

5015)

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50 Functional Description

Term Unit Value

Material Fiber-
glass-rein-
forced
polycar-
bonate

Number of terminals 32

Reverse-battery protection Yes

Overcurrent protection Yes (self-

restoring
fuses)

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PSM – Purpose and Structure 51

5.5 Mechanical installation of PIMs, FIMs, DIMs and PSMs

Mounting variants
Top-hat rail mounting

1 Mounting clip
2 Top-hat rail
3 End clip
Top-hat rail mounting involves automatic grounding by a spring in the mechanism of the PIM.
Screw mounting

1 Mounting screws
2 Mounting clip
Screw mounting involves grounding by means of a separate cable.

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52 Functional Description

Mounting in a protective housing

The modules may be screw-mounted or mounted on top-hat rails in a protective housing for use in
extreme ambient conditions (degree of protection exceeding IP 20).

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MPU 23 – Purpose and Structure 53

6 MPU 23 – Purpose and Structure

6.1 Printed circuit board MPU 23

Purpose and structure of MPU 23

Design

1 Component side 6 LED (yellow) "Data receive on

2 Conductor side CAN1 or CAN2"
3 Plan view 7 LED (yellow) "Data transmit on
4 LED (green) "Power supply (+5 V)" CAN1 or CAN2"
5 LED (red) "Processor reset/fault" 8 Subprint for 2nd interface

Use
MPU 23 is only used in a PIM 1 (with printed circuit board COB 1) or PIM 2 (with printed circuit board COB 3)
Features
• Single-chip processor (68HC11E1) in HCMOS technology
• Integral Watchdog circuit (program run monitoring)
• 7.5 Kbyte RAM main memory
• 2 x 56 Kbyte FEPROM program and data memory
• 512 Byte EEPROM for dialog parameters
• I2C bus for communication with the serial EEPROM (configuration data)
• 8 interruptible 16-bit timer for PIM real-time processes
• Power consumption less than 100 mA

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54 Functional Description

• Wide supply voltage range (24 VDC, −50% to +30%)

• Electrical isolation of the power supply by DC/DC converter
• Internal voltage stabilization (5 VDC) for MPU 23 and the PIM printed circuit boards used
• CAN interface as per ISO 11 898, electrically isolated
• Extendable interface (option) by using sub-PCBs
• CAN: by printed circuit board MPU 23 with CCB 1
• RS422: by printed circuit board MPU 23 with SCB 2
• RS232: by printed circuit board MPU 23 with SCB 4
• Electrically isolated interface power supply
• Status indication by LEDs
• Temperature and operating voltage monitoring
Function
MPU 23 has the following tasks:
• Communication of PIM with higher-level systems.
• Process control, data acquisition and processing.
The standard software is stored in the FEPROM of MPU 23.
Application-specific data (e.g. configurations etc.) can also be transferred to the FEPROM via the CAN bus.
Dialog parameters (e.g. limit values etc.) can be stored in the internal EEPROM.
MPU 23 facilitates the control of the printed circuit boards of a PIM and the processing of their data.
The configuration of the PIMs used (e.g. the PIM printed circuit boards used, the baud rate, the field bus
identifier etc.) are stored in a serial EEPROM located on printed circuit board COB 1 or COB 3.
MPU 23 communicates with the serial EEPROM via the I2C bus.
MPU 23 communicates with the user via the CAN interface.
MPU 23 is equipped with one CAN interface (CAN1).
A second interface may be defined as an option by using a subprint inserted on MPU 23.
It is possible to choose between an RS232, RS422 or second CAN interface.
• MPU 23 with CCB 1, additional CAN interface (CAN2).
• MPU 23 with SCB 2, additional RS422 interface.
• MPU 23 with SCB 4, additional RS422 interface.
MPU 23 is available as a spare part with or without the initial program loader:
• MPU 23 with initial program loader (MTU order no. 504 530 87 97 / S0013).
The system and basic software is automatically loaded in the MPU 23 when a PPS
(Programmable Process Station) is available.
If no PPS is available, the software is loaded via the BDM (Backup Data Module).
• MPU 23 without initial program loader (MTU order no. 504 530 87 97).
Downloading realized by programming unit SST 1-01.

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MPU 23 – Purpose and Structure 55

Function of LEDs during download

Red LED indicator functions

LED State Meaning

Red LED Lit Lit after RESET until RAM and ROM test
(5) have been successfully completed.

Red LED Lit (after test) Serious fault encountered during one of
(5) the following tests:
• RAM test
• ROM test
• Overvoltage test
• Undervoltage test
• Overtemperature test
Watchdog tripped.

Red LED Flashing with 1 Hz System awaiting "System Software

(5) Enable" signal.

Requirements for yellow LED indicator functions:

LED State

Red LED (5) Dark

Green LED (4) Lit

Yellow LED indicator functions

Requirement:
"System Software Enable" signal received within the last 5 s.

LED State Meaning

Yellow Lit "System Software Download Response".

LED (6) PDU received.
This state is maintained
• until downloading has been
completed;
• until the next 1 Kblock of data has
been received;
• if no data is received for 5 s.

Yellow Lit CAN bus transmitting

LED (6) • Alive messages;
• System messages;
• System Software Download
Response.

Yellow Flash Flash-EPROM cells are erased or

LEDs programmed.
(6 and 7)

Connection assignment
MPU 23
Relationship between MPU 23 and the terminals of the PIM.

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56 Functional Description

MPU 23 is always located in slot 1 of the PIM.

Terminal Designation

101/102 Positive supply voltage (+24 VDC)

103/104 Supply voltage ground (GND)

105 Ground of CAN1 controller GND (CAN1)

106 Ground of CAN1 controller GND (CAN1)

107/108 CAN1 interface: Negative input CAN1(L)

109/110 CAN1 interface: Positive input CAN1(H)

111-116 Reserved for extension sub-PCBs.

MPU 23 with CCB 1

Relationship between MPU 23 with CCB 1 and the terminals of the I/O module.
MPU 23 with CCB 1 is always located in slot 1 of the I/O module.
The following terminals are additionally assigned on MPU 23 with CCB 1:

Terminal Designation

111 Ground of CAN2 controller GND (CAN2)

113/114 CAN1 interface: Negative input CAN1(L)

115/116 CAN1 interface: Positive input CAN1(H)

MPU 23 with SCB 2

Relationship between MPU 23 with SCB 2 and the terminals of the PIM.
MPU 23 is always located in slot 1 of the PIM.
The following terminals are additionally assigned on MPU 23 with SCB 2:

Terminal Designation

111 RS422 interface: Positive output A2 (TX)

112 RS422 interface: Negative output A2 (TX)

113/114 RS422 interface: Negative input E1 (RX)

115/116 RS422 interface: Positive input E2 (RX)

MPU 23 with SCB 4

Relationship between MPU 23 with SCB 4 and the terminals of the PIM.
MPU 23 is always located in slot 1 of the PIM.

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MPU 23 – Purpose and Structure 57

The following terminals are additionally assigned on MPU 23 with SCB 4:

Terminal Designation

111 RS232 interface: GND

112 RS232 interface: TXD

113/114 RS232 interface: RXD

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58 Functional Description

6.2 MPU 23 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
17

Weight kg 0.050

Input voltage VDC 24, −50 %

to +30 %

Power consumption mA Less than

135 (with
one CAN
interface)
Less
than 185
(with an
additional
CAN
interface)

Power loss mW Less than

1675

Microcontroller Byte 8HC11E1

with
512 EEPROM
and
256 RAM

Memory Kbyte 7.5 RAM

112
FEPROM

Data transmission

Term Unit Value

CAN bus system As per

ISO 11
898

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MPU 23 – Purpose and Structure 59

Term Unit Value

Baud rate kBd 50 to 1

Electrical isolation Yes, with

optocou-
pler

Term Unit Value

Bit serial As per

RS 232
/ RS 422
standard

Baud rate kBd 1.2 to 19.2

Electrical isolation Yes, with

optocou-
pler

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60 Functional Description

6.3 Printed circuit board MPU 27

Purpose and structure of MPU 27

Design

1 Component side 5 LED (yellow) "CAN communication 7 LED (green) "Power supply (+5 V)"
2 Conductor side CAN2" 8 Connector for mounting display
3 Plan view 6 LED (yellow) "CAN communication module FCB 2
4 LED (red) "Processor reset/fault" CAN1"

Use
MPU 27 may only be used in a PIM 5 (with COB 17) or in a PIM 3 (with COB 5)
The following printed circuit boards for signal input/output are not supported by MPU 27:
• Printed circuit board FCB 1
• Printed circuit board INB 1
• Printed circuit board MFB 2
• Printed circuit board MOB 1
MOB 2 may be used with MPU 27 instead of MOB 1.
Features
• Microcontroller C167 CS with 2 integral CAN controllers
• 1M x 16, offering a total of 2 Mbyte FEPROM
• 512K x 16, offering a total of 1 Mbyte RAM
• 5 channel A/D converter to acquire temperatures and supply voltages
• 4 x PWM channels
• 5 x Capture Register (DRZ speed input channels)

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MPU 23 – Purpose and Structure 61

• Integral Watchdog circuit (program run monitoring)

• LED status indicators for operating voltage, reset and CAN communication
• Switched-mode power supply unit for 24 V/5 V-1A
• 2 x DC/DC converter for electrically isolated CAN power supply
• 2 x CAN interfaces as per ISO 11 898, electrically isolated
• Temperature and operating voltage monitoring (24 V/5 V)
Extended functionality available with pluggable LCD display interface (2*16 LCD and
4 keys for operation) (FCB 2 module).
Function
MPU 27 has the following tasks:
• Communication of PIM with higher-level systems.
• Process control, data acquisition and processing.
The standard software is stored in the FEPROM of MPU 27.
Application-specific data (e.g. configurations etc.) can also be transferred to the FEPROM via the CAN bus.
The configuration of the PIMs used (e.g. the PIM printed circuit boards used, the baud rate, the field bus identifier
etc.) are stored in a serial EEPROM located on printed circuit board COB 5 or COB 17.
MPU 27 communicates with the serial EEPROM via the I2C bus.
MPU 27 communicates with the user via the CAN interface.
MPU 27 is equipped with two CAN interfaces (CAN1 and CAN2).
MPU 27 includes an initial program loader.
The system and basic software is automatically loaded in the MPU 27 when a PPS is available.
If no PPS is available, the software is loaded via the BDM (Backup Data Module).
Function of LEDs during download
Red LED indicator functions

LED State Meaning

Red LED Lit/dark The red LED indicates the state of the
(4) processor printed circuit board.
This LED goes out after a
Power-On-RESET.

Red LED Lit Serious fault encountered

(4) (after Power-On-RESET) Watchdog tripped
• Printed circuit board to be replaced.

Red LED Flashing with 1 Hz System awaiting "System Software

(4) Enable" signal.

Requirements for yellow LED indicator functions:

LED State

Red LED (4) Dark

Green LED (7) Lit

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62 Functional Description

Yellow LED indicator functions

LED State Meaning

Yellow Flash alternately with 4 Hz. Basic software download.

LEDs (5
and 6) Flash synchronously with 4 Hz. Project data download.

Flash irregularly. Data communication on the CAN buses.

An initial program loader program must be installed on the MPU 27 to execute the download feature.

Connection assignment
MPU 27
Relationship between MPU 27 and the terminals of the PIM.
MPU 27 is always located in slot 1 of the PIM.

Terminal Designation

101/102 Positive supply voltage (+24 VDC)

103/104 Supply voltage ground (GND)

105 Ground of CAN1 (GND)

106 Shield

107/108 CAN1 interface: Negative input CAN1(L)

109/110 CAN1 interface: Positive input CAN1 (H)

111 Ground of CAN2 (GND)

112 Not used

113/114 CAN2 interface: Negative input CAN2 (L)

115/116 CAN2 interface: Positive input CAN2 (H)

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MPU 23 – Purpose and Structure 63

6.4 MPU 27 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
17

Weight kg 0.050

Input voltage VDC 24, −50 %

to +30 %

Power consumption mA Less than

350
(depend-
ing on
printed
circuit
boards
used)

Power loss mW Approx.

1200

Microcontroller C167 CS

Memory Mbyte 1 RAM

2
FEPROM

Data transmission

Term Unit Value

CAN bus system As per

ISO 11 898

Baud rate kBd 125 to

250000

Electrical isolation Yes, with

optocou-
pler.

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64 Functional Description

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CCB – Purpose and Structure 65

7 CCB – Purpose and Structure

7.1 Printed circuit board CCB 1

Purpose and structure

Design

1 Component side
2 Conductor side

Use
CCB 1 is only used in MPU 23.
Features
• CAN standard interface extension for MPU 23
• Directly pluggable on MPU 23
• Interface is electrically isolated
Function
CCB 1 is an interface extension for MPU 23.
It realizes a CAN standard interface (ISO 11 898).
Electrically connected to MPU 23 via a plug connector.
CCB 1 converts CAN level signals into TTL level signals.
Signal isolation is realized by optocouplers.
The TTL level signals are required for communication with the single-chip processor on MPU 23.
MPU 23 processes the data and controls the interface drivers.
The interface is connected by the terminal strip of the PIM.

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66 Functional Description

7.2 CCB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 40 x 10 x
4

Weight kg 0.002

Input voltage VDC +5 (±5 %)

from
MPU 23

Power consumption mA Less than

50

Connection Spare
slot on
MPU 23

Data transmission

Term Unit Value

CAN bus system As per

ISO 11 898

Baud rate kBd 3.78 to

1000

Electrical isolation Yes, with

optocou-
pler

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SCB – Purpose and Structure 67

8 SCB – Purpose and Structure

8.1 Printed circuit board SCB 2

Purpose and structure

Design

1 Component side
2 Conductor side

Use
SCB 2 is only used in MPU 23.
Features
• RS422 standard interface extension for MPU 23
• Directly pluggable on MPU 23
• Interface is electrically isolated
Function
SCB 2 is an interface extension for MPU 23.
It realizes an RS422 standard interface.
Electrically connected to MPU 23 via a plug connector.
SCB 2 converts RS422 level signals into TTL level signals.
Signal isolation is realized by optocouplers.
The TTL level signals are required for communication with the single-chip processor on MPU 23.
MPU 23 processes the data and controls the interface drivers.
The interface is connected by the terminal strip of the PIM.

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68 Functional Description

8.2 SCB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 40 x 10 x
4

Weight kg 0.002

Input voltage VDC +5 (±5 %)

from
MPU 23

Power consumption mA Less than

50, via
MPU 23

Connection Spare
slot on
MPU 23

Data transmission

Term Unit Value

CAN bus system As per

RS422
standard

Baud rate kBd 1.2 to

19.2

Electrical isolation Yes, with

optocou-
pler

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SCB – Purpose and Structure 69

8.3 Printed circuit board SCB 3

Purpose and structure

Design

1 Component side 5 LED (green) "Ready" 7 LED (yellow) "Interface 2"

2 Conductor side 6 LED (yellow) "Interface 1" Receiving and transmitting
3 Plan view Receiving and transmitting line active"
4 LED (red) "Printed circuit line active" 8 Connector RS232 interface
board RESET"

Features
• 2 interfaces as per RS422 or RS232 standard
• Interface are electrically isolated
Use
SCB 3 is used as an interface extension (additional serial interfaces), as an interface converter or as an amplifier.
Function
SCB 3 is equipped with two serial transmission channels routed to the terminal strip of the PIM.

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70 Functional Description

1 Transmission channel 1 2 Connector 3 Module housing with SCB 3

The software of MPU 23 or MPU 27 determines which interface is active on which transmission channel.
Only one interface may be active for any one transmission channel.
• Transmission channel 1
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
The RS232 interface is connected via the terminals of the PIM or by a connector.
When connected by the connector, the terminals of the RS232 interface are automatically switched off.
• Transmission channel 2
is equipped with a connection for a serial RS422 interface and a serial RS232 interface.
MPU 23 or MPU 27 processes the data and controls the interface drivers.

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SCB – Purpose and Structure 71

Connection assignment
Relationship between SCB 3 and the terminals of the PIM.

Terminal Designation

n01 Channel 1: O1 of RS422 interface

n02 Channel 2: O1 of RS422 interface

n03 Channel 1: O2 of RS422 interface

n04 Channel 2: O2 of RS422 interface

n05 Channel 1: Ground (GND) of RS422 interface

n06 Channel 2: Ground (GND) of RS422 interface

n07 Channel 1: I1 of RS422 interface

n08 Channel 2: I1 of RS422 interface

n09 Channel 1: I2 of RS422 interface

n10 Channel 2: I2 of RS422 interface

n11 Channel 1: TX of RS232 interface

n12 Channel 2: TX of RS232 interface

n13 Channel 1: Ground (GND) of RS232 interface

n14 Channel 2: Ground (GND) of RS232 interface

n15 Channel 1: RX of RS232 interface

n16 Channel 2: RX of RS232 interface

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72 Functional Description

8.4 SCB 3 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.036

Input voltage VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption mA Less than

100

Power loss mW Less than

425

Data transmission

Term Unit Value

Bit serial As per

RS422
standard

Baud rate kBd 1.2 to

19.2

Electrical isolation With opto-

coupler.

Bit serial As per

RS232-
Standard

Baud rate kBd 1.2 to

19.2

Electrical isolation With opto-

coupler.

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SCB – Purpose and Structure 73

8.5 Printed circuit board SCB 4

Purpose and structure

Design

1 Component side
2 Conductor side

Use
SCB 4 is only used in MPU 23.
Features
• RS232 standard interface extension for MPU 23
• Directly pluggable on MPU 23
• Interface is electrically isolated
Function
SCB 4 is an interface extension for MPU 23.
It realizes an RS232 standard interface.
Electrically connected to MPU 23 via a plug connector.
SCB 4 converts RS232 level signals into TTL level signals.
Signal isolation is realized by optocouplers.
The TTL level signals are required for communication with the single-chip processor on MPU 23.
MPU 23 processes the data and controls the interface drivers.
The interface is connected by the terminal strip of the PIM.

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74 Functional Description

8.6 SCB 4 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 4 x 10 x 4

Weight kg 0.002

Input voltage VDC +5 (±5 %)

from
MPU 23

Power consumption mA Less than

50, via
MPU 23

Connection Spare
slot on
MPU 23

Data transmission

Term Unit Value

Bit serial As per

RS422
standard

Baud rate kBd 1.2 to

19.2

Electrical isolation Yes, with

optocou-
pler

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COB – Purpose and Structure 75

9 COB – Purpose and Structure

9.1 Printed circuit board COB 1

Purpose and structure

Design

1 Plan view
2 Terminal strip 1
3 Slot 1 (MPU 23)
4 LED green (+24 V DC OK)
5 Slot for serial EEPROM
6 Slot 2 (PIM printed circuit board)
7 Terminal strip 2

Features
• Establishes the connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 23- and one PIM printed circuit board
• Guard circuits in the power supply input circuit:
• Overvoltage protection
• Reverse-battery protection
• Overcurrent protection (self-restoring fuses)
• EMC filter
• Guard circuits for CAN and serial interface:
• EMC filter
• Serial EEPROM for PIM module identification and configuration data
• Temperature sensor for terminal temperature
• Light-emitting diode green (supply voltage +24 VDC applied)
Function
COB 1 connects the terminals and the printed circuit boards in the PIM.
COB 1 is equipped with plug connectors for MPU 23 and a PIM printed circuit board.
There are two 2-tier terminal strips on COB 1.
Connections on terminal strip 1:
• PIM power supply
• CAN interface
(Option: 2nd CAN interface, RS232- or RS422 interface)
Connections on terminal strip 2:
• Depending on PIM printed circuit board used

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76 Functional Description

PIM module configuration data are stored in a serial EEPROM.

The data are read via the I2C bus by the MPU 23 of the PIM.
EMC filters and overvoltage protection circuits safeguard the supply voltage of the printed circuit
boards in the PIM against short circuit and polarity reversal.
LED to indicate external +24 VDC supply voltage.
The bus interfaces for communication with other systems are equipped with EMC filters.

1 PIM printed circuit board 4 when SCB 2 used 7 Fuse

2 Self-restoring 5 when CCB 1 used
3 when SCB 4 used 6 Options

Sensor to monitor terminal temperature.

The sensor signal is evaluated by MPU 23.
COB 1 is supplied as a spare part assembly with PIM 1 (module housing, module cassette and COB 1).
The serial EEPROM on COB 1 is programmed with programming cassette SST 2-01.

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COB – Purpose and Structure 77

9.2 COB 1 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 84 x 67 x
36

Weight kg 0.120

Input voltage VDC +24,

−50 % to
+30 %

Power consumption mA Less than

3

Serial EEPROM Kbit 64 (8k x 8)

Overcurrent protection Yes (self-

restoring
fuse F1,
F2 and
F3).

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78 Functional Description

9.3 Printed circuit board COB 3

Purpose and structure

Design

1 Plan view 5 Terminal strip 4 9 LED green (+24 V DC OK)

2 Terminal strip 3 6 Terminal strip 2 10 Slot 1 (MPU 23)
3 Slot 3 (PIM printed circuit board) 7 Slot 2 (PIM printed circuit board) 11 Terminal strip 1
4 Slot 4 (PIM printed circuit board) 8 Slot for serial EEPROM

Use
COB 3 electrically connects the terminals and the printed circuit boards in the PIM.
Features
• Connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 23- and three PIM printed circuit boards
• Guard circuits in the power supply input circuit
• Overvoltage protection
• Reverse-battery protection
• Overcurrent protection (self-restoring fuses)
• EMC filter
• Guard circuits for CAN and serial interface:
• EMC filter
• Serial EEPROM for PIM module identification and configuration data
• Temperature sensor for terminal temperature
• Light-emitting diode green (supply voltage +24 VDC applied)

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COB – Purpose and Structure 79

Function
COB 3 is equipped with connectors for MPU 23 (slot 1) and max. three PIM printed circuit boards (slots 2 to 4).
There are four 2-tier terminal strips on COB 3.
Terminal strip 1 (terminals 101 to 116) establishes connection of:
• PIM power supply
• CAN interface power supply
(Option: 2nd CAN interface, RS232- or RS422 interface).
Terminal strip 2 (terminals 201 to 216) establishes connection of:
• PIM printed circuit board in slot 2.
Terminal strip 3 (terminals 301 to 316) establishes connection of:
• PIM printed circuit board in slot 3.
Terminal strip 4 (terminals 401 to 416) establishes connection of:
• PIM printed circuit board in slot 4.
PIM module configuration data are stored in a serial EEPROM.
The data are read via the I2C bus by the MPU 23 of the PIM.
EMC filters and overvoltage protection circuits safeguard the supply voltage of the printed circuit
boards in the PIM against short circuit and polarity reversal.
LED to indicate external +24 VDC supply voltage.
The bus interfaces for communication with other systems are equipped with EMC filters.

1 PIM printed circuit board 4 when SCB 2 used 7 Fuse

2 Self-restoring 5 when SCB 4 used
3 when CCB 1 used 6 Options

Sensor to monitor terminal temperature.

The sensor signal is evaluated by MPU 23.

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80 Functional Description

COB 3 is supplied as a spare part assembly with PIM 2 (module housing, module cassette and COB 3).
The serial EEPROM on COB 3 is programmed with programming cassette SST 2-01.

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COB – Purpose and Structure 81

9.4 COB 3 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 84 x 135 x
36

Weight kg 0.230

Input voltage VDC +24,

−50 % to
+30 %

Power consumption mA Less than

3

Serial EEPROM Kbit 64 (8k x 8)

Overcurrent protection Yes (self-

restoring
fuse F1,
F2, F3, F4
and F5)

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82 Functional Description

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PAB – Purpose and Structure 83

10 PAB – Purpose and Structure

10.1 Printed circuit board PAB 2

Purpose and structure

Design

1 Component side 3 Not equipped

2 Conductor side 4 Plan view

Use
PAB 2 is only intended for use used in a PIM 1 (with COB 1 and MPU 23) or in a PIM 2 (with COB 3 and MPU 23)
Features
Programming adapter for setting the baud rate of the CAN bus and the node address of a PIM
Function
PAB 2 sets the node address and baud rate of the CAN interface of PIM.
Node address and baud rate are programmed with programming cassette SST 2-01 (comprising MPU 23 and PAB 2).
The node address (00 - 31) of the relevant PIM is set with the two rotary switches S1 and S2.
The two rotary switches S4 and S5 are used to select the baud rate at which data are
transmitted to the PIM via the CAN bus.

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84 Functional Description

As two CAN buses can be connected to one PIM (MPU 23 with CCB 1), switch S4 is used to set the baud rate of the
CAN1 bus (MPU 23, always present) and rotary switch S5 to set the baud rate of the CAN2 bus (CCB 1, option). If one
of the rotary switches (S4 or S5) is set to 0, the baud rate set at the other switch when programming both interfaces.
Adjustable values as baud rates:

S1 Rotary switch node address 1st digit (tens)

S2 Rotary switch node address 2nd digit (ones)
S3 "Programming start" key
S4 Rotary switch baud rate CAN1 interface
S5 Rotary switch baud rate CAN2 interface

Rotary switch setting Baud rate

0 No baud rate, the value set at the other switch is used for both
interfaces

1 50 kilobaud

2 100 kilobaud

3 125 kilobaud

4 160 kilobaud

5 200 kilobaud

6 250 kilobaud

7 400 kilobaud

8 500 kilobaud

9 1000 kilobaud

• Press “Programming start” key

• Set values are used

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PAB – Purpose and Structure 85

10.2 PAB 2 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
14

Weight kg 0.024

Supply voltage VDC +5 (±5 %)

from
MPU 23

Power consumption (5 VDC) mA Less than

10

Power loss mW Less than

50

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86 Functional Description

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FCB – Purpose and Structure 87

11 FCB – Purpose and Structure

11.1 Printed circuit board FCB 1

Purpose and structure

Design

1 Component side 4 Four-figure 7-segment display 7 Fuses

2 Conductor side 5 LED (yellow) "Relay K2 activated"
3 Plan view 6 LED (yellow) "Relay K1 activated"

Use
FCB 1 can only be used in devices with MPU 23.
Features
• Display of alarms and fault codes
• Output of binary information by transistor output stages
• Independent activation of two positive-switching and two ground switching transistor output stages by MPU 23
• Output current monitoring and short-circuit protection
• Electrical isolation of output stage circuits by optocouplers
• Operating voltage of output stages (+12 VDC - +36 VDC) is supplied separately
(protected by self-restoring fuse F3)
• Output of binary information by relays
• Independent activation of the two relays by MPU 23
• Indication of relay activation by LEDs (yellow)

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88 Functional Description

• Short-circuit protection for each relay by fuse (F1 and F2)

• High switching capacity (50 W)
• All outputs equipped with EMC protective filter.
Function
FCB 1 is used to display alarms and fault codes and to output binary information.
Alarm display and storage
Alarm messages (fault codes) from a higher-level system are transmitted to MPU 23 via
a serial bus (RS422, RS232 or CAN).
MPU 23 processes and saves the alarm messages.
Alarm messages are displayed on the four-figure 7-segment display on FCB 1.
MPU 23 and FCB 1 communicate via the internal module bus.
Alarms are recorded over a period lasting 12 hours. They are categorized in four chronological groups:

Group Alarms

1 Current alarms

2 Alarms which occurred in the last hour

3 Alarms which occurred in the last 1 to 4 hours

4 Alarms which occurred in the last 4 to 12 hours

The first figure on the 7-segment display indicates the alarm group.
The alarm messages (second to fourth figure on the 7-segment display) in a group are
displayed in ascending order for 3 seconds.
Display is interrupted for 5 seconds when changing groups.
Output of binary information by MOS transistor output stages
The external operating voltage of the output stages is connected to the PIM via
terminals n09 (+UEXT) and n10 (GNDEXT).
It ranges between +12 VDC and +36 VDC and is independent of the operating voltage of the PIMs.
The output stage circuit is protected by a self-restoring fuse F3 (1.1 A) on printed circuit board FCB 1.
Printed circuit board FCB 1 is equipped with two positive-switching and two ground-switching MOS power transistors.
Electrical isolation between the output stages and the control logic is realized by optocouplers.
The MOS power transistors feature the following guard circuits:
• Overvoltage protection
allowing direct connection of inductive loads (relays etc.).
• Overcurrent protection
switches off the relevant output stage in case of short-circuit.

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FCB – Purpose and Structure 89

1 (self-restoring, 1.1 A)
2 Module housing with FCB 1

1 (self-restoring, 1.1 A)
2 Module housing with FCB 1

Output of binary information by relays

FCB 1 is equipped with two relays.
The relays are activated by MPU 23.
Relay activation is indicated by LEDs.
Two changeover contacts are provided at the terminals of the PIM. The relay changeover contacts
are connected in parallel to increase switching capacity.

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90 Functional Description

1 Fuse, 3.15 A

Connection assignment
Relationship between FCB 1 and the terminals of the PIM.

Terminal Designation

n01 Relay K1: NC contact

n02 Relay K1: NO contact

n03 Relay K1: Common connection

n04 Relay K2: Common connection

n05 Relay K2: NO contact

n06 Relay K2: NC contact

n07 Not used

n08 Transistor output 1 (positive-switching)

n09 External switching voltage (+UEXT)

n10 External switching voltage ground (GNDEXT)

n11 Not used

n12 Transistor output 2 (positive-switching)

n13 Not used

n14 Not used

n15 Transistor output 3 (ground-switching)

n16 Transistor output 4 (ground-switching)

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11.2 FCB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.040

Supply voltage VDC +5 (±5 %)

from
MPU 23

Power consumption (5 VDC) mA Less than

75

Power loss mW Less than

400

Display

Term Unit Value

Type 7-seg-
ment
display
(LED).

Binary outputs (relays)

Term Unit Value

Switching capacity per relay W Max. 50

Switching voltage VDC Max. 36

Switching current A Max. 2 (at

24 VDC)

Short-circuit protection A Fuse

(3.15) per
relay.

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92 Functional Description

Term Unit Value

Relay switching time ms Max. 10

Relay actuation cycle Max. 20

times per
second.

Transistor outputs (MOS transistors)

Term Unit Value

Externe operating voltage VDC +12 - +36

(+UEXT))

Switching current per output mA Max. 250

Short-circuit protection A Self-

restoring
fuse (1.1)
Electronic
monitoring
with cutoff.

Electrical isolation Yes,

between
output
stage
circuit and
control
logic.

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COB – Purpose and Structure 93

12 COB – Purpose and Structure

12.1 Printed circuit board COB 17

Purpose and structure

Design

1 Plan view
2 Terminal strip 1
3 Rotary switch, baud rate for both CAN interfaces
4 Rotary switch, node no. (Tens)
5 Rotary switch, node no. (Ones)
6 Terminal strip 2
7 Slot 2 (PIM printed circuit board)
8 Soldered serial EEPROM
9 LED green (+24 V DC OK)
10 Slot 1 (MPU 27)

Features
• Establishes the connection between the module periphery and the printed circuit boards of the PIM
• Slots for one MPU 27- and one PIM printed circuit board
• Guard circuits in the power supply input circuit:
• Overvoltage protection
• Reverse-battery protection
• Overcurrent protection (self-restoring fuses)
• EMC filter
• Light-emitting diode green (supply voltage +24 VDC applied)
• EMC guard circuits for CAN interfaces
• Soldered serial EEPROM (128K x 8) for PIM module identification and configuration data
• Temperature sensor for terminal temperature
• Rotary switch for CAN node setting
• Rotary switch for baud rate setting (for both CAN interfaces)
Function
COB 17 connects the terminals and the printed circuit boards in the PIM.
COB 17 is equipped with connectors for MPU 27 (slot 1) and one PIM printed circuit board (slots 2).
There are two 2-tier terminal strips on COB 17.
Connections on terminal strip 1 (terminals 101 to 116):
• PIM power supply
• CAN interface

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94 Functional Description

Connections on terminal strip 2 (terminals 201 to 216):

• Depending on PIM printed circuit board used
The module configuration data of the PIM (node address setting and baud rate at the rotary
switches) are read via the I2C bus by the MPU 27 of the PIM.
These data are subsequently written in the serial EEPROM of the motherboard (COB) by the MPU 27.
EMC filters and overvoltage protection circuits safeguard the supply voltage of the printed circuit
boards in the PIM against short circuit and polarity reversal.
LED to indicate external +24 VDC supply voltage.
The bus interfaces for communication with other systems are equipped with EMC filters.
Sensor to monitor terminal temperature.
The sensor signal is evaluated by MPU 27.
COB 17 is supplied as a spare part assembly with PIM 5 (module housing, module cassette and COB 17).

1 PIM printed circuit board 2 Self-restoring 3 Fuse

Rotary switches
PIM module identification data are set with the rotary switches on COB 17.

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COB – Purpose and Structure 95

Node number

S1 Baud rate setting switch

S2 Node setting switch, tens
S3 Node setting switch, ones
The node setting is made as follows (node number "12" is set below by way of example):
• Set the tens of the node with switch S2 (for the example "12" to 1).
• Set the ones of the node with switch S3 (for the example "12" to 2).
Baud rate (transmission rate) of the two CAN interfaces
The baud rate is set to the following values at switch S1:
• Pos. 0: 1 MBaud
• Pos. 1: 500 kBaud
• Pos. 2: 250 kBaud
• Pos. 3: 125 kBaud
The setting defines the baud rate of both buses (CAN1 and CAN2).
Different settings for the two buses are not possible.

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96 Functional Description

12.2 COB 17 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 84 x 67 x
36

Weight kg 0.120

Input voltage VDC +24,

−50 % to
+30 %

Power consumption mA Less than

3

Serial EEPROM K 128 x 8

Overcurrent protection Yes (self-

restoring
fuse F1)

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COB – Purpose and Structure 97

12.3 COB 5 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 84 x 135 x 36

Weight kg 0.230

Input voltage VDC +24,

−50 % to
+30 %

Power consumption mA Less than

3

Serial EEPROM K 128 x 8

Overcurrent protection Yes (self-

restoring
fuse F1,
F2, F3, F4
and F5)

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98 Functional Description

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FCB – Purpose and Structure 99

13 FCB – Purpose and Structure

13.1 Display module FCB 2

Purpose and structure

Design

1 View in housing
2 Display
3 ENTER key
4 Up key
5 Down key
6 ESC key

Use
FCB 2 is only mounted on PIM cassettes with MPU 27.
Function
The LCD module comprises a two-line (2 x 16 figure) illuminated LCD display and 4 keys.
The display shows system information, parameters, data etc.
FCB 2 is supplied as a separate module or together with a PIM 5 or a PIM 3.
Versatile use with the following variants:
• PIM cassette with MPU 27 is used with display module
• PIM cassette with MPU 27 is used without display module (e.g. poor accessibility to terminal box)
• The display module is temporarily mounted for servicing (e.g. during initial startup).
Scrolling through the main menu is possible with the Up/Down keys (4 and 5).
The desired menu is then selected with the ENTER key (3). Scrolling in a sub-menu is
possible with the Up/Down keys (4 and 5).
On the "Password page" the ENTER key (3) selects the point and the Up/Down keys (4 and 5) select the characters.
Pressing the ESC key moves back.

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100 Functional Description

13.2 FCB 2 – Technical data

Term Unit Value

Dimensions (H x W x D) mm 44 x 62 x
24

Weight kg 0.035

Input voltage VDC +5 (±5 %)

from
MPU 27

Power consumption mA Approx.

35

Power loss mW Approx.

175

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14 AIB – Purpose and Structure

14.1 Printed circuit board AIB 1

Purpose and structure

Design

1 Component side 3 Plan view 5 LED (red) "Printed circuit

2 Conductor side 4 LED (green) “Power supply” (±12 V) board RESET"

Use
Printed circuit board AIB 1 is used to acquire resistance, current and voltage signals.
Features
• Four independent analog channels.
• Each analog channel is suitable for acquiring resistance, voltage and current signals.
• Software-configuration of analog channels.
• Automatic calibration of measuring amplifier and A/D converter.
• High resolution with 12-bit A/D converter.
• Internal reference voltage sources.
• All inputs equipped with EMC protective filter.
• LED status indication (not on AIB1-01)

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102 Functional Description

Function
The various input signals are connected according to defined connection diagrams.
Configuration of the signal types connected to the various analog channels is realized by the software.
An analog channel has four input terminals with the following functions:
• The internal 10 VDC reference voltage is tapped at terminal A for resistance measuring
(e.g. for Pt100 resistance thermometer). The reference voltage (or reference current) is only
connected when channels are appropriately configured.
• Terminals B and C may be considered as differential voltage inputs of an operation
amplifier. A differential filter between the terminals offers optimum interference voltage
suppression and offers EMC protection at the same time.
• A reference potential (ground) is provided via terminal D . A resistor required for current measuring
(4 mA 0 20 mA) is connected between terminal D and PIM ground.
The input signals of the four analog channels are selected by a multiplexer and supplied to a measuring amplifier.
Measuring amplifier gain-time is controlled automatically by the measuring amplifier.
It depends on the configured signal source of the analog channel concerned.
A 12-bit A/D converter converts the amplified analog input signal into a data word for
digital processing by MPU 23 or MPU 27.
Connection assignment
Relationship between AIB 1 and the terminals of the PIM.
The variable n in terminal designations stands for the slot used in the PIM.

Terminal Abbreviation Designation

n01 A Reference voltage Uref1 *)

n02 B Differential voltage input (−)

n03 C Differential voltage input (+)

n04 D Ground

n05 A Reference voltage Uref2 *)

n06 B Differential voltage input (−)

n07 C Differential voltage input (+)

n08 D Ground

n09 A Reference voltage input Uref3 *)

n10 B Differential voltage input (−)

n11 C Differential voltage input (+)

n12 D Ground

n13 A Reference voltage Uref4 *)

n14 B Differential voltage input (−)

n15 C Differential voltage input (+)

n16 D Ground

*) Depending on channel configuration.

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AIB – Purpose and Structure 103

Connection examples

1 Channel 1
2 Channel 2
3 Channel 3
4 Channel 4
5 Terminal strip for one PIM printed circuit board
Terminal assignment of printed circuit board AIB 1, the variable n depends on the slot used.

Connection of a 4-wire sensor, e.g.: Pt100, Ni100.

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104 Functional Description

Connection of a 2-wire sensor, e.g.: Pt1000, Ni1000.

Connection of a NiCr-Ni sensor.

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AIB – Purpose and Structure 105

Connection of a current source.

Connection of a DC voltage source.

Connection of a potentiometer.
* This resistor (221 kΩ) is used for cable damage monitoring (faulty slider or cable connection disrupted).

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106 Functional Description

14.2 AIB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

110

Power consumption (24 VDC) mA Less than

50

Power loss mW Less than

550

Electrical isolation Yes, to

module
bus

Common-mode voltage at inputs B and C VDC Less than

10 (to
ground).

Analog input temperature sensor

Term Unit Value

Sensor power supply Internal,

short-
circuit-
proof

Sensor current mA Approx.

1.2

Sensor connection 2 or 4-wire

possible

Sensor monitoring Short

circuit and
disruption

Measuring ranges

Ni100 °C −60 - +180

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AIB – Purpose and Structure 107

Term Unit Value

Pt100 °C −200 -
+850

Ni1000 °C −60 - +180

Pt1000 °C −200 -
+850

Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade

Measuring error K ±1.2

(without
sensor)
< 1 % over
the entire
measuring
range.

Analog input current source

Term Unit Value

Sensor power supply; VDC 16.8 - 32,

Note on ground distribution. external,
module
ground
terminal
103 or
104 nec-
essary.

Sensor monitoring

Signal: 4 mA - 20 mA mA Sensor
fault at
/ < 2 and
/ > 22
(config-
urable)

Signal: 0 mA - 20 mA mA Sensor
fault at /
> 22 (con-
figurable)

Measuring range mA 0 - +25

Input filter Hz fg = 10
(RC
low-pass)
with
6 dB/decade

Resolution Bit Internal 12

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108 Functional Description

Term Unit Value

Measuring error % Less

than 0.5
absolute
(without
sensor).

Sampling rate Hz fa > 20

Compliance voltage VDC Less than

4

Input resistance Ω 50

Analog input voltage source

Term Unit Value

Measuring range VDC -0.25 -

+10.25

Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade

Input resistance kΩ Greater

than 50

Resolution Bit 12 internal

Measuring error % Less

than 0.5
absolute
(without
sensor).

Analog input potentiometer

Term Unit Value

Power supply VDC 10,

±0.5 %,
internal

Measuring current mA Max. 10,

short-
circuit-
proof

Source resistance kΩ 1 ≤ R ≤ 10

Measuring range− VDC -0.25 -

+10.25

Sensor monitoring Short

circuit and
disruption.

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AIB – Purpose and Structure 109

Term Unit Value

Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade

Input resistance kΩ Greater

than 50

Resolution Bit 12 internal

Measuring error % Less

than 0.5
absolute
(without
sensor).

Analog input thermocouple

Term Unit Value

Measuring range mV −5 - +50

Sensor monitoring Disruption

Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade

Input resistance kΩ Greater

than 50

Resolution Bit 12 internal

Measuring error % Less

than 0.5
absolute
(without
sensor).

Terminal temperature compensation Yes with

tempera-
ture sen-
sor.

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110 Functional Description

14.3 Printed circuit board AIB 2

Purpose and structure

Design

1 Component side 3 Plan view 5 LED (yellow) "Output 2 active"

2 Conductor side 4 LED (yellow) "Output 1 active"

Features
• Two independent electrically-interconnected analog input channels respectively for the acquisition of:
• One voltage signal (0 VDC to +10 VDC) or
• One current signal from 4 mA to 20 mA (two-wire connection)
• Two independent analog output channels respectively for the output of:
• One voltage signal (0 VDC to +10 VDC) or
• One current signal from 4 mA to 20 mA (two-wire connection)
• Software-configuration of analog channels
• Electrically isolated inputs/outputs
• All inputs/outputs equipped with EMC protective filter.
• Status indication by LEDs
Function
AIB 2 acquires and outputs current and voltage signals. Configuration of the signal type connected to
an analog channel is realized by the software and appropriate circuitry.
Input channels
Two analog input channels acquire current and voltage signals. Each input channel acquires voltage or current signals

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AIB – Purpose and Structure 111

1 Module housing with AIB 2

2 Input signal 1

1 Module housing with AIB 2

2 Input signal 1
The input signals are filtered and digitalized by a 12-bit A/D converter. The input circuit is
electrically isolated from the electronics by optocouplers.
Data are processed and evaluated by MPU 23 or MPU 27.
Both input channels are referenced to the same ground, i.e. terminals n02 and n06 are connected internally.
Output channels
Two analog output channels output current and voltage signals. Each output channel outputs voltage or
current signals. Mixed operation (current output and voltage output) is not possible.
Operational availability of output channels 1 and 2 is indicated by two LEDs.

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112 Functional Description

1 Output signal 1

1 Output signal 1
The operating voltage of the external voltage (+ UEXT) must be filtered by filter module FIM 1 before supply.

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AIB – Purpose and Structure 113

Connection assignment

Terminal Designation

n01 Input channel 1: Positive input voltage (0 VDC - 10 VDC)

n02 Input channel 1: Ground (GND), internally connected to n06

n03 Input channel 1: Current input (4 mA - 20 mA)

n04 Input channel 2: Current input (4 mA - 20 mA)

n05 Input channel 2: Positive input voltage (0 VDC - 10 VDC)

n06 Input channel 2: Ground (GND), internally connected to n02

n07 Not used

n08 Not used

n09 Output channel 1: Positive output voltage (0 VDC - 10 VDC)

n10 Output channel 1: Current output (4 mA - 20 mA)

n11 Output channel 1: Positive external supply voltage (+ UEXT) via filter module
FIM 1

n12 Output channel 1: External supply voltage ground (GNDEXT )

n13 Output channel 2: Positive output voltage (0 VDC - 10 VDC)

n14 Output channel 2: Current output (4 - 20 mA)

n15 Output channel 2: Positive external supply voltage (+ UEXT) via filter module
FIM 1

n16 Output channel 2: External supply voltage ground (GNDEXT )

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114 Functional Description

14.4 AIB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) A Less than

80

Power loss mW Less than

400

Input channels

Term Unit Value

Input filter Hz fg = 70
(RC
low-pass)
with
6 dB/decade

Resolution Bit 12 internal

Measuring error % Less

than 0.5
absolute
(without
sensor)

Sampling rate Hz fa > 20

Electrical isolation Yes,

between
electron-
ics and
outputs,
no,
between
inputs
channel
1 and
channel 2.

Analog input current signal

Signal monitoring

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Term Unit Value

Signal: 4 mA 0 20 mA mA Sensor
fault at
/ < 2 and
/ > 22 (con-
figurable)

Signal: 0 mA 0 20 mA mA Sensor
fault at /
> 22 (con-
figurable)

Compliance voltage VDC Less than

4

Input resistance Ω Approx.

120

Measuring range mA 0 - +25

Analog input voltage signal

Measuring current mA Less than

1

Measuring range VDC 0 - +10.25

Sensor monitoring Disruption

Input resistance kΩ Greater

than 25

Output channels

Term Unit Value

Analog output current signal

Power supply VDC 7.5 - 32,

external,

Compliance voltage VDC 7.5

Output current of current source mA 4 - 20

Resolution Bit 12

Measuring error % Less

than 0.5
absolute

Electrical isolation Yes

Analog output voltage signal

Power supply VDC 16.8 - 32,

external,

Power consumption mA Less than

15

Output voltage VDC 0 - 10

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116 Functional Description

Term Unit Value

Output current of voltage source mA Less than

10

Resolution Bit 12

Measuring error % Less

than 0.5
absolute

Electrical isolation Yes

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AIB – Purpose and Structure 117

14.5 Printed circuit board AIB 3

Purpose and structure

Design

1 Component side 6 LED (red) "Printed circuit

2 Conductor side board RESET"
3 Plan view 7 LED (green) "Operation"
4 LED (yellow) "Spare" 8 LED (green) "Power supply (+15 V)"
5 LED (yellow) "Spare" 9 LED (green) "Power supply (−15 V)"

Features
• 8 analog channels for the acquisition of current signals
• Automatic calibration of measuring amplifiers and A/D converter
• High resolution with 12-bit A/D converter
• Internal reference voltage sources
• All inputs equipped with EMC protective filter.
• Status indication by LEDs
• Overcurrent protection

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118 Functional Description

Function

1 Analog channel 1
2 Module housing with AIB 3
3 Self-restoring fuse
AIB 3 acquires max. eight current signals (4 mA - 20 mA).
Function is described for one analog channel. All other analog channels are identical in structure.
Each analog channel is equipped with an input for the acquisition of the current signal and a voltage
output for sensor supply (the output voltage depends on the supply voltage of the corresponding PIM).
The output voltage is protected by one fuse for each analog channel.
The current signal is selected by a multiplexer and subsequently amplified.
A 12-bit-A/D converter digitalizes the current signal. Data are processed and evaluated by MPU 23 or MPU 27.

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AIB – Purpose and Structure 119

Connection assignment

Terminal Designation

n01 Analog channel 1: Output voltage 1 (+24 VDC)

n02 Analog channel 1: Current input 1

n03 Analog channel 2: Output voltage 2 (+24 VDC)

n04 Analog channel 2: Current input 2

n05 Analog channel 3: Output voltage 3 (+24 VDC)

n06 Analog channel 3: Current input 3

n07 Analog channel 4: Output voltage 4 (+24 VDC)

n08 Analog channel 4: Current input 4

n09 Analog channel 5: Output voltage 5 (+24 VDC)

n10 Analog channel 5: Current input 5

n11 Analog channel 6: Output voltage 6 (+24 VDC)

n12 Analog channel 6: Current input 6

n13 Analog channel 7: Output voltage 7 (+24 VDC)

n14 Analog channel 7: Current input 7

n15 Analog channel 8: Output voltage 8 (+24 VDC)

n16 Analog channel 8: Current input 8

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120 Functional Description

14.6 AIB 3 – Technical data

General

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA < 50

Power consumption (24 VDC) mA < 200

Power loss mW < 660

Analog channel

Power supply VDC 24,

internal
(−50 %
to +30 %,
depending
on the
supply
voltage of
the PIM)

Signal monitoring

Signal: 4 mA - 20 mA mA Sensor
fault at
/ < 2 and
/ > 22
(config-
urable)

Signal: 0 mA - 20 mA mA Sensor
fault at /
> 22 (con-
figurable)

Measuring range mA 0 - +25

Input filter Hz fg = 10
(RC
low-pass)
with
6 dB/decade

Resolution 12 bit

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AIB – Purpose and Structure 121

Measuring error % < 0.5

absolute

Sampling rate Hz fa > 20

Compliance voltage VDC <4

Input resistance Ω Approx.

80

Overcurrent limitation mA Approx.

50 - 70

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122 Functional Description

14.7 Printed circuit board AIB 4

Purpose and structure

Design

1 Component side 4 LED (red) "Printed circuit

2 Conductor side board RESET"
3 Plan view

Features
• Four independent electrically isolated analog channels to acquire current signals
(4 mA - 20 mA, two-wire connection)
• High resolution with 12-bit A/D converter
• Overcurrent protection for analog channels
• All inputs and outputs equipped with EMC protective filter.
• Provision of +24 VDC for power supply of current sources
• Fault indication by LED
Function
AIB 4 acquires current signals ranging between 4 mA - 20 mA. The four input channels are
electrically isolated from each other and from the electronics.
Each input channel is equipped with:
• Overcurrent protection circuit
• Reverse-battery protection
• EMC protection filter
Input signals digitalized by a 12-bit-A/D converter.

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AIB – Purpose and Structure 123

Data are processed and evaluated by MPU 23 or MPU 27.

Failure of one or more A/D converters leads to a fault message (summary alarm), indicated by red LED on AIB 4.
Operation of current sources with external or with the internal power supply possible due to
electrical isolation of the four analog channels.

1 Module housing with AIB 4

2 Input signal 1
Two outputs are provided for use of the internal power supply of AIB 4.
Each output is protected by a self-restoring fuse (200 mA) and is equipped with an EMC filter.

1 Module housing with AIB 4

2 Input signal 1
However, both outputs may only be loaded with a total current of max. 250 mA. The
current is otherwise limited by the COB.

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124 Functional Description

Connection assignment

Terminal Designation

n01 Input channel 1: Current input (4 mA - 20 mA)

n02 Input channel 1: Ground of input channel 1

n03 Input channel 1: Current input (4 mA - 20 mA)

n04 Input channel 2: Ground of input channel 2

n05 Not used

n06 Not used

n07 Input channel 3: Current input (4 mA - 20 mA)

n08 Input channel 3: Ground of input channel 3

n09 Input channel 4: Current input (4 mA - 20 mA)

n10 Input channel 4: Ground of input channel 4

n11 Not used

n12 Not used

n13 Positive output voltage (+24 VDC)

n14 Output voltage ground (GND)

n15 Positive output voltage (+24 VDC)

n16 Output voltage ground (GND)

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AIB – Purpose and Structure 125

14.8 AIB 4 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.034

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) A Less than

80

Power loss mW Less than

400

Input channels

Term Unit Value

Electrical isolation Yes,

between
electron-
ics and
outputs,
Yes,
between
the inputs
of a
channel.

Input resistance Ω Approx.

120

Compliance voltage VDC Less than

4

Input filter Hz fg = 70
(RC
low-pass)
with
6 dB/decade

Measuring range mA 0 - +25

A/D converter

Resolution Bit 12

Measuring error % Less

than 0.5
absolute
(without
sensor)

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126 Functional Description

Term Unit Value

Sampling rate Hz fa > 20

Signal monitoring

Signal: 4 mA - 20 mA mA Sensor
fault at
/ < 2 and
/ > 22
(config-
urable)

Signal: 0 mA - 20 mA mA Sensor
fault at /
> 22 (con-
figurable)

Power supply VDC 24,

internal
(−50 % to
+30 %,
depending
on the
supply
voltage of
the PIM).

Power consumption mA Max. 250

for both
channels
together.

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BIB – Purpose and Structure 127

15 BIB – Purpose and Structure

15.1 Printed circuit board BIB 1

Purpose and structure

Design

1 Component side 8 LED (yellow) "Channel 3 active" 14 LED (yellow) "Channel 6 active"
2 Conductor side 9 LED (red) "Cabling damage 15 LED (red) "Cabling damage
3 Plan view channel 3" channel 6"
4 LED (yellow) "Channel 1 active" 10 LED (yellow) "Channel 4 active" 16 LED (yellow) "Channel 7 active"
5 LED (red) "Cabling damage 11 LED (red) "Cabling damage 17 LED (red) "Cabling damage
channel 1" channel 4" channel 7"
6 LED (yellow) "Channel 2 active" 12 LED (yellow) "Channel 5 active" 18 LED (yellow) "Channel 8 active"
7 LED (red) "Cabling damage 13 LED (red) "Cabling damage 19 LED (red) "Cabling damage
channel 2" channel 5" channel 8"

Features
• 8 electrically isolated binary channels in two-wire technology
• Status indication of binary channels by LEDs (yellow)
• Cable damage monitoring of binary channel connecting lines
• Indication cabling damage by LEDs (red)
• Wide input voltage range (36 VDC) of binary channels
• Constant input current (approx. 4 mA) in the input voltage range between 8 VDC and 36 VDC
• RF filter, reverse-battery protection

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128 Functional Description

Function
Function of BIB 1 is described for one binary channel. All other binary channels are identical in structure.
Each binary channel is equipped with two inputs (two-wire technology) and is activated by an external voltage.
The optocoupler on BIB 1 is activated when the switch is closed. The current which then flows is
limited to approx. 4 mA regardless of the external switching voltage used.

1 (cable damage monitoring)

2 Module housing with BIB 1
3 Binary channel 1
The admissible input voltage range of the binary channel is 36 VDC.
The following applies to the input voltage (Ui) of the binary channel:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1").
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0").
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range).
The input signal of the corresponding binary channel is electrically isolated by an optocoupler. The
channel is sampled cyclically by MPU 23 or MPU 27. Each binary channel is assigned an LED (yellow).
The relevant LED lights up when a binary channel is activated (logic "1").
A resistor (33 kΩ) is connected in parallel to the switching contact for cable damage monitoring. The
quiescent current which thus flows is evaluated by a separate optocoupler and sampled cyclically
by MPU 23 or MPU 27. Each binary channel is assigned an LED (red). The relevant LED (red) of
the affected binary channel flashes in case of cabling damage.

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BIB – Purpose and Structure 129

Connection assignment

Terminal Designation

n01 Binary channel 1: Positive binary input

n02 Binary channel 1: Negative binary input

n03 Binary channel 2: Positive binary input

n04 Binary channel 2: Negative binary input

n05 Binary channel 3: Positive binary input

n06 Binary channel 3: Negative binary input

n07 Binary channel 4: Positive binary input

n08 Binary channel 4: Negative binary input

n09 Binary channel 5: Positive binary input

n10 Binary channel 5: Negative binary input

n11 Binary channel 6: Positive binary input

n12 Binary channel 6: Negative binary input

n13 Binary channel 7: Positive binary input

n14 Binary channel 7: Negative binary input

n15 Binary channel 8: Positive binary input

n16 Binary channel 8: Negative binary input

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130 Functional Description

15.2 BIB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.026

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) mA Less than

30

Power loss mW Less than

150

Binary inputs

Term Unit Value

Input voltage range VDC Less than

36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

(for cable
damage
monitor-
ing)

Sensor connection Two-pole

Electrical isolation Yes, with

optocou-
pler

Input filter Low-pass

(RC) with
6 dB/decade

Sampling cycle of binary inputs ms Approx.

50

Cable length for sensor connection m Max. 5

(unshielded)
twisted.
Max. 50
(shielded)
twisted.

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BIB – Purpose and Structure 131

15.3 Printed circuit board BIB 2

Purpose and structure

Design

1 Component side 8 LED (yellow) "Channel 3 active" 14 LED (yellow) "Channel 6 active"
2 Conductor side 9 LED (red) "Cabling damage 15 LED (red) "Cabling damage
3 Plan view channel 3" channel 6"
4 LED (yellow) "Channel 1 active" 10 LED (yellow) "Channel 4 active" 16 LED (yellow) "Channel 7 active"
5 LED (red) "Cabling damage 11 LED (red) "Cabling damage 17 LED (red) "Cabling damage
channel 1" channel 4" channel 7"
6 LED (yellow) "Channel 2 active" 12 LED (yellow) "Channel 5 active" 18 LED (yellow) "Channel 8 active"
7 LED (red) "Cabling damage 13 LED (red) "Cabling damage 19 LED (red) "Cabling damage
channel 2" channel 5" channel 8"

Features
• 8 electrically isolated binary channels
• Status indication of binary channels by LEDs (yellow)
• Cable damage monitoring of binary channel connecting lines
• Indication of cabling damage by LEDs (red)
• Wide input voltage range (36 VDC) of binary channels
• Constant input current (approx. 4 mA) in the input voltage range between 8 VDC and 36 VDC
• RF filter, reverse-battery protection
• Failure of +24 VDC (switching voltage) indicated by LED.
Function
Function of BIB 2 is described for one binary channel. All other binary channels are identical in structure.

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132 Functional Description

Each binary channel is equipped with a binary input and a voltage output (+24 VDC). The switching voltage
(+24 VDC) is provided by the PIM and is protected by the fuse on the COB.
All red LEDs light up in case of switching voltage failure. All binary inputs are electrically isolated by optocouplers.

1 (cable damage monitoring)

2 Module housing with BIB 2
3 Binary channel 1
An optocoupler on BIB 2 is activated when the switching voltage (24 VDC) is applied to the binary
input. The current which then flows is limited to approx. 4 mA.
The following applies to the switching voltage:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1").
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0").
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range).
The input signal of the corresponding binary channel is electrically isolated by an optocoupler. The
channel is sampled cyclically by MPU 23 or MPU 27. Each binary channel is assigned an LED (yellow).
The relevant LED lights up when a binary channel is activated (logic "1").
A resistor (33 kΩ) is connected in parallel to the switching contact for cable damage monitoring. The quiescent
current which thus flows is evaluated by a separate optocoupler. Each binary channel is assigned an LED
(red). The relevant LED (red) of the affected binary input flashes in case of cabling damage.

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BIB – Purpose and Structure 133

Connection assignment

Terminal Designation

n01 Binary channel 1: Switching voltage (+24 VDC)

n02 Binary channel 1: Binary input 1

n03 Binary channel 2: Switching voltage (+24 VDC)

n04 Binary channel 2: Binary input 2

n05 Binary channel 3: Switching voltage (+24 VDC)

n06 Binary channel 3: Binary input 3

n07 Binary channel 4: Switching voltage (+24 VDC)

n08 Binary channel 4: Binary input 4

n09 Binary channel 5: Switching voltage (+24 VDC)

n10 Binary channel 5: Binary input 5

n11 Binary channel 6: Switching voltage (+24 VDC)

n12 Binary channel 6: Binary input 6

n13 Binary channel 7: Switching voltage (+24 VDC)

n14 Binary channel 7: Binary input 7

n15 Binary channel 8: Switching voltage (+24 VDC)

n16 Binary channel 8: Binary input 8

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134 Functional Description

15.4 BIB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.026

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

30

Power consumption (24 VDC) mA Less than

32

Power loss mW Less than

280

Binary inputs

Term Unit Value

Input voltage range VDC Max. 36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

Sensor connection Two-pole

Electrical isolation Yes, with

optocou-
pler.

Input filter Low-pass

(RC) with
6 dB/decade

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BIB – Purpose and Structure 135

Term Unit Value

Sampling cycle of binary inputs ms Approx.

50

Cable length for sensor connection m Max. 5

(unshielded)
twisted.
Max. 50
(shielded)
twisted.

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136 Functional Description

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BOB – Purpose and Structure 137

16 BOB – Purpose and Structure

16.1 Printed circuit board BOB 1

Purpose and structure

Design

1 Component side 5 LED (yellow) "Relay K2 activated" 8 LED (red) "Printed circuit
2 Conductor side 6 LED (yellow) "Relay K3 activated" board RESET"
3 Plan view 7 LED (yellow) "Relay K4 activated" 9 Fuses
4 LED (yellow) "Relay K1 activated"

Features
• Output of binary information by relays
• Separate activation of the four relays by MPU 23 or MPU 27.
• Four free changeover contacts with overvoltage protection circuit, on changeover contact
(K4) designed as double contact (K4.1 and K4.2)
• Indication of relay activation by LEDs (yellow)
• Short-circuit protection for each relay by fuse
• Monitoring of relay switching states and fault indication by LED (red)
• Cable damage monitoring and fault indication by LED (red) (BOB 1-02 only, no function on BOB 1-02/A)
• High switching capacity (50 W)
Function
BOB 1 is equipped with four relays (K1, K2, K3 and K4) to output binary information.

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138 Functional Description

The relays are activated by MPU 23 or MPU 27. Relay activation is indicated by LEDs (yellow).
Five changeover contacts are available to the user at the terminals of the PIM:
• Relay K1: One changeover contact with cable damage monitoring for NC and NO contacts
• Relay K2: One changeover contact with cable damage monitoring for NC and NO contacts
• Relay K3: One changeover contact with cable damage monitoring for NC and NO contacts
• Relay K4: One changeover contact with cable damage monitoring for NC and NO contacts (K4.1)
One changeover contact without cable damage monitoring (K4.2)
The changeover contacts of relays K1 to K3 are connected in parallel to reduce contact loading.

1 Fuse
Relays K1, K2, K3 and K4.1 are equipped with double cable damage monitoring for NC and NO
contacts. Monitoring is realized by loading the external switching voltage with a constant current (typ.
0.5 mA). The monitoring current also flows when the contact is open.
A fault message is generated (LED Fault lights up red, not on BOB 1-02/A) if the control signal differs
from the switching state of the relay contacts, or if no monitoring current flows.

1 Fuse
The connections of both changeover contacts are routed out on relay K4. Switching state and cable damage
monitoring (not on BOB 1-02/A) is only realized at changeover contact K4.1 (terminals n13, n12 and n11).

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BOB – Purpose and Structure 139

Connection assignment
Relationship between BOB 1 and the terminals of the PIM.

Terminal Designation

n01 Relay K1: NC contact

n02 Relay K1: NO contact

n03 Relay K1: Common connection

n04 Relay K2: Common connection

n05 Relay K2: NO contact

n06 Relay K2: NC contact

n07 Relay K3: NC contact

n08 Relay K3: NO contact

n09 Relay K3: Common connection

n10 Not used

n11 Relay K4: NC contact 1

n12 Relay K4: NO contact 1

n13 Relay K4: Common connection 1

n14 Relay K4: Common connection 2

n15 Relay K4: NO contact 2 (unmonitored)

n16 Relay K4: NC contact 2 (unmonitored)

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140 Functional Description

16.2 BOB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.042

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

25

Power consumption (24 VDC) mA Less than

50

Power loss mW Less than

925

Binary outputs

Term Unit Value

Switching capacity per relay W Max. 50

Switching voltage (external) VDC Max. 36

Switching current A Max. 2 (at

24 VDC)

Current for monitoring mA Max. 1

(per relay)

Short-circuit protection A Fuse

(3.15)

Relay switching time ms Max. 10

Relay actuation cycle /s Max. 20

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BOB – Purpose and Structure 141

16.3 Printed circuit board BOB 2

Purpose and structure

Design

1 Component side 9 LED (yellow) "Transistor output 15 LED (yellow) "Transistor output
2 Conductor side 6 activated" 12 activated"
3 Plan view 10 LED (yellow) "Transistor output 16 LED (yellow) "Transistor output
4 LED (yellow) "Transistor output 7 activated" 13 activated"
1 activated" 11 LED (yellow) "Transistor output 17 LED (yellow) "Transistor output
5 LED (yellow) "Transistor output 8 activated" 14 activated"
2 activated" 12 LED (yellow) "Transistor output 18 LED (green) "Power supply (+24 V)"
6 LED (yellow) "Transistor output 9 activated" 19 Fuses
3 activated" 13 LED (yellow) "Transistor output
7 LED (yellow) "Transistor output 10 activated"
4 activated" 14 LED (yellow) "Transistor output
8 LED (yellow) "Transistor output 11 activated"
5 activated"

Features
• Output of binary information by transistor output stages
• Separate activation of 14 transistor output stages (positive switching) by MPU 23 or MPU 27
• Indication of transistor switching states by LEDs (yellow)
• Output current monitoring and limitation
• Electrical isolation of output stage circuit by optocoupler
• Operating voltage of output stages (+12 - +36 VDC) supplied separately.
• All outputs equipped with EMC protective filter.

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142 Functional Description

Function
BOB 2 is equipped with 14 identical MOS transistor output stages (positive switching) to output binary information.
The external operating voltage of the output stages is connected to the PIM via terminals n15 (+UEXT) and n16
(GNDEXT). It ranges between +12 VDC and +36 VDC independently of the operating voltage of the PIMs.
The output stage circuit is protected by a fuse (3.15 A).
MOS power transistors are used as output stages. Electrical isolation between the output
stages and the control logic is realized by optocouplers.

1 Fuse 3.15 A
2 Module housing with BOB 2
The MOS power transistors feature the following guard circuits:
• Overvoltage protection
allowing direct connection of inductive loads (e.g. relays etc.).
• Overcurrent protection
switches off the relevant output stage in case of short-circuit.
Switching states of output stage transistors are indicated by LEDs (yellow).

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BOB – Purpose and Structure 143

Connection assignment
Relationship between BOB 2 and the terminals of the PIM.

Terminal Designation

n01 Transistor output 1 (positive-switching)

n02 Transistor output 2 (positive-switching)

n03 Transistor output 3 (positive-switching)

n04 Transistor output 4 (positive-switching)

n05 Transistor output 5 (positive-switching)

n06 Transistor output 6 (positive-switching)

n07 Transistor output 7 (positive-switching)

n08 Transistor output 8 (positive-switching)

n09 Transistor output 9 (positive-switching)

n10 Transistor output 10 (positive-switching)

n11 Transistor output 11 (positive-switching)

n12 Transistor output 12 (positive-switching)

n13 Transistor output 13 (positive-switching)

n14 Transistor output 14 (positive-switching)

n15 Positive external operating voltage (+UEXT)

n16 Negative external operating voltage (GNDEXT)

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144 Functional Description

16.4 BOB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) mA Less than

10

Power loss mW Less than

50

Transistor outputs

Term Unit Value

External operating voltage (+UEXT) VDC +12 - +36

Short-circuit protection (+UEXT) A Fuse

(3.15)

Switching current mA Per

output:
Max. 250
Total:
Max. 3 A.

Short-circuit protection Electronic

monitor-
ing.

Electrical isolation Yes,

between
output
stage
circuit and
control
logic.

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BOB – Purpose and Structure 145

16.5 Printed circuit board BOB 3

Purpose and structure

Design

1 Component side 9 LED (yellow) "Transistor output 15 LED (yellow) "Transistor output
2 Conductor side 6 activated" 12 activated"
3 Plan view 10 LED (yellow) "Transistor output 16 LED (yellow) "Transistor output
4 LED (yellow) "Transistor output 7 activated" 13 activated"
1 activated" 11 LED (yellow) "Transistor output 17 LED (yellow) "Transistor output
5 LED (yellow) "Transistor output 8 activated" 14 activated"
2 activated" 12 LED (yellow) "Transistor output 18 LED (green) "Power supply (+24 V)"
6 LED (yellow) "Transistor output 9 activated" 19 Fuse
3 activated" 13 LED (yellow) "Transistor output
7 LED (yellow) "Transistor output 10 activated"
4 activated" 14 LED (yellow) "Transistor output
8 LED (yellow) "Transistor output 11 activated"
5 activated"

Features
• Output of binary information by transistor output stages
• Separate activation of 14 transistor output stages (ground switching) by MPU 23 or MPU 27
• Indication of transistor switching states by LEDs (yellow)
• Output current monitoring and limitation
• Electrical isolation of output stage circuit by optocoupler
• Operating voltage of output stages supplied separately.
• Monitoring of external operating voltage
• All outputs equipped with EMC protective filter.

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146 Functional Description

Function
BOB 3 is equipped with 14 identical MOS transistor output stages (ground switching) to output binary information.
The external operating voltage of the output stages is connected to the PIM via terminals n15 (+UEXT) and n16
(GNDEXT). It ranges between +12 VDC and +36 VDC independently of the operating voltage of the PIMs.
The output stage circuit is protected by a fuse (3.15 A) on BOB 2.
MOS transistors are used as output stages. Electrical isolation between the output stages
and the control logic is realized by optocouplers.

1 Fuse (3.15 A)
2 Module housing with BOB 3
The MOS transistors feature the following guard circuits:
• Overvoltage protection
allowing direct connection of inductive loads (e.g. relays etc.).
• Overcurrent protection
switches off the relevant output stage in case of short-circuit.
Switch-off is saved and must be reset by the software.
Switching states of output stage transistors are indicated by LEDs (yellow).

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BOB – Purpose and Structure 147

Connection assignment
Relationship between BOB 3 and the terminals of the PIM.

Terminal Designation

n01 Transistor output 1: Ground switching

n02 Transistor output 2: Ground switching

n03 Transistor output 3: Ground switching

n04 Transistor output 4: Ground switching

n05 Transistor output 5: Ground switching

n06 Transistor output 6: Ground switching

n07 Transistor output 7: Ground switching

n08 Transistor output 8: Ground switching

n09 Transistor output 9: Ground switching

n10 Transistor output 10: Ground switching

n11 Transistor output 11: Ground switching

n12 Transistor output 12: Ground switching

n13 Transistor output 13: Ground switching

n14 Transistor output 14: Ground switching

n15 Positive external operating voltage (+UEXT)

n16 Negative external operating voltage (GNDEXT)

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148 Functional Description

16.6 BOB 3 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) mA Less than

10

Power loss mW Less than

50

Transistor outputs

Term Unit Value

External operating voltage (+UEXT) VDC +12 - +36

Short-circuit protection (+UEXT) A Fuse

(3.15)

Switching current mA Per

output:
Max. 250
Total:
Max. 3 A.

Short-circuit protection Electronic

monitoring

Electrical isolation Yes,

between
output
stage
circuit and
control
logic.

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EGB – Purpose and Structure 149

17 EGB – Purpose and Structure

17.1 Printed circuit board EGB 1

Purpose and structure

Design

1 Component side 6 LED (green) "Operation"

2 Conductor side 7 LED (red) "Printed circuit
3 Plan view board RESET"
4 LED (yellow) "Spare" 8 LED (green) "Power supply (+12 V)"
5 LED (yellow) "Spare" 9 LED (green) "Power supply (−12 V)"

Features
• 8 analog channels for the acquisition of voltage signals (0 mV - 40 mV)
• Automatic calibration of measuring amplifier and A/D converter
• Internal reference voltage sources
• Terminal compensation for NiCr-Ni temperature sensors (integrated on COB)
• High resolution with 12-bit A/D converter
• All inputs equipped with EMC protective filter.
• Status indication by LEDs
Function
EGB 1 acquires max. eight voltage signals ranging between 0 mV - 40 mV. The use of differential inputs
makes the analog channels suitable for measuring the signals from NiCr-Ni thermocouples.

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150 Functional Description

Function is described for one analog channel. All other analog channels are identical in structure.
Each analog channel features a differential voltage input. A differential filter in the input circuit offers optimum
interference voltage suppression and offers EMC protection at the same time.

1 Analog channel 1
2 Module housing with EGB 1
3 NiCr-Ni sensor
The voltage signal is selected by a multiplexer and subsequently amplified. A 12-bit-A/D converter
digitalizes the voltage signal. Data are processed and evaluated by MPU 23 or MPU 27.
Temperature compensation is performed by the software.

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EGB – Purpose and Structure 151

Connection assignment
Relationship between EGB 1 and the terminals of the PIM.

Terminal Designation

n01 Analog channel 1: Differential voltage input (+)

n02 Analog channel 1: Differential voltage input (−)

n03 Analog channel 2: Differential voltage input (+)

n04 Analog channel 2: Differential voltage input (−)

n05 Analog channel 3: Differential voltage input (+)

n06 Analog channel 3: Differential voltage input (−)

n07 Analog channel 4: Differential voltage input (+)

n08 Analog channel 4: Differential voltage input (−)

n09 Analog channel 5: Differential voltage input (+)

n10 Analog channel 5: Differential voltage input (−)

n11 Analog channel 6: Differential voltage input (+)

n12 Analog channel 6: Differential voltage input (−)

n13 Analog channel 7: Differential voltage input (+)

n14 Analog channel 7: Differential voltage input (−)

n15 Analog channel 8: Differential voltage input (+)

n16 Analog channel 8: Differential voltage input (−)

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152 Functional Description

17.2 EGB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27

Power consumption (5 VDC) mA Less than

80

Power loss mW Less than

420

Analog channel

Term Unit Value

Measuring range mV 0 - +40

Sensor monitoring Disruption

Input filter Hz fg = 22
(RC
low-pass)
with
6 dB/decade

Resolution Bit 12

Measuring error % Less

than 0.5
absolute
(without
sensor)

Sampling rate Hz fa > 20

Terminal temperature compensation Yes, by

software
(absolute
tempera-
ture acqui-
sition on
printed cir-
cuit board
COB)

Input resistance kΩ Greater

than 50

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IIB – Purpose and Structure 153

18 IIB – Purpose and Structure

18.1 Printed circuit board IIB 1

Purpose and structure

Design

1 Component side 6 LED (yellow) "Binary channel 9 LED (yellow) "Binary channel
2 Conductor side 4 active" 1 active"
3 Plan view 7 LED (yellow) "Binary channel
4 LED (green) "Ready" 3 active"
5 LED (red) "Printed circuit 8 LED (yellow) "Binary channel
board RESET" 2 active"

Features
• Instrument outputs
• 4 analog voltage outputs for instrument control
• Output voltage ranging between 0 VDC - +10 VDC
• Voltage decoupling by isolation amplifier
• Binary inputs
• 4 electrically isolated binary channels in two-wire technology
• Status indication of binary channels by LEDs (yellow)
• Wide input voltage range (36 VDC) of binary channels
• Constant input current (approx. 4 mA) in the input voltage range 8 VDC - 36 VDC
• RF filter, reverse-battery protection

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154 Functional Description

Function
Instrument outputs

Control of analog display instruments, all instrument outputs are identical in structure.
The output voltage (0 VDC - +10 VDC) is generated from a data word by 8-bit-D/A converters and
routed to the terminals of the PIM via an isolation amplifier (buffer).
Binary inputs

Acquisition of binary signals (state), all binary channels are identical, function described for one binary channel.
Each binary channel is equipped with two inputs (two-wire technology) which are activated by an external voltage.
The current which then flows is limited to approx. 4 mA regardless of the external switching voltage used.
Input voltage range of the binary channel 36 VDC.
The following applies to the input voltage (Ui) of the binary channel:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1").
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0").
• 4 VDC v Ui ≤ 8 VDC should be avoided (inadmissible range).
The input signal of the corresponding binary channel is electrically isolated by an optocoupler. The
channels are sampled cyclically by MPU 23 or MPU 27.
Each binary channel is assigned an LED (yellow). The relevant LED lights up when a
binary channel is activated (logic "1").

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Connection assignment
Relationship between IIB 1 and the terminals of the PIM.

Terminal Designation

n01 Binary channel 1: Positive binary input

n02 Binary channel 1: Negative binary input

n03 Binary channel 2: Positive binary input

n04 Binary channel 2: Negative binary input

n05 Binary channel 3: Positive binary input

n06 Binary channel 3: Negative binary input

n07 Binary channel 4: Positive binary input

n08 Binary channel 4: Negative binary input

n09 Positive output voltage for instrument 1

n10 Ground (GND) for instrument 1

n11 Positive output voltage for instrument 2

n12 Ground (GND) for instrument 2

n13 Positive output voltage for instrument 3

n14 Ground (GND) for instrument 3

n15 Positive output voltage for instrument 4

n16 Ground (GND) for instrument 4

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156 Functional Description

18.2 IIB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.024

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

15

Power consumption (24 VDC) mA Less than

50

Power loss mW Less than

440

Instrument outputs

Term Unit Value

Output voltage range VDC +0 - +10

(±5 %)

Output current mA Max. 5

Isolation amplifier Yes

Electrical isolation No

Binary inputs

Term Unit Value

Input voltage range VDC Less than

36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

Sensor connection Two-pole

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Term Unit Value

Electrical isolation Yes,

between
inputs and
between
inputs and
electron-
ics.

Input filter Low-pass

(RC) with
6 dB/decade

Sampling cycle of binary inputs ms Approx.

50

Cable length for sensor connection m Max. 5

(unshielded)
twisted.
Max. 50
(shielded)
twisted.

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19 INB – Purpose and Structure

19.1 Printed circuit board INB 1

Purpose and structure

Design

1 Component side 4 LED (yellow) "Spare" 6 LED (green) "Spare"

2 Conductor side 5 LED (red) "Printed circuit
3 Plan view board RESET"

Use
INB 1 is only used in a PIM 1 (with printed circuit board COB 1 and processor printed circuit board MPU 23)
or in a PIM 2 (with printed circuit board COB 3 and processor printed circuit board MPU 23).
Features
• Instrument outputs
• 4 outputs to control display instruments
• Instrument output as voltage or current output
• 2 outputs supply positive output signals
• 2 outputs supply positive and negative output signals
• Short-circuit-proof instrument outputs
• High resolution with 12-bit D/A converter
• Dimmer
• Wide dimming range (0 % - 100 %) by PWM

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• Output current monitoring and limitation

• RF filter, reverse-battery protection
• Status indication by LEDs
Function
Instrument outputs
Control of display instruments.
The output signals are generated by a 12-bit-D/A converter and routed to the terminals
of the PIM via isolation amplifier (buffer).

Two outputs to output positive output signals.

• Available voltage ranges:
• 0 VDC - +2.5 VDC
• 0 VDC - +5.0 VDC
• 0 VDC - +10.0 VDC
• Available current range:
• 0 mA - +1.0 mA
Two outputs to output positive and negative output signals.
Available voltage ranges:
• −2.5 VDC - 0 VDC - +2.5 VDC
• −5.0 VDC - 0 VDC - +5.0 VDC
• −10.0 VDC - 0 VDC - +10.0 VDC
Available current range:
• −1.0 mA - 0 mA - +1.0 mA
Dimmer
Regulation of instrument illumination.

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INB – Purpose and Structure 161

The operating voltage for the dimmable instrument illumination is provided by an external voltage source.
This voltage is smoothed on INB 1 and protected by an RF and reverse-battery protection circuit.
The dimming voltage is generated by a PWM circuit and features a current monitoring circuit. Max. 0.4 A may
flow for a dimming voltage of 24 VDC. The dimming voltage range lies between 0 % - 100 %.

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Connection assignment
Relationship between INB 1 and the terminals of the PIM.

Terminal Designation

n01 Output 1: Current output (0 mA - +1 mA)

n02 Output 1: Ground (GND)

n03 Output 1: Voltage output

(0 VDC - +2.5 VDC,
0 VDC - +5 VDC or
0 VDC - +10 VDC)

n04 Output 1: Voltage output

(0 VDC - +2.5 VDC,
0 VDC - +5 VDC or
0 VDC - +10 VDC)

n05 Output 2: Current output (0 mA - +1 mA)

n06 Output 2: Ground (GND)

n07 Output 3: Current output (−1 mA - 0 mA - +1 mA)

n08 Output 3: Ground (GND)

n09 Output 3: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n10 Output 4: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n11 Output 4: Current output (−1 mA - 0 mA - +1 mA)

n12 Output 4: Ground (GND)

n13 Output: +UDIMM

n14 Output GNDDIMM

n15 Input: +UEXT

n16 Input GNDEXT

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19.2 INB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltage VDC +5 (±5 %)

from
MPU 23
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

10

Power consumption (24 VDC) mA Less than

25

Power loss mW Less than

650

Instrument outputs

Term Unit Value

Resolution Bit 12 internal

Isolation amplifier Yes

Electrical isolation No

Positive output voltages

Voltage ranges VDC 0 - +2.5

(±0.5 %)
0 - +5.0
(±0.5 %)
0 - +10.0
(±0.5 %)

Output current mA Max. 5

Positive and negative output voltages

Voltage ranges VDC −2.5 -

0 - +2.5
(±0.5 %)
−5.0 -
0 - +5.0
(±0.5 %)
−10.0 -
0 - +10.0
(±0.5 %)

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164 Functional Description

Term Unit Value

Output current mA Max. 5

Positive output current

Output current range mA 0 - +1.0

(±1 %)

Compliance voltage VDC Max. 5

Positive and negative output current

Output current range mA −1.0 -

0 - +1.0
(±1 %)

Compliance voltage VDC Max. 5

Dimmer

Term Unit Value

Input voltage range VDC Less than

36

Input filter Yes

Reverse-battery protection Yes

Input fuse A Self-

restoring
fuse (1.1)

Output voltage Veff 0 – 30

(±2 %)

Output current A Less than

0.4

Short-circuit protection Yes,

electronic

Clock frequency for PWM kHz 1.84

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19.3 Printed circuit board INB 2

Purpose and structure

Design

1 Component side 5 LED (yellow) "Instrument

2 Conductor side outputs active"
3 Plan view 6 LED (yellow) "Dimming voltage
4 LED (green) "Power supply (+15 V)" output active"

Features
• Instrument outputs
• 4 outputs to control display instruments
• Instrument output as voltage or current output
• Bipolar or unipolar output signals
• Short-circuit-proof instrument outputs
• High resolution with 12-bit D/A converter
• Dimmer
• Wide dimming range (0 % - 100 %) by PWM
• Output current monitoring and limitation
• RF filter, reverse-battery protection
• Status indication by LEDs
Function
Instrument outputs
Control of display instruments.

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166 Functional Description

The output signals are generated by a 12-bit-D/A converter and routed to the terminals
of the PIM via isolation amplifier (buffer).

Each instrument output can be used as a voltage or current output. The output signal type
and level can be configured by the software.
Unipolar output signals:
• Voltage ranges:
• 0 VDC - +2.5 VDC
• 0 VDC - +5.0 VDC
• 0 VDC - +10.0 VDC
• Current range:
• 0 mA - +1.0 mA
Bipolar output signals:
Voltage ranges:
• −2.5 VDC - 0 VDC - +2.5 VDC
• −5.0 VDC - 0 VDC - +5.0 VDC
• −10.0 VDC - 0 VDC - +10.0 VDC
Current range:
• −1.0 mA - 0 mA - +1.0 mA
Dimmer
Regulation of instrument illumination.

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INB – Purpose and Structure 167

The internal PIM supply voltage is used as an operating voltage for the dimmable instrument illumination.
This voltage is protected by a self-restoring fuse on the COB.
The dimming voltage is generated by a PWM circuit and features a current monitoring circuit. Max. 0.15 A
may flow for a dimming voltage of 24 VDC. The dimming voltage range lies between 0 % - 100 %.
Connection assignment
Relationship between INB 2 and the terminals of the PIM.

Terminal Designation

n01 Output 1: Current output (0 mA - +1 mA)

n02 Output 1: Ground (GND)

n03 Output 1: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n04 Output 1: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n05 Output 2: Current output (−1 mA - 0 mA - +1 mA)

n06 Output 2: Ground (GND)

n07 Output 3: Current output (−1 mA - 0 mA - +1 mA)

n08 Output 3: Ground (GND)

n09 Output 3: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n10 Output 4: Voltage output

(−2.5 VDC - 0 VDC - +2.5 VDC,
−5 VDC - 0 VDC - +5 VDC or
−10 VDC - 0 VDC - +10 VDC)

n11 Output 4: Current output (−1 mA - 0 mA - +1 mA)

n12 Output 4: Ground (GND)

n13 Output: +UDIMM

n14 Output GNDDIMM

n15 Input: +UEXT

n16 Input GNDEXT

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168 Functional Description

19.4 INB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltage VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

10

Power consumption (24 VDC) mA Less than

200

Power loss mW Less than

1200

Instrument outputs

Term Unit Value

Resolution Bit 12 internal

Electrical isolation No

Output voltages

Voltage ranges VDC −2.5 -

0 - +2.5
(±0.5 %)
−5.0 -
0 - +5.0
(±0.5 %)
−10.0 -
0 - +10.0
(±0.5 %)

Output current mA Max. 4

Positive and negative output current

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INB – Purpose and Structure 169

Term Unit Value

Output current range mA −1.0 -

0 - +1.0
(±1 %)

Compliance voltage VDC Max. 5

Dimmer output

Term Unit Value

Output voltage Veff 0 - 24

(±2 %),
pulse-
width
modulated

Output current A Less than

0.15

Short-circuit protection Yes,

electronic

Clock frequency for PWM kHz 1.84

Dimming range % 0 - 100

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170 Functional Description

19.5 Printed circuit board INB 3

Purpose and structure

Design

1 Component side 6 LED (yellow) "Current output 10 LED (yellow) "Current output
2 Conductor side 3 active" 7 active"
3 Plan view 7 LED (yellow) "Current output 11 LED (yellow) "Frequency
4 LED (yellow) "Current output 4 active" output active"
1 active" 8 LED (yellow) "Current output 12 LED (green) "Power supply
5 LED (yellow) "Current output 5 active" (+15 V) OK"
2 active" 9 LED (yellow) "Current output 13 LED (red) "Printed circuit
6 active" board RESET"

Use
INB 3 is only used in a PIM 5 (with COB 17 and MPU 27) or in a PIM 3 (with COB 5 and
MPU 27). Operation with MPU 23 is not possible.
Features
• Instrument outputs
• 7 current outputs (4 mA - 20 mA) to control display instruments
• High resolution with 10-bit D/A converter
• 1 frequency output (0 Hz - 1500 Hz) to control a display instrument
• Short-circuit-proof outputs
• Status indication by LEDs

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INB – Purpose and Structure 171

Function
Control of up to seven display instruments with current inputs (4 mA - 20 mA) and a display instrument
with a frequency input (0 Hz - 1500 Hz) at the same time.
Current outputs
Seven independent current sources.
Control of current sources by 10-bit-D/A converter on INB 3.

Yellow status LEDs are assigned to the current outputs. The LEDs signal current
flow at the corresponding current output.
Each current source features an overcurrent protection circuit and is short-circuit-proof
(current limited to max. 25 mA per output).
The max. load impedance of 300 Ω per channel must not be exceeded.
Frequency output
Control of a display instrument.

The frequency output supplies a binary output signal with a 1:1 pulse-duty factor.
The output voltage of the signal depends on the operating voltage and is normally +24 VDC
(20.5 VDC ≤ Uhigh ≤ +23.7 VDC and Ulow = 0 VDC).
The function of the frequency output is indicated by a yellow status LED.
The frequency output features an overcurrent protection circuit and is short-circuit-proof.

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172 Functional Description

The frequency output of INB 3 is specially designed for connection of a frequency-dependent

speed instrument ("VDO-Ocean-Line" series).
Connection assignment
Relationship between INB 3 and the terminals of the PIM.

Terminal Designation

n01 Current output 1 (0 mA - 20 mA)

n02 Ground (GND)

n03 Current output 2 (0 mA - 20 mA)

n04 Ground (GND)

n05 Current output 3 (0 mA - 20 mA)

n06 Ground (GND)

n07 Current output 4 (0 mA - 20 mA)

n08 Ground (GND)

n09 Current output 5 (0 mA - 20 mA)

n10 Ground (GND)

n11 Current output 6 (0 mA - 20 mA)

n12 Ground (GND)

n13 Current output 7 (0 mA - 20 mA)

n14 Ground (GND)

n15 Frequency output (0 Hz - 1500 Hz)

n16 Ground (GND)

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19.6 INB 3 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.026

Supply voltage VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

20

Power consumption (24 VDC) mA Less

than 10
(without
load).
Less
than 200
(loaded
with
7 x 25)

Power loss mW Less than

340 (with-
out load).
Less than
3.0 W
(loaded
with 7 x 25
mA)

Instrument outputs

Term Unit Value

Instrument outputs (current outputs)

Output current range mA 4 - 20

(±1 %)

Short-circuit-proof Yes

Resolution of D/A converter Bit 10

Max. load impedance Ω R <

300 per
channel

Electrical isolation No

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174 Functional Description

Term Unit Value

Frequency output

Frequency range Hz 0 - 1500

Pulse-duty factor 1:1

Power supply V 24 internal

(depend-
ing on
the supply
voltage of
the PIM).

Output voltage VDC At 24:

20.5 ≤
Uhigh ≤
+23.7
Ulow + 0
Paral-
lel con-
nection
of max.
3 instru-
ments
(VDO) pos-
sible.

Short-circuit-proof Yes

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20 MFB – Purpose and Structure

20.1 Printed circuit board MFB 1

Purpose and structure

Design

1 Component side 6 LED (yellow) "Analog speed 11 LED (green) "Ready"

2 Conductor side signal 2" 12 Fuses
3 Plan view 7 LED (yellow) "Binary speed
4 LED (yellow) "Analog speed signal 2"
signal 1" 8 LED (yellow) "Relay K2 activated"
5 LED (yellow) "Binary speed 9 LED (yellow) "Relay K1 activated"
signal 1" 10 LED (green) "+24 V output"

Use
MFB 1 is used in slot 2 or slot 3 in conjunction with MPU 23. Slot 4 is not possible in this case.
Slot 2, 3, or 4 is used in conjunction with processor printed circuit board MPU 27.
Features
• Status indication by LEDs
• Electrically isolated power supply of the channels by DC/DC converter
• All inputs equipped with EMC protective filter
• Inputs for analog speed signals (input voltage up to 80 VAC)
• Electrically isolated, symmetrical and ungrounded inputs

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176 Functional Description

• Separate control of input hysteresis

• The inputs are suitable for speed acquisition of:
• Inductive speed transmitters or
• Tachogenerators
• Inputs for binary speed signals
• Electrically isolated inputs
• Reverse-battery protection and constant input current
• The inputs are suitable:
• For speed acquisition of binary sensors or
• as binary channel (status interrogation)
• Binary outputs
• Output of binary information by two relays
• Separate activation of the two relays by MPU 23 or MPU 27.
• Two free changeover contacts with overvoltage protection circuit
• Indication of relay activation by LEDs
• Short-circuit protection for each relay by fuse
• High switching capacity (50 W)
• 24 VDC output for electronic transmitters or sensors
Function
Two independent speed acquisition channels are available to the user.
Each of these two channels comprises an input for analog speed signals (tachogenerator or inductive sensor)
and an input for binary speed signals (electronic transmitter or status interrogation).
If one speed channel is used for the acquisition of an analog speed signal, the speed input for binary
speed signals may only be used for binary status interrogation.
The pulses are switched directly via a multiplexer or via a 10:1-divider on the plug connector of MFB 1. This
signal path makes real-time processing of the speed signal by MPU 23 or MPU 27 possible
Inputs for analog speed signals
Signal acquisition of a tachogenerator or an inductive speed transmitter.
The analog speed signal passes to an adapter network via the input terminals. The network has the following tasks:
• Input filter (symmetrical, ungrounded)
• Ensuring a wide input voltage range (up to 80 VAC)
• EMC protection
A series-connected comparator converts the analog signals (e.g. sinusoidal) into square-wave pulses with TTL level.
Additional hysteresis control allows varying comparator switching thresholds to be set.
Electrical isolation is realized by optocouplers.
Inputs for binary speed signals
Acquisition of signals from an electronic transmitter (pulses) or a binary signal (state).

The binary channel is directly controlled by an external voltage.

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MFB – Purpose and Structure 177

The current which then flows is limited to approx. 4 mA regardless of the external switching voltage used.
Input voltage range for the binary signal 36 VDC.
The following applies to the input voltage (Ui) of the signal:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1")
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0")
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range)
The binary input signal is electrically isolated by an optocoupler. An active signal (logic "1") at the input terminals is
indicated by illumination of the corresponding LED ("Binary speed signal 1" and/or "Binary speed signal 2").
The status is interrogated cyclically by MPU 23 or MPU 27 if the binary speed input is used to acquire a binary state .
Output of binary information
Two relays (K1 and K2) on MFB 1 output binary information.

The relays are activated by MPU 23 or MPU 27.

Relay activation is indicated by LEDs.
Two changeover contacts are available to the user at the terminals of the PIM.
The two changeover contacts are connected in parallel to reduce contact loading.
The 24 VDC output (depending on PIM supply voltage) is used to supply power to electronic transmitters or sensors.

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178 Functional Description

Connection assignment
Relationship between MFB 1 and the terminals of the PIM.

Terminal Designation

n01 Input for analog speed signal 1

n02 Input for analog speed signal 1

n03 Positive input of binary speed signal 1

n04 Negative input of binary speed signal 1

n05 Input for analog speed signal 2

n06 Input for analog speed signal 2

n07 Positive input of binary speed signal 2

n08 Negative input of binary speed signal 2

n09 Output +24 VDC

n10 Ground for output +24 VDC

n11 Relay K1: NC contact

n12 Relay K1: NO contact

n13 Relay K1: Common connection

n14 Relay K2: Common connection

n15 Relay K2: NO contact

n16 Relay K2: NC contact

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MFB – Purpose and Structure 179

20.2 MFB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.040

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

70

Power consumption (24 VDC) mA Less than

35 and
output
current
for the 24
VDC
output
(config-
uration-
depen-
dent)

Power loss mW Less than

750

Analog inputs

Term Unit Value

Input voltage range

Tachogenerator VAC Ueff < 80

Inductive sensor VDC −36 < U <

+36

Input sensitivity 1 Vpp 1

Input sensitivity 2 Vpp 4 (config-

urable by
MPU 23 or
MPU 27)

Input resistance kW Min. 24

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180 Functional Description

Term Unit Value

Measuring range Hz 0.1- 12000

(Fre-
quencies
greater
than
750 are
acquired
by a 10:1
prescaler.)

Electrical isolation Yes, with

optocou-
pler

Input filter kHz fg = 7.3

low-pass
(RC) with
6 dB/decade

Binary inputs

Term Unit Value

Input voltage range VDC Max. 36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

Sensor connection Two-pole

Electrical isolation Yes, with

optocou-
pler

Input filter kHz fg = 16

low-pass
(RC) with
6 dB/decade

Frequency measuring range Hz 0.1 -

12000

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MFB – Purpose and Structure 181

Term Unit Value

Sampling cycle of binary inputs ms Approx.

50

Cable length for sensor connection m Max. 5

(unshielded)
Max. 50
(shielded)

Binary outputs

Term Unit Value

Switching capacity per relay W Max. 50

Switching current A Max. 2 (at

24 V)

Switching voltage (external) VDC Max. 36

Short-circuit protection A Fuse

(3.15)

Relay actuation cycle ms Max. 10

24 VDC output

Term Unit Value

Output voltage VDC +24

(−50 % to
+30 %),
depending
on the
supply
voltage of
the PIM

Output current A Max. 0.1

Short-circuit protection A Self-

restoring
fuse (0.2)

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182 Functional Description

20.3 Printed circuit board MFB 2

Purpose and structure

Design

1 Component side 7 LED (yellow) "Transistor output 12 LED (yellow) "Binary input
2 Conductor side 2 activated" 1 activated"
3 Plan view 8 LED (yellow) "Transistor output 13 LED (red) "Printed circuit
4 LED (yellow) "Transistor output 1 activated" board RESET"
5 activated" 9 LED (green) "UBATT (+24 VDC) OK"
5 LED (yellow) "Transistor output 10 LED (yellow) "Binary input
4 activated" 3 activated"
6 LED (yellow) "Transistor output 11 LED (yellow) "Binary input
3 activated" 2 activated"

Use
MFB 2 is only used in a PIM 4 (with LMB 2 and MPU 29). Operation with MPU 23 or MPU 27 is not possible.
MFB 2 has been specially designed for connection of a "Rexroth" command unit.
Features
• Analog inputs
• Two independent analog channels for acquisition of potentiometers
• Cabling damage and sensor monitoring
• High resolution with 12-bit A/D converter
• EMC protection filter
• Binary inputs
• Three electrically isolated binary inputs
• Wide input voltage range (8 VDC to 36 VDC)

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MFB – Purpose and Structure 183

• Constant input current over the entire input voltage range

• Reverse-battery protection
• Status indication of each binary channel by LEDs (yellow)
• EMC protection filter
• Binary outputs
• Output of binary information by five transistor output stages (positive switching)
• Output current monitoring and limitation
• Electrical isolation of output stage circuit by optocoupler
• Indication of transistor switching states by LEDs (yellow)
• EMC protection filter
• Provision of a +UBATT (+24 VDC) voltage for command unit supply
Function
MFB 2 is used to:
• Acquire two potentiometers
• Acquire three binary signals
• Output of five binary signals (transistor output stages, positive switching)
• Provide a supply voltage (+24 VDC, depending on the PIM supply voltage)
Analog inputs
Signal acquisition of potentiometers (voltage divider).
Each analog channel has the following connections:
• Reference voltage output
A reference voltage (UREF = 4.096 VDC, no-load voltage) is provided at this output for potentiometer connection.
• Voltage input
The divider voltage of the potentiometer (slide) is tapped at this input. The divider voltage
UIN lies in the following range: 0 V ≤ UIN ≤ 4.096 V
• Reference potential/base point
The base point of the potentiometer is connected here.

The voltages from each analog channel of all three connections are acquired and digitalized
by the multiplexer of the A/D converter on MFB 2.
Constant sampling of the reference voltage (UREF), divider voltage (UIN) and the voltage at
the base point of the potentiometer (UBP) makes it possible to determine the exact divider
voltage and thus the precise position of the potentiometer.
The measuring method (evaluation of individual voltages) also realizes the cabling
damage and sensor monitoring features.
Binary inputs
Acquisition of binary signals.

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184 Functional Description

Each binary acquisition channel has one input (single-wire technology).

An external power supply or the power supply routed out from MFB 2 is used to control the binary inputs.
The maximum input voltage of a binary input is 36 VDC.
The current which then flows is limited to approx. 4 mA regardless of the external input voltage used.
The following applies to the input voltage (Ui) of the binary channel:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1").
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0").
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range).
The input signal of each binary channel is electrically isolated by an optocoupler. The binary
input signals are interrogated cyclically by MPU 29.
Each binary input is assigned an LED (yellow) which indicates the respective switching state. The
relevant LED lights up when a binary channel is activated (logic "1").
Transistor outputs
MFB 2 is equipped with 5 identical MOS transistor output stages to output binary information.

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MFB – Purpose and Structure 185

The MOS transistor output stages are supplied by the internal power supply (+24 VDC) of MFB 2. The
maximum switching current per binary output must not exceed 100 mA.
The MOS transistor output stages are electrically isolated from the control logic by optocouplers.
The MOS power transistors feature overcurrent protection. The affected output stage is switched
off in case of short circuit at the transistor output.
Switching states of output stage transistors are indicated by LEDs (yellow).
Connection assignment
Signal assignment of connector ST1 on MFB 2.
This connector establishes the electrical connections to the motherboard.

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186 Functional Description

Connection to the signal inputs and outputs of MFB 2 is established via the terminals provided
on the relevant motherboard (e.g. LMB 2).

Pin assignment Designation

ST1-01 Potentiometer 1 high point (UREF1)

ST1-02 Potentiometer 1 slide (UIN1)

ST1-03 Potentiometer 1 base point (UBP1)

ST1-04 Potentiometer 2 high point (UREF2)

ST1-05 Potentiometer 2 slide (UIN2)

ST1-06 Potentiometer 2 base point (UBP2)

ST1-07 Transistor output 1 (positive-switching)

ST1-08 Transistor output 2 (positive-switching)

ST1-09 Transistor output 3 (positive-switching)

ST1-10 Transistor output 4 (positive-switching)

ST1-11 Transistor output 5 (positive-switching)

ST1-12 Binary input 1

ST1-13 Binary input 2

ST1-14 Binary input 3

ST1-15 Positive internal operating voltage (+UBATT)

ST1-16 Internal operating voltage ground (GNDBATT)

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MFB – Purpose and Structure 187

20.4 MFB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.030

Supply voltages VDC +5 (±5 %)

from
MPU 23
or MPU 27
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

20

Power consumption (24 VDC) mA Less than

12 and
output cur-
rent for
the 24
VDC out-
put (con-
figuration-
depen-
dent)

Power loss mW Less

than 400
(without
transistor
outputs)

Analog inputs / potentiometer inputs

Term Unit Value

A/D converter

Resolution Bit 12

Measuring error % Less

than 0.5
absolute
(without
sensor)

Measuring range UIN VDC 0 ≤ UIN ≤

4.096

Source resistance kΩ 1 ≤ R ≤ 10

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188 Functional Description

Term Unit Value

Input filter (MUX inputs) Hz fg =

220, RC
low-pass
with
6 dB/decade

Sampling rate Hz fg > 10

Electrical isolation No

Internal reference voltage source

Reference voltage VDC UREF =

4.096
(idle)

Max. output current per channel mA IREF ≤ 5

Monitoring

Sensor monitoring Yes

Cable damage monitoring Yes

Binary inputs

Term Unit Value

Input voltage range VDC Less than

36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

Sensor connection Single

pole (ref-
erenced to
GNDBATT)

Electrical isolation Yes, with

optocou-
pler

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MFB – Purpose and Structure 189

Term Unit Value

Input filter kHz fg = 16

low-pass
(RC) with
6 dB/decade

Cable length for sensor connection m Max. 5

(unshielded)
Max. 50
(shielded)

Transistor outputs

Term Unit Value

Switching voltage (+UBATT) VDC Nominal

+24
(depend-
ing on
the power
supply of
LMB).

Switching current per output mA Max. 100

Short-circuit protection Electronic

monitoring

Electrical isolation Yes,

between
output
stage
circuit and
control
logic

Power supply output

Term Unit Value

Output voltage (+UBATT) VDC Nominal

+24
(depend-
ing on
the power
supply of
LMB).

Output current mA Max. 200

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MOB – Purpose and Structure 191

21 MOB – Purpose and Structure

21.1 Printed circuit board MOB 1

Purpose and structure

Design

1 Component side 6 LED (yellow) "Output stage 9 LED (green) "Current regulation
2 Conductor side B active" output stage A/B active"
3 Plan view 7 LED (yellow) "Output stage
4 LED (yellow) "Output stage A active"
D active" 8 LED (green) "Current regulation
5 LED (yellow) "Output stage output stage C/D active"
C active"

Use
MOB 1 is only used in a PIM 1 (with COB 1 and MPU 23) or in a PIM 2 (with COB 3 and MPU 23).
Operation with MPU 27 is not possible.
Features
• Transistor output stages for inductive loads, e.g.:
• Control of stepper motors (unipolar or bipolar)
• Control of DC motors in full-bridge operation
• Control of DC motors in half-bridge operation
• Dynamic control of solenoid valves
• Static control of solenoid valves (positive and ground switching)

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192 Functional Description

• Control and monitoring of output stage transistors by single-chip processor (68HC711) with HCMOS technology
• Electrical isolation between control electronics and output stage transistors
• All outputs equipped with guard circuits against inductive voltage peaks
• Output current monitoring and limitation for transistor output stages
• Operating voltage of output stages supplied separately
• Status indication by LEDs
• EMC protection filter
Function
MOB 1 has four complementary transistor output stages(A, B, C and D), controlled by a type 68HC711 microcontroller.
All transistor output stages feature overvoltage and overcurrent guard circuits. The overvoltage protection
allows direct connection of inductive loads (e.g. electric motors, relays, solenoid valves etc.).
The overcurrent guard circuit switches off the output stage concerned for the duration of a short circuit.
Current regulation (max. 2 A) of inductive loads is only possible when connected at terminals 1 and 3 / 15 and 13.
The operating voltages for the transistor output stages A/B and C/D are supplied separately for each pair of
output stages (+UAB and +UCD). Separate supply of the operating voltage and electrical isolation of the power
circuit from the control electronics allow consumers to be operated in different supply networks.
The operating voltage for the relevant transistor output stage is filtered by filter module FIM 1 prior to supply.

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 Ext. cabling

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MOB – Purpose and Structure 193

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 Ext. cabling

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 Ext. cabling

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194 Functional Description

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 Ext. cabling
Various applications may be set by the software by using a microcontroller on MOB 1.
The transistor output stages may be configured as full-bridge, half-bridge and static transistor outputs by the software.
The following applications are thus possible:
• Control of a bipolar stepper motor
• Control of a unipolar stepper motor
• Control of two DC motors by full-bridging
• Dynamic control of two solenoid valves by half-bridging and static control of two loads by
positive or ground switching transistor output stages

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MOB – Purpose and Structure 195

Connection assignment
Relationship between printed circuit board MOB 1 and the terminals of the PIM.

Terminal Designation

n01 Power output stage B

n02 Power output stage A

n03 Current regulation compensation output stages A and B

n04 Low output output stage B

n05 Low output output stage A

n06 Negative operating voltage (GNDAB) of output stages A and B (internally

connected to terminal n08!)

n07 Supply of positive operating voltage (+UAB) for output stages A and B

n08 Supply of negative operating voltage (GNDAB) for output stages A and B

n09 Supply of positive operating voltage (+UCD) for output stages C and D

n10 Supply of negative operating voltage (GNDCD) for output stages C and D

n11 Low output output stage C

n12 Negative operating voltage (GNDCD) of output stages C and D (internally

connected to terminal n10!)

n13 Current regulation compensation output stages C and D

n14 Low output output stage D

n15 Power output stage D

n16 Power output stage C

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196 Functional Description

21.2 MOB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.034

Supply voltages VDC +5 (±5 %)

from
MPU 23
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

80

Power loss mW Less than

1000
(load-
depen-
dent).

Microcontroller Byte 68HC711 E9

(8 MHz)
with
512 EEPROM
768 RAM

Memory Kbyte 12 EPROM

Power circuit

Term Unit Value

External operating voltage (+UEXT) VDC +16 - +32

(via filter
module
FIM 1)

Output current (IEXT) per output stage A Max. 2

(sum of
all output
stages
max. 4 A)

Current regulation tolerance mA ±20

Short-circuit protection Yes,

electronic
monitoring

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MOB – Purpose and Structure 197

Term Unit Value

Electrical isolation Yes,

between
output
stage
circuit and
control
logic,
between
output
stage
pairs A/B
and C/D.

PWM adjustment range % 0 - 100

PWM resolution Bit 16

PWM frequency range Hz 100 - 2000

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198 Functional Description

21.3 Printed circuit board MOB 2

Purpose and structure

Design

1 Component side 5 LED (yellow) "Output stage 8 LED (green) "Ext. power supply
2 Conductor side C active" output stage C/D OK"
3 Plan view 6 LED (yellow) "Output stage 9 LED (green) "Ext. power supply
4 LED (yellow) "Output stage B active" output stage A/B OK"
D active" 7 LED (yellow) "Output stage 10 LED (red) "Printed circuit
A active" board RESET"

Use
MOB 2 is only used in a PIM 5 (with COB 17 and MPU 27) or in a PIM 3 (with COB 5 and MPU 27).
Features
• Four complementary transistor output stages for inductive loads, e.g.:
• Control of two DC motors
• Dynamic control of solenoid valves
• Static control of solenoid valves (positive and ground switching)
• Control and monitoring of output stage transistors
• Electrical isolation between control electronics and output stage transistors
• All outputs equipped with guard circuits against inductive voltage peaks
• Output current monitoring and limitation for transistor output stages
• Output current limitation is configurable for applications with current regulation (50 mA to max. 2 A)
• Operating voltage of output stages supplied separately
• Status indication by LEDs

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MOB – Purpose and Structure 199

• EMC protection filter

Function
MOB 2 has four complementary transistor output stages (A, B, C and D), controlled by a microcontroller.
All transistor output stages feature overvoltage and overcurrent guard circuits. The overvoltage protection
allows direct connection of inductive loads (e.g. electric motor, relays, solenoid valves).
The overcurrent guard circuit switches off the output stage concerned for the duration of a short circuit.
Each complementary transistor output stage A/B or C/D features current regulation (max. 2 A) for inductive
loads. Current regulation is only possible when connected at the appropriate terminals.
The operating voltages for the transistor output stages A/B and C/D are supplied separately for each pair of
output stages (+UAB and +UCD). Separate supply of the operating voltage and electrical isolation of the power
circuit from the control electronics allow consumers to be operated in different supply networks.
The operating voltage for the relevant transistor output stage is filtered by filter module FIM 1 prior to supply.

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 External cabling

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 External cabling

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200 Functional Description

The two inductive loads must be connected either positive or ground switching at each complementary
transistor output stage (A/B or C/D). Mixed operation (one load positive-switching, the other load
negative-switching) is not possible in a complementary transistor output stage.

1 Output stage A
2 Output stage B
3 Output stage C
4 Output stage D
5 Ext. cabling
Each complementary transistor output stage has just one current regulation stage; for
A/B the B-stage, for C/D the D-stage.
Various applications may be set by the software by using a microcontroller on MOB 2.
The transistor output stages may be configured as full-bridge, half-bridge and static transistor outputs by the software.
The following applications are thus possible:
• Control of two DC motors by full-bridging
• Dynamic control of two solenoid valves by half-bridging and static control of two loads by
positive or ground switching transistor output stages

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MOB – Purpose and Structure 201

Connection assignment
Relationship between printed circuit board MOB 1 and the terminals of the PIM.

Terminal Designation

n01 Power output stage B

n02 Power output stage A

n03 Current regulation compensation output stages A and B

n04 Low output output stage B

n05 Low output output stage A

n06 Negative operating voltage (GNDAB) of output stages A and B (internally

connected to terminal n08!)

n07 Supply of positive operating voltage (+UAB) for output stages A and B

n08 Supply of negative operating voltage (GNDAB) for output stages A and B

n09 Supply of positive operating voltage (+UCD) for output stages C and D

n10 Supply of negative operating voltage (GNDCD) for output stages C and D

n11 Low output output stage C

n12 Negative operating voltage (GNDCD) of output stages C and D (internally

connected to terminal n10!)

n13 Current regulation compensation output stages C and D

n14 Low output output stage D

n15 Power output stage D

n16 Power output stage C

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202 Functional Description

21.4 MOB 2 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.034

Supply voltages VDC +5 (±5 %)

from
MPU 27

Power consumption (5 VDC) mA Less than

20

Power loss mW Less than

1000
(load-
depen-
dent).

Power circuit

Term Unit Value

External operating voltage (+UEXT) VDC +24

(−50 %
to +30 %,
via filter
module
FIM 1)

Power consumption (+24 VDC, UEXT) mA Less

than 15
(without
load).

Power loss mW Less

than 360
(without
load).

Output current (IEXT) per output stage A Max. 2

(sum of
all output
stages
max. 4)

Current regulation tolerance mA ±20

Short-circuit protection Yes, elec-

tronic
monitor-
ing.

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MOB – Purpose and Structure 203

Term Unit Value

Electrical isolation Yes,

between
output
stage
circuit and
control
logic
between
output
stage
pairs A/B
and C/D.

PWM adjustment range % 0 - 100

PWM frequency range Hz 10 - 1500

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204 Functional Description

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SAB – Purpose and Structure 205

22 SAB – Purpose and Structure

22.1 Printed circuit board SAB 1

Purpose and structure

Design

1 Component side 5 LED (yellow) "Binary channel 8 LED (yellow) "Relay K2 activated"
2 Conductor side active" 9 LED (yellow) "Relay K3 activated"
3 Plan view 6 LED (yellow) "Transistor output 10 Fuses
4 LED (red) "Cabling damage activated"
binary input" 7 LED (yellow) "Relay K1 activated"

Features
• CAN interface as per ISO 11 898, electrically isolated
• Output of binary information by three relays
• Separate control of relays
• Status indication of relay control by LED (yellow)
• Short-circuit protection for each relay by fuses (F2 to F5)
• High switching capacity (50 W)
• Output of binary information by transistor output stage
• Electrical isolation of output stage circuit by optocoupler
• Separate supply of operating voltage for transistor output stage
• Output current monitoring and limitation
• Status indication of transistor control by LED (yellow)

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206 Functional Description

• Binary input
• Electrically isolated binary input
• Status indication of binary input by LED (yellow)
• Cable damage monitoring of binary channel connecting lines
• Indication of cabling damage by LED (red)
• Wide input voltage range (36 VDC)
• Constant input current (approx. 4 mA) in the input voltage range between 8 VDC and 36 VDC
• EMC protection filter
Function
Binary input
Acquisition of a binary signal.
It is equipped with two inputs (two-wire technology) and is activated by an external voltage.
The maximum input voltage of the binary channel is 36 VDC.
The following applies to the input voltage (Ui) of the binary channel:
• Ui ≥ 8 VDC is interpreted as binary channel activated (logic "1")
• Ui ≤ 4 VDC is interpreted as binary channel deactivated (logic "0")
• 4 VDC v Ui ≤ 8 VDC must be avoided (inadmissible range)

1 33 kΩ (cable damage monitoring)

2 Module housing with SAB 1
3 Binary channel
The input signal of the binary channel is electrically isolated by an optocoupler. The current which then
flows is limited to approx. 4 mA regardless of the external switching voltage used.
The current state of the binary channel is indicated by a status indicator (yellow LED) on SAB 1.
The LED lights up when the binary channel is activated (logic "1").
A resistor (33 kΩ) is connected in parallel to the switching contact to realize cable damage monitoring.
The quiescent current which thus flows is evaluated by a separate optocoupler. The red LED
"Cabling damage binary input" flashes in case of cabling damage.
MOS transistor output stage to output binary information
The external operating voltage of the transistor output stage is connected to the PIM via terminals n12
(+UEXT) and n14 (GNDEXT ) and lies in the range +12 VDC to +36 VDC.
The external operating voltage may be independent of the operating voltage of the PIMs and
is protected by a self-restoring fuse (1.1 A) on SAB 1.
The control electronics are isolated from the output stage circuit by an optocoupler.

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SAB – Purpose and Structure 207

1 self-restoring 1.1 A
2 Module housing with SAB 1
The MOS transistor output stage features the following guard circuits:
• Overvoltage protection
allowing direct connection of inductive loads (e.g. relays etc.).
• Overcurrent protection
switches off the transistor output stage in case of short-circuit.
Relay for output of binary information
SAB 1 is equipped with three relays to output binary information.

1 Fuse 3.15 A

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208 Functional Description

1 Fuse 3.15 A

1 Fuse 3.15 A
Relay activation is indicated by one yellow LED respectively.
The make circuits of the three relays are protected by fuses (3.15 A).

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SAB – Purpose and Structure 209

Connection assignment
Relationship between SAB 1 and the terminals of the PIM.

Terminal Designation

n01 CAN interface: Positive input CAN (H)

n02 CAN interface: Negative input CAN(L)

n03 Ground of CAN controller (GND(CAN1)

n04 Relay K1: Common connection

n05 Relay K1: NO contact K1.2

n06 Relay K1: NO contact K1.1

n07 Relay K2: NC contact

n08 Relay K2: NO contact

n09 Relay K2: Common connection

n10 Relay K3: NO contact

n11 Relay K3: Common connection

n12 Positive external operating voltage (+UEXT)

n13 Transistor output (positive-switching)

n14 Negative external operating voltage (GNDEXT)

n15 Binary channel: Positive binary input

n16 Binary channel: Negative binary input

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210 Functional Description

22.2 SAB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.044

Supply voltages VDC +5 (±5

%) from
MPU 23
+24
(−50 % to
+30 %) via
COB

Power consumption (5 VDC) mA Less than

60

Power consumption (24 VDC) mA Less than

15

Power loss mW Less than

660

CAN interface

Term Unit Value

CAN bus system As per

ISO 11 898

Baud rate kBd 50 to 1000

Electrical isolation Yes, with

optocou-
pler

Transistor output

Term Unit Value

External operating voltage (+UEXT) VDC +12 - +36

Short-circuit protection (+UEXT) A Self-

restoring
fuse (1.1)

Switching current mA Max. 250

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SAB – Purpose and Structure 211

Term Unit Value

Short-circuit protection Electronic

monitoring

Electrical isolation Yes,

between
output
stage
circuit and
control
logic.

Relay outputs

Term Unit Value

Switching capacity per relay W Max. 50

Switching voltage (external) VDC Max. 36

Switching current A Max. 2 (at

24 VDC)

Short-circuit protection A Fuse

(3.15)

Relay switching time ms Max. 10

Relay actuation cycle /s Max. 20

Binary input

Term Unit Value

Input voltage range VDC Less than

36

Input voltage for logic "1" VDC Min. 8

Input voltage for logic "0" VDC Max. 4

Input current for logic "1" mA Approx. 4

Input current for logic "0" mA Max. 1

(for cable
damage
monitor-
ing)

Sensor connection Two-pole

Electrical isolation Yes, with

optocou-
pler

Input filter Low-pass

(RC) with
6 dB/decade

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212 Functional Description

Term Unit Value

Sampling cycle of binary inputs ms Approx.

50

Cable length for sensor connection m Max. 5

(unshielded)
twisted.
Max. 50
(shielded)
twisted.

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ROB – Purpose and Structure 213

23 ROB – Purpose and Structure

23.1 Printed circuit board ROB 1

Purpose and structure

Design

1 Component side 7 LED (green) "Relay input for

2 Conductor side K4 activated"
3 Plan view 8 LED (green) "Relay input for
4 LED (green) "Relay input for K5 activated"
K1 activated" 9 LED (green) "Relay input for
5 LED (green) "Relay input for K6 activated"
K2 activated" 10 LED (green) "Relay input for
6 LED (green) "Relay input for K7 activated"
K3 activated"

Use
ROB 1 is not bus-compatible, i.e. it cannot be used in any of the PIMs (PIM 1, PIM 2, PIM 3, PIM 5). ROB 1 is
intended for special applications (e.g. gearbox controllers) featuring a COB which is specially designed for ROB 1.
Features
• 7 different relay switching stages
• Indication of relay switching states by LEDs (green)
• Relay operating voltage from 12 V to 36 V
• All outputs applied to dedicated connector pins

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214 Functional Description

Function
ROB 1 is equipped with 7 different relay stages to output binary information.
Switching states of relays are indicated by LEDs (green).

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ROB – Purpose and Structure 215

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216 Functional Description

Connection assignment
Pin assignment for connecting external systems to the MTU automation system
depends on the COB motherboard used.

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ROB – Purpose and Structure 217

23.2 ROB 1 – Technical data

General

Term Unit Value

Dimensions (H x W x D) mm 59 x 63 x
15

Weight kg 0.050

Binary outputs and inputs

Term Unit Value

Relays K1, K4, K5, K6 and K7

(Relay K5 features four inputs with OR function)

Relay supply VDC +12 - +36

Contacts A 1

Relay K2 and K3 (parallel-connected)

Relay supply VDC +12 - +36

Contacts A 2

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218 Functional Description

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Workshop Manual 219

Workshop Manual

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220 Workshop Manual

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Malfunctions 221

24 Malfunctions

24.1 Troubleshooting

24.1.1 Troubleshooting – LEDs on printed circuit boards

The troubleshooting table below allows faults to be pinpointed when they are not
indicated by the display or alarm systems.
Applicable to all troubleshooting activities:
• Various fuses always protect certain sections. Always check whether one of these
fuses is faulty before taking further action.
• The system incorporates numerous self-restoring fuses. Always switch the system off, wait five
minutes and then switch back on first before continuing troubleshooting.

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222 Workshop Manual

LED indicators on COB 17 / COB 1 and COB 5 / COB 3

1 LED (green) "Power supply

(+24 V DC)"

Symptom Meaning Action

LED Power supply of PIM (+24 V) missing Check supply

"Power
supply
(+24
VDC)"
dark

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Malfunctions 223

LED indicators on MPU 23 / 27

1 LED (green) "Power supply (+5 V)"

2 LED (red) "Processor reset/fault"
3 LED (yellow) "Data receive on CAN1 or CAN2"
4 LED (yellow) "Data transmit on CAN1 or CAN2"
5 LED (yellow) "CAN 2 communication"
6 LED (yellow) "CAN 1 communication"

Symptom Meaning Action

LED Power supply of PIM (+24 V) missing Check supply

"Power
supply Self-restoring fuse on COB 1 / 17 or COB 3 / 5 tripped 1. Switch off power supply.
(+5 V)" 2. Wait 30 seconds.
dark 3. Switch on power supply.

COB 1 / 17 or COB 3 / 5 faulty Replace PIM

Mechanical fault in PIM basic module

Power supply of MPU 23 (+5 V) faulty Replace MPU 23 / 27

LED "Pro- Program or processor fault 1. Switch power supply on/off;

cessor 2. Replace MPU 23 / 27;
reset/fault" 3. Contact Service
lit

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224 Workshop Manual

LED indicators on AIB 1 / 3

1 LED (green) "Power supply (±12 V)"

2 LED (red) "Printed circuit board RESET"
3 LED (yellow) order-specific configuration
4 LED (yellow) order-specific configuration
5 LED (yellow) order-specific configuration
6 LED (green) "Power supply (+15 V)"
7 LED (green) "Power supply (−15 V)"

Symptom Meaning Action

LED Power supply of PIM (+24 V) missing. Check supply.

"Power
supply Self-restoring fuse on COB 1 / 17 or COB 3 / 5 tripped. 1. Switch off power supply.
(+15 V)" 2. Wait 30 seconds.
dark 3. Switch on power supply.
LED AIB 1 / 3 faulty. Replace AIB 1 / 3.
"Power
supply COB 1 / 17 or COB 3 / 5 faulty Replace PIM.
(−15 V)"
Mechanical fault in PIM basic module.
dark

LED Program or processor fault. 1. Switch power supply on/off;

"Printed 2. Replace MPU 23;
circuit 3. Contact Service
board
RESET" Sensor or sensor cabling faulty. Check sensor or sensor cabling.
lit
AIB 3 faulty. Replace AIB 3.

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Malfunctions 225

LED indicators on BIB 1 / 2

1 LED (yellow) "Channel 1 active"

2 LED (red) "Cabling damage channel 1"
3 LED (yellow) "Channel 2 active"
4 LED (red) "Cabling damage channel 2"
5 LED (yellow) "Channel 3 active"
6 LED (red) "Cabling damage channel 3"
7 LED (yellow) "Channel 4 active"
8 LED (red) "Cabling damage channel 4"
9 LED (yellow) "Channel 5 active"
10 LED (red) "Cabling damage channel 5"
11 LED (yellow) "Channel 6 active"
12 LED (red) "Cabling damage channel 6"
13 LED (yellow) "Channel 7 active"
14 LED (red) "Cabling damage channel 7"
15 LED (yellow) "Channel 8 active"
16 LED (red) "Cabling damage channel 8"

Symptom Meaning Action

LED Power supply of PIM (+24 V) missing. Check supply.

"Channel
0 active" Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
dark, COB 5 tripped. 2. Wait 30 seconds.
although 3. Switch on power supply.
corre-
spond- BIB 1 / 2 faulty. Replace BIB 1 / 2
ing binary
COB 1 or COB 3 / COB 17 or COB 5 faulty; Replace PIM
input is
correctly Mechanical fault in PIM basic module.
activated

LED External power supply for switching contact missing. Check supply
"Cabling
damage Switching contact cabling faulty 1. Check switching contact cabling;
channel 0" Switching contact is faulty. 2. Check switching contact.
lit (applies
only when BIB 1 / 2 faulty. Replace BIB 1 / 2.
external
switching
contact is
jumpered
with a
resistor
(33 kΩ)!)

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226 Workshop Manual

Symptom Meaning Action

All red Power supply (+24 V) for switching contacts missing 1. Switch off power supply.
LEDs as self-restoring fuse on COB 1 or COB 3 / COB 17 or 2. Wait 30 seconds.
("Cabling COB 5 has tripped. 3. Switch on power supply.
damage
channel BIB 2 faulty. Replace BIB 2.
0") lit

LED indicators on BOB 1 / 2 / 3

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Malfunctions 227

1 LED (yellow) "Channel 1 active" 7 LED (yellow) "Channel 4 active" 13 LED (yellow) "Channel 7 active"
2 LED (red) "Cabling damage 8 LED (red) "Cabling damage 14 LED (red) "Cabling damage
channel 1" channel 4" channel 7"
3 LED (yellow) "Channel 2 active" 9 LED (yellow) "Channel 5 active" 15 LED (yellow) "Channel 8 active"
4 LED (red) "Cabling damage 10 LED (red) "Cabling damage 16 LED (red) "Cabling damage
channel 2" channel 5" channel 8"
5 LED (yellow) "Channel 3 active" 11 LED (yellow) "Channel 6 active"
6 LED (red) "Cabling damage 12 LED (red) "Cabling damage
channel 3" channel 6"

Symptom Meaning Action

I/O Power supply of PIM (+24 V) missing. Check supply.

channels
on BOB Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
1/2/3 out COB 5 tripped. 2. Wait 30 seconds.
of order 3. Switch on power supply.
No LED lit, BOB 1/2/3 faulty. Replace BIB 1 / 2.
although
corre- COB 1 or COB 3 / COB 17 or COB 5 faulty. Replace PIM.
sponding
Mechanical fault in PIM basic module.
channels
are acti-
vated

Signal at Fuse tripped: Replace fuse.

NO con- F1 for relay K1;
tacts of
F2 for relay K2;
relay (K1,
K2, K3 or F3 for relay K3;
K4) not F4 for relay K4.1;
switched F5 for relay K4.2;
through,
although BOB 1 faulty. Replace BOB 1.
corre-
spond-
ing LED
"Relay
activated"
is lit

LED External power supply for transistor output stages (+24 Check supply.
"Power V) missing.
supply
(+24 V)" Fuse F1 tripped. Replace fuse.
dark
BOB 2/3 faulty. Replace BOB 2/3.
Transis-
tor out-
put does
not switch
although
corre-
spond-
ing LED
"Transis-
tor acti-
vated" is
lit

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228 Workshop Manual

LED indicators on EGB 1 / FCB 1 / INB 2 / MOB 2 / MFB 1 / SAB 1

1 LED (yellow) "Channel 1 active" 6 LED (red) "Cabling damage 12 LED (red) "Cabling damage
2 LED (red) "Cabling damage channel 3" channel 6"
channel 1" 7 LED (yellow) "Channel 4 active" 13 LED (yellow) "Channel 7 active"
3 LED (yellow) "Data receive on 8 LED (red) "Cabling damage 14 LED (red) "Cabling damage
CAN1 or CAN2" LED (yellow) channel 4" channel 7"
"Channel 2 active" 9 LED (yellow) "Channel 5 active" 15 LED (yellow) "Channel 8 active"
4 LED (red) "Cabling damage 10 LED (red) "Cabling damage 16 LED (red) "Cabling damage
channel 2" channel 5" channel 8"
5 LED (yellow) "Channel 3 active" 11 LED (yellow) "Channel 6 active"

Symptom Meaning Action

EBG 1

LED Power supply of PIM (+24 V) missing Check supply.

"Power
supply
(+12 V)" Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
dark COB 5 tripped. 2. Wait 30 seconds.
3. Switch on power supply.
LED
"Power EGB 1 faulty. Replace EGB 1.
supply
(−12 V)" COB 1 or COB 3 / COB 17 or COB 5 faulty; Replace PIM.
dark Mechanical fault in PIM basic module.

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Malfunctions 229

Symptom Meaning Action

LED Sensor or sensor cabling faulty. Check sensor or sensor cabling.

"Printed
circuit EGB 1 faulty. Replace EGB 1.
board
RESET"
lit

FCB 1

I/O Power supply of PIM (+24 V) missing. Check supply.

channels
on FCB Self-restoring fuse on COB 1 or COB 3 tripped. 1. Switch off power supply.
1 out of 2. Wait 30 seconds.
order 3. Switch on power supply.
No LED lit, FCB 1 faulty. Replace FCB 1.
although
corre- COB 1 or COB 3 faulty Replace PIM.
sponding
Mechanical fault in PIM basic module.
channels
are acti-
vated

Transistor External power supply for transistor output stages (+24 Check supply.
output V) missing.
(T1, T2,
T3 or T4) Self-restoring fuse on FCB 1 tripped. 1. Switch off power supply.
does not 2. Wait 30 seconds.
switch 3. Switch on power supply.

FCB 1 faulty. Replace FCB 1.

Signal at Fuse tripped F1 for relay K1 F2 for relay K2. Replace fuse.
NO con-
tacts of FCB 1 faulty. Replace FCB 1.
relay (K1
or K2 ) not
switched
through,
although
corre-
spond-
ing LED
"Relay
activated"
is lit

INB 2

LED Power supply of PIM (+24 V) missing. Check supply.

"Power
supply (15 Self-restoring fuse on COB 1 or COB 3 tripped. 1. Switch off power supply.
V)" dark 2. Wait 30 seconds.
3. Switch on power supply.

INB 2 faulty. Replace INB 2.

COB 1 or COB 3 faulty Replace PIM.

Mechanical fault in PIM basic module.

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230 Workshop Manual

Symptom Meaning Action

LED INB 2 faulty. Replace INB 2.

"Instru-
ment
outputs
active"
dark

MOB 2

LED Program or processor fault. 1. Switch power supply on/off;

"Printed 2. Replace MPU 23;
circuit 3. Contact Service
board
RESET"
lit

LED "Ext. No power supply at terminal n07. Check supply.

power
supply
output
stage A/B"
dark

LED "Ext. No power supply at terminal n09. Check supply.

power
supply
output
stage
C/D" dark

Con- Power supply of PIM (+24 V) missing. Check supply.

nected
devices Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
not acti- COB 5 tripped. 2. Wait 30 seconds.
vated 3. Switch on power supply.
No LED
"Output
stage
active" lit,
although
corre-
sponding
channels
are acti-
vated

MFB 1

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Malfunctions 231

Symptom Meaning Action

Speed Power supply of PIM (+24 V) missing Check supply.

acquisi-
tion chan- Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
nels on COB 5 tripped. 2. Wait 30 seconds.
MFB 1 out 3. Switch on power supply.
of order
MFB 1 faulty. Replace MFB 1.
No LED lit,
although COB 1 or COB 3 / COB 17 or COB 5 faulty. Replace PIM.
corre-
Mechanical fault in PIM basic module.
sponding
channels
are acti-
vated

LED "+24 Power supply of PIM (+24 V) missing. Check supply.

V output"
dark Self-restoring fuse (F1) on MFB 1 tripped. 1. Switch off power supply.
2. Wait 30 seconds.
3. Switch on power supply.

MFB 1 faulty. Replace MFB 1.

Signal at Fuse tripped F1 for relay K1 F2 for relay K2. Replace fuse.
NO con-
tacts of MFB 1 faulty. Replace MFB 1.
relay (K1
or K2 ) not
switched
through,
although
corre-
spond-
ing LED
"Relay
activated"
is lit

SAB 1

I/O Power supply of PIM (+24 V) missing Check supply.

channels
on SAB Self-restoring fuse on COB 1 or COB 3 / COB 17 or 1. Switch off power supply.
1 out of COB 5 tripped. 2. Wait 30 seconds.
order 3. Switch on power supply.

COB 1 or COB 3 / COB 17 or COB 5 faulty; Replace PIM.

Mechanical fault in PIM basic module.

SAB 1 faulty. Replace SAB 1.

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232 Workshop Manual

Symptom Meaning Action

LED SAB 1 faulty. Replace SAB 1.

"Binary
input
active"
dark,
although
corre-
spond-
ing binary
input is
correctly
activated

LED External power supply for switching contact missing. Check supply.
"Cabling
damage Switching contact cabling faulty • Check switching contact cabling;
binary Switching contact does not switch. • Check switching contact.
input" lit
(applies SAB 1 faulty. Replace SAB 1.
only when
external
switching
contact is
jumpered
with a
resistor
(33 kΩ)!)

Transis- External power supply for transistor output stage (+24 Check supply.
tor out- V) missing.
put does
not switch Self-restoring fuse on SAB 1 tripped. 1. Switch off power supply.
although 2. Wait 30 seconds.
corre- 3. Switch on power supply.
spond-
ing LED SAB 1 faulty. Replace SAB 1.
"Transis-
tor output
activated"
is lit

Signal at Power supply of PIM (+24 V) missing. Check supply.

NO con-
tacts of Fuse tripped F4 for relay K2 F5 for relay K3. Replace fuse.
relay (K2
or K3 ) not SAB 1 faulty. Replace SAB 1.
switched
through,
although
corre-
spond-
ing LED
"Relay
activated"
is lit

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Malfunctions 233

Symptom Meaning Action

NO con- Power supply of PIM (+24 V) missing. Check supply.

tact 1 of
relay K1 Fuse tripped F2 for relay K1 (NO contact 1) F3 for relay Replace fuse.
or NO K1 (NO contact 2).
contact 2
of relay SAB 1 faulty. Replace SAB 1.
K1 does
not switch
signal
through
although
corre-
spond-
ing LED
"Relay
activated"
is lit

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234 Workshop Manual

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Work Descriptions 235

25 Work Descriptions

25.1 Power supply – Check

Wiring fires due to short-circuits.
Damage to components, major material damage!
CAUTION • Ensure that connections do not come into contact with each other.
• When making connections, make sure that polarity of connections is correct.

Main circuit breaker – Switching on/repair.

1. Check that the main circuit breaker is switched on.
Result: Main circuit breaker faulty, replace main circuit breaker.
2. Check cabling.
Result: Cabling faulty, repair cabling (→ Page 240).
3. Tighten screw terminals.

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236 Workshop Manual

25.2 Printed circuit board – Replacement

Preconditions
• Power supply switched off.

Spare parts
Designation / Use Part No. Qty.
Printed circuit board

Replacing a printed circuit board

1. Insert screwdriver in recess (5) and turn.
Result: Module cassette (4) jumps out of locking
device.
2. Remove module cassette (4) from basic module.
3. Insert screwdriver in recess in cover (3) and
press down.
Result: Cover (3) is levered up.
4. Slide printed circuit board (1) out of module
cassette (4) exerting gentle pressure on connector
(2).
5. Insert new printed circuit board in module
cassette (4).
6. Close cover (3).
7. Insert module cassette (4) in basic module.
Result: Module cassette engaged.
8. Check firm seating of module cassette (4) on
top-hat rail (6).
1 Printed circuit board
2 Connector
3 Cover
4 Module cassette
5 Recess
6 Top-hat rail

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Work Descriptions 237

25.3 Fuse – Replacement

Preconditions
• Power supply switched off.

Spare parts
Designation / Use Part No. Qty.
Fuses

Insufficiently protected electric circuits.

Risk of damage to electronic units or fire!
CAUTION • Ensure that fuses are replaced by ones with the same electrical rating.

Replacing a fuse
1. Remove module cassette with affected board from basic module (→ Page 236).
2. Remove printed circuit board (→ Page 236)
3. Extract faulty fuse from board.
4. Insert new fuse in printed circuit board.
5. Install printed circuit board in module cassette (→ Page 236).
6. Install module cassette in basic module (→ Page 236).

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238 Workshop Manual

25.4 PIM – Replacement

Preconditions
• Power supply switched off.
Removing and installing a PIM
1. Note position and terminal number of connecting
wires.
2. Undo terminals and pull out connected wires.
3. Insert screwdriver in recess in holding clips (4) and
lever away from top-hat rail (2).
Result: Top-hat rail disengages.
4. Remove PIM.
Note: Procedure only necessary for replacing
PIMs of type PIM 1 and PIM 2. PIMs of
types PIM 3 and PIM 5 are not equipped
with plugged ICs.

5. Remove module cassettes from old PIM.

6. Program EEPROM in new PIM (Contact Service).
7. Install PIM in reverse order.

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Work Descriptions 239

25.5 PIM – Replacement, screw-mounting

Preconditions
• Power supply switched off.
Removing and installing a PIM
1. Note position of connecting wires.
2. Undo terminals and pull out connected wires.
3. Unscrew screws (2 and 3).
4. Remove PIM (1).
Note: Procedure only necessary for replacing
PIMs of type PIM 1 and PIM 2. PIMs of
types PIM 3 and PIM 5 are not equipped
with plugged ICs.

5. Remove module cassettes from old PIM.

6. Program EEPROM in new PIM (Contact Service).
7. Install PIM in reverse order.

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240 Workshop Manual

25.6 Wiring – Repair

Special tools
Designation / Use Part No. Qty.
Hot-air blower 0005388520 1
Broad nozzle 0005388220 1

Material
Designation / Use Part No. Qty.
Cable ties in different sizes
Self-adhesive insulating tape
Heat-shrinkable hose (of different diameters)

Wiring – Repair
1. Repair brittle or damaged cable insulation, buckled or chafed areas with self-adhesive insulating tape or
heat-shrinkable hose until complete cable replacement.
2. Replace faulty cable (short circuit, torn, broken) entirely or contact MTU Service.
3. Replace faulty cable ties, cable clamps, heat-shrinkable hoses.
4. Check completeness of markings and legibility of inscriptions. Renew marking/inscription if required.

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Appendix 241

Appendix

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242 Appendix

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Appendix 243

26 Appendix

26.1 Conversion tables

Length
Unit A multiplied by factor = Unit B

in 25.4 = mm

ft 0.3048 =m

yd 0.9144 =m

stat. mile 1.609 = km

yd 3 = ft

yd 36 = in

Unit B multiplied by factor = Unit A

mm 0.3937 = in
m 3.281 = ft

km 0.6215 = stat. mile

Area
Unit A multiplied by factor = Unit B

in2 645.16 = mm2

ft2 0.0929 = m2

yd2 0.8361 = m2

stat. mile2 2.5889 = km2

Unit B multiplied by factor Unit A

mm2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2

km2 0.3863 stat. mile2

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244 Appendix

Volume
Unit A multiplied by factor = Unit B

in3 16387 = mm3

ft3 0.02832 = m3

yd3 0.7646 = m3

gallon (US) 3.787 = dm3

gallon (Brit.) 4.546 = dm3

Unit B multiplied by factor = Unit A

cm3 0.06102 = in3
m3 35.31 = ft3

dm3 0.2642 = gallon (US)

dm3 0.22 = gallon (Brit.)

Speed
Unit A multiplied by factor = Unit B

ft/s 0.3048 = m/s

stat. mile/h (mph) 1.609 = km/h

knot (Brit.) 1.852 = km/h

Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s

km/h 0.6215 = stat. mile/h (mph)

km/h 0.54 = knot (Brit.)

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Appendix 245

Mass
Unit A multiplied by factor = Unit B

lb 0.4536 = kg
oz 28.35 =g

ton 1.016 =t

Unit B multiplied by factor = Unit A

g 0.03527 = oz

kg 2.205 = lb

t 0.9843 = ton

Force
Unit A multiplied by factor = Unit B

lb 0.4536 = kp

lb 4.4483 =N

Unit B multiplied by factor = Unit A

kp 2.205 = lb

N 0.101972 = kp

kp 9.80665 =N

Density
Unit A multiplied by factor = Unit B

lb s2/ft4 515.4 = kg/m3

Unit B multiplied by factor = Unit A

kg/m3 0.00194 = lb s2/ft4

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246 Appendix

Torque
Unit A multiplied by factor = Unit B

ft lb 1.3563 = Nm

Unit B multiplied by factor = Unit A

Nm 0.7373 = ft lb

Pressure
Unit A multiplied by factor = Unit B

lb/sq in (psi) 703.1 = kp/m2 (mm WS)

lb/sq in (psi) 0.06895 = bar

lb/sq ft 47.883 = Pa

in QS 0.03386 = bar

in QS 345.3 = kp/m2

Unit B multiplied by factor = Unit A

atm 760 = mm QS

atm 1.0133 = bar

atm 10332 = kp/m2 (mm WS)

atm 1.0332 = kp/cm2 (at)

atm 14.696 = lb/sq in

bar 14.503 = lb/sq in

Mass moment, 2nd grade

Unit A multiplied by factor = Unit B

ft lb s2 1.3563 = kg m2

Unit B multiplied by factor = Unit A

kg m2 0.7373 = ft lb s2

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Appendix 247

Energy
Unit A multiplied by factor = Unit B

ft lb 1.356 =J

kcal 4186.8 =J

BTU 1055 =J

CHU 1899 =J

Unit B multiplied by factor = Unit A

J 0.7376 = ft lb

J 0.0002389 = kcal

J 0.0009479 = BTU

J 0.00052656 = CHU

Power
Unit A multiplied by factor = Unit B

HP (horse power) 0.7355 = kW

HP 0.7457 = kW

BTU/s 1.055 = kW

kcal/h 1.163 =W

HP 550 = ft lb/s

Unit B multiplied by factor = Unit A

kW 1.36 = PS

kW 1.341 = HP

kW 0.9479 = BTU/s

W 0.8598 = kcal/h

ft lb/s 0.0018 = HP

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248 Appendix

Temperature
Celsius Kelvin Fahrenheit Réaumur

x°C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R

xK = x − 273.15 °C = 9/5(x − 273.15) + 32 °F = 4/5 (x − 273.15) °R

x°F = 5/9(x − 32) °C =5/9 (x − 32) + 273.15 = 4/9 (x − 32) °R

K

x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F

Fuel consumption
Unit A multiplied by factor = Unit B

mile/gal (US) 0.4251 = km/l

gal/mile (US) 2.3527 = l/km

Unit B multiplied by factor = Unit A

km/l 2.3527 = mile/gal (US)

l/km 0.4251 = gal/mile (US)

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Appendix 249

26.2 List of abbreviations

Abbrevia- Meaning Explanation

tion

AL Alarm Alarm (general)

ANSI American National Standards Institute Umbrella organization administering and coordinating
U.S. standards

ATL Abgasturbolader Exhaust turbocharger

BR Baureihe Series

CAN Controller Area Network Data bus system, bus standard

CPP Controllable Pitch Propeller

DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche
Industrie-Norm")

DIS Display unit Display panel

DL Default Lost Alarm: Default CAN bus failure

ECS Engine Control System Engine management system

ECU Engine Control Unit Engine governor

EDM Engine Data Module Memory module for engine data

EMU Engine Monitoring Unit

FLS Fluids and Lubricants Specification MTU Publication No. A01061/..

FPP Fixed Pitch Propeller

GCU Gear Control Unit

GMU Gear Monitoring Unit

HI High Alarm: Measured value exceeds 1st maximum limit

HIHI High High Alarm: Measured value exceeds 2nd maximum limit

HT High Temperature

ICFN ISO - Continuous rating - Fuel stop power Power specification in accordance with DIN-ISO 3046-7
- Net

IDM Interface Data Module Memory module for interface data

IMO International Maritime Organization

ISO International Organization for

Standardization

KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204

KS Kraftseite Engine driving end in accordance with DIN ISO 1204

LCD Liquid Crystal Display, Liquid Crystal

Device

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250 Appendix

Abbrevia- Meaning Explanation

tion

LCU Local Control Unit LOP subassembly

LED Light Emitting Diode

LMU Local Monitoring Unit LOP subassembly

LO Low Alarm: Measured value lower than 1st minimum limit

LOLO Low Low Alarm: Measured value lower than 2nd minimum limit

LOP Local Operating Panel

LOS Local Operating Station

MCS Monitoring and Control System

MG Message

MPU Microprocessor Unit, Microprocessing

Unit

OT Oberer Totpunkt Top dead center (TDC)

P-xyz Pressure-xyz Pressure measuring point xyz

PAN Panel Control panel

PCU Propeller Control Unit

PIM Peripheral Interface Module

RCS Remote Control System

RL Redundancy Lost Alarm: Redundant CAN bus failure

SAE Society of Automotive Engineers U.S. standardization organization

SD Sensor Defect Alarm: Sensor failure

SDAF Shut Down Air Flaps Emergency-air shutoff flaps

SPC Spare Parts Catalog

SS Safety System Indicated alarm is initiated by the safety system

SSK Schnellschlussklappe(n) Emergency-air shutoff-flap(s)

T-xyz Temperature-xyz Temperature measuring point xyz

TC Tools Catalog

TD Transmitter Deviation Alarm: Sensor comparison fault

UT Unterer Totpunkt Bottom dead center (BDC)

VS Voith Schneider Voith-Schneider drive

WJ Water Jet Waterjet drive

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Appendix 251

26.3 Index
A INB 3 – Technical data . . . . . . . . . . . . . . . . . . 173
AIB 1 – Technical data . . . . . . . . . . . . . . . . . . 106 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
AIB 2 – Technical data . . . . . . . . . . . . . . . . . . 114
AIB 3 – Technical data . . . . . . . . . . . . . . . . . . 120 L
AIB 4 – Technical data . . . . . . . . . . . . . . . . . . 125 List of abbreviations .................... 249
Auxiliary materials, fire prevention and
environmental protection . . . . . . . . . . . . . . . . . 12
M
Mechanical installation of PIMs, FIMs, DIMs and
B PSMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
BIB 1 – Technical data . . . . . . . . . . . . . . . . . . 130 MFB 1 – Technical data . . . . . . . . . . . . . . . . . 179
BIB 2 – Technical data . . . . . . . . . . . . . . . . . . 134 MFB 2 – Technical data . . . . . . . . . . . . . . . . . 187
BOB 1 – Technical data . . . . . . . . . . . . . . . . . 140 MOB 1 – Technical data . . . . . . . . . . . . . . . . . 196
BOB 2 – Technical data . . . . . . . . . . . . . . . . . 144 MOB 2 – Technical data . . . . . . . . . . . . . . . . . 202
BOB 3 – Technical data . . . . . . . . . . . . . . . . . 148 MPU 23 – Technical data . . . . . . . . . . . . . . . . 58
MPU 27 – Technical data . . . . . . . . . . . . . . . . 63
C
CCB 1 – Technical data . . . . . . . . . . . . . . . . . 66 O
COB 1 – Technical data . . . . . . . . . . . . . . . . . 77 Overview of PIM printed circuit boards ...... 24
COB 17 – Technical data . . . . . . . . . . . . . . . . 96
COB 3 – Technical data . . . . . . . . . . . . . . . . . 81 P
COB 5 – Technical data . . . . . . . . . . . . . . . . . 97 PAB 2 – Technical data . . . . . . . . . . . . . . . . . . 85
Conversion tables . . . . . . . . . . . . . . . . . . . . . . 243 Peripheral Interface Modules (PIMs) . . . . . . . . 17,
19, 21–22
D Personnel and organizational require-
DIM – Technical data . . . . . . . . . . . . . . . . . . . 41 ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Dimmer module 3 . . . . . . . . . . . . . . . . . . . . . . 35 PIM – Replacement . . . . . . . . . . . . . . . . . . . . 238
Display module FCB 2 . . . . . . . . . . . . . . . . . . 99 PIM – Replacement, screw-mounting . . . . . . . 239
PIM – Technical data . . . . . . . . . . . . . . . . . . . 27
Power supply – Check . . . . . . . . . . . . . . . . . . 235
E
Power supply modules . . . . . . . . . . . . . . . . . . 43,
EGB 1 – Technical data ................. 152
47
Printed circuit board – Replacement . . . . . . . . 236
F Printed circuit board AIB 1 . . . . . . . . . . . . . . . 101
FCB 1 – Technical data . . . . . . . . . . . . . . . . . . 91 Printed circuit board AIB 2 . . . . . . . . . . . . . . . 110
FCB 2 – Technical data . . . . . . . . . . . . . . . . . . 100 Printed circuit board AIB 3 . . . . . . . . . . . . . . . 117
Filter module 1 . . . . . . . . . . . . . . . . . . . . . . . . 31 Printed circuit board AIB 4 . . . . . . . . . . . . . . . 122
FIM 1 – Technical data . . . . . . . . . . . . . . . . . . 33 Printed circuit board BIB 1 . . . . . . . . . . . . . . . 127
Fuse – Replacement . . . . . . . . . . . . . . . . . . . . 237 Printed circuit board BIB 2 . . . . . . . . . . . . . . . 131
Printed circuit board BOB 1 . . . . . . . . . . . . . . 137
G Printed circuit board BOB 2 . . . . . . . . . . . . . . 141
General conditions ..................... 07 Printed circuit board BOB 3 . . . . . . . . . . . . . . 145
Printed circuit board CCB 1 . . . . . . . . . . . . . . 65
I Printed circuit board COB 1 . . . . . . . . . . . . . . 75
IIB 1 – Technical data . . . . . . . . . . . . . . . . . . . 156 Printed circuit board COB 17 . . . . . . . . . . . . . 93
INB 1 – Technical data . . . . . . . . . . . . . . . . . . 163 Printed circuit board COB 3 . . . . . . . . . . . . . . 78
INB 2 – Technical data . . . . . . . . . . . . . . . . . . 168 Printed circuit board EGB 1 . . . . . . . . . . . . . . 149

E531439/06E 05-09 © MTU

252 Appendix

Printed circuit board FCB 1 . . . . . . . . . . . . . . . 87 S

Printed circuit board IIB 1 . . . . . . . . . . . . . . . . 153 SAB 1 – Technical data . . . . . . . . . . . . . . . . . . 210
Printed circuit board INB 1 . . . . . . . . . . . . . . . 159 Safety precautions when working on the
Printed circuit board INB 2 . . . . . . . . . . . . . . . 165 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
Printed circuit board INB 3 . . . . . . . . . . . . . . . 170 SCB 2 – Technical data . . . . . . . . . . . . . . . . . . 68
Printed circuit board MFB 1 . . . . . . . . . . . . . . 175 SCB 3 – Technical data . . . . . . . . . . . . . . . . . . 72
Printed circuit board MFB 2 . . . . . . . . . . . . . . 182 SCB 4 – Technical data . . . . . . . . . . . . . . . . . . 74
Printed circuit board MOB 1 . . . . . . . . . . . . . . 191 Standards for warning notices in the
publication . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Printed circuit board MOB 2 . . . . . . . . . . . . . . 198
Printed circuit board MPU 23 . . . . . . . . . . . . . 53
Printed circuit board MPU 27 . . . . . . . . . . . . . 60 T
Printed circuit board PAB 2 . . . . . . . . . . . . . . . 83 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 221
Troubleshooting – LEDs on printed circuit
Printed circuit board ROB 1 . . . . . . . . . . . . . . 213 boards . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Printed circuit board SAB 1 . . . . . . . . . . . . . . . 205 Troubleshooting – LEDs on printed circuit
Printed circuit board SCB 2 . . . . . . . . . . . . . . . 67 boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Printed circuit board SCB 3 . . . . . . . . . . . . . . . 69
Printed circuit board SCB 4 . . . . . . . . . . . . . . . 73 W
PSM – Technical data . . . . . . . . . . . . . . . . . . . 45, Wiring – Repair . . . . . . . . . . . . . . . . . . . . . . . . 240
49

R
ROB 1 – Technical data ................. 217

E531439/06E 05-09 © MTU

Parts catalog

Parts catalog

E531439/06E © MTU
Preface 1

Preface
This catalog is published for parts requisitioning purposes and provides assistance in engine disassembly and
reassembly. It contains a complete list of all engine components, including those which are not available as
replacement parts.

Illustrations
- The page heading includes a five-digit illustrated table number and, in the second section, an additional
illustration registration number.

Explanation of Columns
- C/N (Callout No.): Provides a cross-reference from illustration to text section. Non-illustrated parts are indicated
by the suffix „Z“ after the C/N.
- Part No.: This is the number valid for ordering the associated part.
- Designation: In addition to the precise part name, this column provides indication as to whether it is a single
part, or an element of an assembly or functional group. An indented designation indicates the part concerned is
included in the previous less or non-indented designation.
- Q/U (Quantity in Unit): This column indicates the quantity of this part required for the functional group. Qty. „0“
indicates part is replaced by an SA or KW part or that it is a repair stage component.
- U/M (Unit of Measure): The 2-character codes indicate: EA = each, KG = Kilogramm, MR = Meter, RL = Roll,
SE = Set.
- FN (Footnote): Provides additional parts information. The codes have the following meaning:
AB Supplied as a complete assembly. Repair by manufacturer only.
KE Individual parts not obtainable through the parts supply system
KF Calibrated part. For ordering, observe “Ordering Procedure” as described below.
NB As required

- Supplementary Designation: This column contains additional information, such as applicable standards,
subcontractor designations etc.
- Item No.: This is the line identification number within the parts group.
- Remarks: This column is intended for supplementary information.

Amendments Service
Part No. Changes and amendments which occur after publication of the catalog will not be published. We therefore
recommend updating of the catalog part numbers by the end user. This information is provided, for instance, in
order confirmations and/or on equipment labels.

Cross-reference List
A cross-reference list is published in association with this catalog which provides a consecutively numbered
reference to all parts listed in the catalog and their location on/in the engine. The list appears at the end of the
catalog.

EK175E - 02.02 - © MTU

2 Preface

Ordering Procedure
The following information is essential for replacement order processing:
- Order number
- MTU serial number and type (see engine name plate)
- Part number
- Designation
- Quantity and unit of measurement
- Unit designation (e.g. A056)

When ordering a calibrated part (marked by "KF" in the "FN" column), add the following additional information:

If the calibration No. is known (see part's nameplate):

Add the calibration No., preceded by an oblique stroke, as an extension to the part number ("/xxxxx"); e.g.: 002 536
28 10/E1234.
Here, the extension "E1234" would be the part's calibration number on the nameplate.

If the calibration No. is not known:

Give a detailed description of the required part's installation location by quoting the complete Device Description
code (e.g. "= 37.1.1 + A022 - F003") plus the part number extension "/77" (e.g. 500 536 28 10/77).
In this case, the calibrated spare part will be supplied under a new part number. The Device Description is found on
the nameplate at the part's installation location, or in the corresponding Wiring Diagram.

When ordering a non-calibrated adjustable part (marked by "KF" in the "FN" column) which should not be
calibrated by the factory:
Add extension "/76" to the part number (e.g. 002 536 28 10/76).

To avoid errors, please confirm all telephone orders in writing.

Factory Repairs

Parts shipped to MTU for repair should have MTU order No. and engine serial number identification (tag or label,
for example).

Exchange Components (Reman)

Exchange components are parts overhauled by the manufacturer, providing the same properties with regard to
service life and quality as new parts.
Components which are included in the reman exchange procedure are marked by the following letters added
before the item number:
for instance: E 524 010 3520 = new component in exchange procedure
R 524 010 3520 = reman component in exchange procedure
C 524 010 3520 = used part (core)

Exchange Procedure
With the introduction of exchange components, the so-called core deposit will also be charged for new parts. The
core deposit will be indicated separately on the invoice and the respective value will be credited upon return of
reusable components.
For further information refer to Service Information 01/S0028.

© MTU EK175E - 02.02 -

 511 00
00237A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00237A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

01 528 530 22 83/76 ZB MODUL PIM 1-04 1 EA AB 510002

MODULAR SYSTEM
02 528 530 19 83/76 ZB MODUL PIM 2-03 1 EA AB 510004
MODULAR SYSTEM
03 528 530 06 83 ZB MODUL MCS-5/PIM 3 1 EA KF 510006
MODULAR SYSTEM
04 528 530 26 83 ZB MODUL MCS-5/PIM 5 1 EA 510008
MODULAR SYSTEM
05 529 530 93 12 ZB STECKK. AIB 1-02 1 EA 510010
PLUG-IN BOARD
06 529 530 39 12 ZB STECKK. AIB 2-02 1 EA 510012
PLUG-IN BOARD
07 529 530 38 12 ZB STECKK. AIB 3-02 1 EA 510014
PLUG-IN BOARD
08 529 530 49 12 ZB STECKK. AIB 4-01 1 EA AB 510016
PLUG-IN BOARD

- 1 -
EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00237A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

09 529 530 88 12 ZB STECKK. BIB 1-02 1 EA 510018

PLUG-IN BOARD
10 504 530 08 97 ZB STECKK. BIB 2-01 1 EA 510020
PLUG-IN BOARD
11 504 530 78 92 ZB STECKK. CCB 1-01 1 EA 510022
PLUG-IN BOARD
12 504 530 74 92 ZB STECKK. EGB 1-01 1 EA 510024
PLUG-IN BOARD
13 504 530 98 92 ZB STECKK. IIB 1-01 1 EA 510026
PLUG-IN BOARD
14 504 530 32 97 ZB STECKK. INB 1-01 1 EA 510028
PLUG-IN BOARD
15 504 530 54 97 ZB STECKK. INB 2-01 1 EA 510030
PLUG-IN BOARD
16 529 530 82 12/76 ZB STECKK.MPU 23-03 1 EA AB 510032
PLUG-IN BOARD
17 5295308212/S0001 ZB STECKK.MPU 23-03 1 EA 510034
PLUG-IN BOARD
18 529 530 68 12 ZB STECKK. MPU 27-01 1 EA KF 510036
PLUG-IN BOARD
19 5295305912/S0003 ZB STECKK. MOB 1-02 1 EA AB 510038
PLUG-IN BOARD
20 504 530 68 97 ZB STECKK. PAB 2-01 1 EA AB 510040
PLUG-IN BOARD
21 504 530 77 92 ZB STECKK. SCB 2-01 1 EA 510042
PLUG-IN BOARD
22 504 530 89 92 ZB STECKK. SCB 3-01 1 EA 510044
PLUG-IN BOARD
23 504 530 56 97 ZB STECKK. SCB 4-01 1 EA 510046
PLUG-IN BOARD
24 529 530 86 12 ZB STECKK. BOB 1-02 1 EA 510048
PLUG-IN BOARD
25 529 530 95 12 ZB STECKK.BOB 1-02/A 1 EA 510050
PLUG-IN BOARD
26 529 530 87 12 ZB STECKK BOB 2-02 1 EA AB 510052
PLUG-IN BOARD
27 504 530 39 97 ZB STECKK. BOB 3-01 1 EA 510054
PLUG-IN BOARD
28 529 530 05 13 ZB STECKK.FCB 1-01/A 1 EA 510056
PLUG-IN BOARD
29 529 530 04 13 ZB STECKK.MFB 1-01/A 1 EA 510058
PLUG-IN BOARD
30 529 530 89 12 ZB STECKK. SAB 1-02 1 EA 510060
PLUG-IN BOARD

- 2 -
EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00237A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

31 529 530 90 12 ZB STECKK. INB 3-01 1 EA 510062

PLUG-IN BOARD
32 529 530 91 12 ZB STECKK. MFB 2-01 1 EA 510064
PLUG-IN BOARD
33 529 530 10 13 ZB STECKK.MOB 2-01 1 EA 510066
PLUG-IN BOARD
34Z 526 530 99 12 ZB STECKK.ROB 1-01 1 EA 510068
PLUG-IN BOARD

- 3 -
- 4 -
 511 00
00242A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00242A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

504 530 39 97 ZB STECKK. BOB 3-01 1 EA 510070

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 1 EA 510072
.FUSE

- 5 -
- 6 -
 511 00
K0119A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : K0119A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

529 530 04 13 ZB STECKK.MFB 1-01/A 1 EA 510074

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 2 EA 510076
.FUSE

- 7 -
- 8 -
 511 00
00238A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00238A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

529 530 05 13 ZB STECKK.FCB 1-01/A 1 EA 510078

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 2 EA 510080
.FUSE

- 9 -
- 10 -
 511 00
K0102A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : K0102A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

529 530 87 12 ZB STECKK BOB 2-02 1 EA AB 510082

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 1 EA 510084
.FUSE

- 11 -
- 12 -
 511 00
00239A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00239A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

529 530 89 12 ZB STECKK. SAB 1-02 1 EA 510086

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 4 EA 510088
.FUSE

- 13 -
- 14 -
 511 00
K0063A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : K0063A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

529 530 95 12 ZB STECKK.BOB 1-02/A 1 EA 510090

PLUG-IN BOARD
01 001 531 76 86 .SICHERUNG 3,15A/F 5 EA 510092
.FUSE

- 15 -
- 16 -
 511 00
00240A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00240A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

01 510 538 42 75 ZB DISPLAY FCB 1 EA 510094

TERMINAL
02 528 530 25 83 ZB MODUL PIM 3-FCB 1 EA AB 510096
MODULAR SYSTEM
03 528 530 27 83 ZB MODUL PIM 5-FCB 1 EA 510098
MODULAR SYSTEM

- 17 -
- 18 -
 511 00
00241A

EDITION : 07.03 GAPL 511 ALARMANLAGE CATALOG : E531439/06DE

EGC : 511 ALARM SYSTEM ILLUST.TABLE: 511 00

PROJECT EABR GA/SA/KW : 069.700063/92 REG.NO. : 00241A

ORTZ BESTELLNUMMER BENENNUNG STO BZEH FN ZUSATZBEZ./SUPPLEMENTARY DESIGNATION POS.-NR.

C/N PART NO. DESIGNATION Q/U U/M FN BEMERKUNG / REMARKS ITEM

01 528 530 21 83 ZB FILTERMOD.FIM1-02 1 EA 510100

MODULAR SYSTEM
02 526 530 21 13 ZB STECKK DIM 3-01/A 1 EA 510102
PLUG-IN BOARD
03 529 530 44 12 ZB MODUL PSM 3-01 1 EA KF 510104
MODULAR SYSTEM
04 529 530 94 12 ZB MODUL PSM 3-01/A 1 EA AB 510106
PLUG-IN BOARD

- 19 -
- 20 -
Technical Publication

Querverweisliste von MTU-

Bestellnummern zum Ortsvorkommen
im Ersatzteil-Katalog, mit englischen
Benennungen

Cross-reference list of MTU order

numbers included in the Spare Parts
Catalog, with English designations
Vorwort
Diese Querverweisliste ist in Teil 1 und Teil 2 unterteilt.

Teil 1:
• Enthält alle Bestellnummern, die im Ersatzteilkatalog enthalten sind und ist somit ein nach Bestellnummern
geordnetes Inhaltsverzeichnis.
• Die Bestellnummern sind in der linken Spalte in steigender Nummernfolge aufgeführt.
• Bildtafel, Registriernummer, Ortszahl geben an, an wieviel Einbaustellen dieses Bauteil vorkommt.
• In der Spalte Benennung ist die Bauteilbenennung in die entsprechende Sprache übersetzt.
• Bei Bestellnummernänderungen sind in der rechten Spalte die aktuellen Bestellnummern angedruckt.

Teil 2:
• Enthält alle aktualisierten Bestellnummern.
• Die Bestellnummern sind in der rechten Spalte in steigender Nummernfolge aufgeführt.

Preface
This cross-reference list is divided into Part 1 and Part 2.

Part 1:
• Part 1 is a listing of all Order Numbers contained in the spare parts catalog and provides a Catalog Index set
up on an order number basis.
• Order Numbers appear in the left-hand column in numerical sequence.
• Table, Registration and Callout Nos. are provided to locate the part in the catalog.
• The Designation column indicates the part’s name.
• New Order Numbers appearing in the right-hand column are numbers resulting from an order number change.

Part 2:
• Part 2 is a listing of all updated Order Numbers.
• The right-hand column contains all new Order Numbers in numerical sequence.
Teil 1
Part 1
 Q U E R V E R W E I S L I S T E
C R O S S - R E F E R E N C E L I S T
CATALOG E531439/06DE PROJECT : EABR EDITION : 07.03 SHEET : 1

PART NO. DESIGNATION ILL. REG.NO C/N PART NO NEW

TABLE

001 531 76 86 FUSE 511-00 K0102A 01

SICHERUNG 3,15A/F K0119A 01
00238A 01
00242A 01
00239A 01
K0063A 01
504 530 08 97 PLUG-IN BOARD 511-00 00237A 10
ZB STECKK. BIB 2-01
504 530 32 97 PLUG-IN BOARD 511-00 00237A 14
ZB STECKK. INB 1-01
504 530 39 97 PLUG-IN BOARD 511-00 00237A 27
ZB STECKK. BOB 3-01 00242A 000
504 530 54 97 PLUG-IN BOARD 511-00 00237A 15
ZB STECKK. INB 2-01
504 530 56 97 PLUG-IN BOARD 511-00 00237A 23
ZB STECKK. SCB 4-01
504 530 68 97 PLUG-IN BOARD 511-00 00237A 20
ZB STECKK. PAB 2-01
504 530 74 92 PLUG-IN BOARD 511-00 00237A 12
ZB STECKK. EGB 1-01
504 530 77 92 PLUG-IN BOARD 511-00 00237A 21
ZB STECKK. SCB 2-01
504 530 78 92 PLUG-IN BOARD 511-00 00237A 11
ZB STECKK. CCB 1-01
504 530 89 92 PLUG-IN BOARD 511-00 00237A 22
ZB STECKK. SCB 3-01
504 530 98 92 PLUG-IN BOARD 511-00 00237A 13
ZB STECKK. IIB 1-01
510 538 42 75 TERMINAL 511-00 00240A 01
ZB DISPLAY FCB
526 530 21 13 PLUG-IN BOARD 511-00 00241A 02
ZB STECKK DIM 3-01/A
526 530 99 12 PLUG-IN BOARD 511-00 00237A 34Z
ZB STECKK.ROB 1-01
528 530 06 83 MODULAR SYSTEM 511-00 00237A 03
ZB MODUL MCS-5/PIM 3
528 530 19 83/76 MODULAR SYSTEM 511-00 00237A 02
ZB MODUL PIM 2-03
528 530 21 83 MODULAR SYSTEM 511-00 00241A 01
ZB FILTERMOD.FIM1-02
528 530 22 83/76 MODULAR SYSTEM 511-00 00237A 01
ZB MODUL PIM 1-04
528 530 25 83 MODULAR SYSTEM 511-00 00240A 02
ZB MODUL PIM 3-FCB
528 530 26 83 MODULAR SYSTEM 511-00 00237A 04
ZB MODUL MCS-5/PIM 5
528 530 27 83 MODULAR SYSTEM 511-00 00240A 03
ZB MODUL PIM 5-FCB
529 530 04 13 PLUG-IN BOARD 511-00 00237A 29
ZB STECKK.MFB 1-01/A K0119A 000
529 530 05 13 PLUG-IN BOARD 511-00 00237A 28
ZB STECKK.FCB 1-01/A 00238A 000
529 530 10 13 PLUG-IN BOARD 511-00 00237A 33
ZB STECKK.MOB 2-01
529 530 38 12 PLUG-IN BOARD 511-00 00237A 07
ZB STECKK. AIB 3-02
529 530 39 12 PLUG-IN BOARD 511-00 00237A 06
ZB STECKK. AIB 2-02
529 530 44 12 MODULAR SYSTEM 511-00 00241A 03
ZB MODUL PSM 3-01
529 530 49 12 PLUG-IN BOARD 511-00 00237A 08
ZB STECKK. AIB 4-01
5295305912/S0003 PLUG-IN BOARD 511-00 00237A 19
 Q U E R V E R W E I S L I S T E
C R O S S - R E F E R E N C E L I S T
CATALOG E531439/06DE PROJECT : EABR EDITION : 07.03 SHEET : 2

PART NO. DESIGNATION ILL. REG.NO C/N PART NO NEW

TABLE

ZB STECKK. MOB 1-02

529 530 68 12 PLUG-IN BOARD 511-00 00237A 18
ZB STECKK. MPU 27-01
5295308212/S0001 PLUG-IN BOARD 511-00 00237A 17
ZB STECKK.MPU 23-03
529 530 82 12/76 PLUG-IN BOARD 511-00 00237A 16
ZB STECKK.MPU 23-03
529 530 86 12 PLUG-IN BOARD 511-00 00237A 24
ZB STECKK. BOB 1-02
529 530 87 12 PLUG-IN BOARD 511-00 00237A 26
ZB STECKK BOB 2-02 K0102A 000
529 530 88 12 PLUG-IN BOARD 511-00 00237A 09
ZB STECKK. BIB 1-02
529 530 89 12 PLUG-IN BOARD 511-00 00237A 30
ZB STECKK. SAB 1-02 00239A 000
529 530 90 12 PLUG-IN BOARD 511-00 00237A 31
ZB STECKK. INB 3-01
529 530 91 12 PLUG-IN BOARD 511-00 00237A 32
ZB STECKK. MFB 2-01
529 530 93 12 PLUG-IN BOARD 511-00 00237A 05
ZB STECKK. AIB 1-02
529 530 94 12 PLUG-IN BOARD 511-00 00241A 04
ZB MODUL PSM 3-01/A
529 530 95 12 PLUG-IN BOARD 511-00 00237A 25
ZB STECKK.BOB 1-02/A K0063A 000