CZONE 80-911-0119-00 Combination Output Interface with Connectors User Manual

CZONE 80-911-0119-00 Combination Output Interface with Connectors User Manual

Copyright
This document is copyright 2016 under the Creative Commons agreement. Rights are granted to research and reproduce elements of this document for non- commercial purposes on the condition that BEP is credited as the source. Electronic re-distribution of the document in any format is restricted, to maintain quality and version control.

Important

BEP strives to ensure all information is correct at the time of printing. However, the company reserves the right to change without notice any features and specifications of either its products or associated documentation.
Translations : In the event that there is a difference between a translation of this manual and the English version, the English version should be considered the official version.
It is the owner’s sole responsibility to install and operate the device in a manner that will not cause accidents, personal injury or property damage.

GENERAL INFORMATION

1.1 USE OF THIS MANUAL

Copyright © 2016 BEP Marine. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written permission of BEP Marine is prohibited. This manual serves as a guideline for the safe and effective operation, maintenance and possible correction of minor malfunctions of the Combination Output Interface, called COI further in this manual.

This manual is valid for the following models:

It is obligatory that every person who works on or with the COI is completely familiar with the contents of this manual, and that he/she carefully follows the instructions contained herein.

Installation of, and work on the COI, may be carried out only by qualified, authorized and trained personnel, consistent with the locally applicable standards and taking into consideration the safety guidelines and measures (chapter 2 of this manual). Please keep this manual in a secure place!

1.2 GUARANTEE SPECIFICATIONS

BEP Marine guarantees that this unit has been built according to the legally applicable standards and specifications. Should work take place which is not in accordance with the guidelines, instructions and specifications contained in this Installation manual, then damage may occur and/or the unit may not fulfil its specifications. All of these matters may mean that the guarantee becomes invalid.

1.3 QUALITY

During their production and prior to their delivery, all of our units are extensivley tested and inspected. The standard guarantee period is two years.

1.4 VALIDITY OF THIS MANUAL

All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the Combined Output Interface delivered by BEP Marine.

1.5 LIABILITY

BEP can accept no liability for:

• Consequential damage due to use of the COI. Possible errors in the manuals and the results thereof

CAREFUL! Never remove the identification label

Important technical information required for service and maintenance can be derived from the type number plate.

1.6 CHANGES TO THE COMBINED OUTPUT INTERFACE

Changes to the COI may be carried out only after obtaining the written permission of BEP.

SAFETY AND INSTALLATION PRECAUTIONS

2.2 WARNINGS AND SYMBOLS

Safety instructions and warnings are marked in this manual by the following pictograms:

CAUTION
Special data, restrictions and rules with regard to preventing damage.

WARNING
A WARNING refers to possible injury to the user or significant material damage to the COI if the user does not (carefully) follow the procedures.

A procedure, circumstance, etc, which deserves extra attention.

2.3 USE FOR INTENDED PURPOSE

1. The COI is constructed as per the applicable safety-technical guidelines.

2. Use the COI only:
   • In technically correct conditions
   • In a closed space, protected against rain, moisture, dust and condensation
   • Observing the instructions in the installation manual
   WARNING Never use the COI in locations where there is danger of gas or dust explosion or potentially flammable products!

3. Use of the COI other than mentioned in point 2 is not considered to be consistent with the intended purpose. BEP Marine is not liable for any damage resulting from the above.

2.4 ORGANIZATIONAL MEASURES

The user must always:

• Have access to the user’s manual and be familiar with the contents of this manual

2.5 MAINTENANCE AND REPAIR

• Switch off supply to the system
• Be sure that third parties cannot reverse the measures taken
• If maintenance and repairs are required, only use original spare parts

2.6 GENERAL SAFETY AND INSTALLATION PRECAUTIONS

• Connection and protection must be done in accordance with local standards
• Do not work on the COI or system if it is still connected to a power source. Only allow changes in your electrical system to be carried out by qualified electricians
• Check the wiring at least once a year. Defects such as loose connections, burned cables, etc. must be corrected immediately

OVERVIEW

3.1 DESCRIPTION

The Combination Output Interface (COI) combines multiple input and output devices in to one module, providing a high density 30 channel module which minimizes installation, interconnections and footprint, while delivering best value per circuit. The COI features the same proven, rugged CZone design including IPX5 water ingress protection and complete mechanical fuse protection plus bypass on all circuits as required by ABYC/CE. Industry standard Deutsch connectors provide “plug and play” installation

3.2 FEATURES

• High density 30 channel module minimizes installation, interconnections and footprint, while delivering best value per circuit
• Full mechanical fuse protection plus bypass on all circuits as required by ABYC/CE & AS/NZS 3004 Standards
• Industry standard Deutsch connectors provide fast, plug-n-play installation
• Optional cable cover offers improved aesthetics and greater mounting flexibility
• Proven, rugged CZone design includes IPX5 Water Ingress Protection and NMEA 2000 certification
• High power Bilge Pump channels allow manual control plus “pump running” feedback from a single channel – without additional wiring
• USB port provides easy system update from USB flash drive

3.3 COI OVERVIEW

Figure 1. COI with covers

Figure 2. COI no covers

1. Top Cover
2. Clips for Top Cover Removal
3. Optional Cable Cover
4. Circuit Label
5. Circuit Fuses
6. Main Positive Stud
7. Low Current Output Connector
8. Negative Stud
9. High Current Output Connector
10. Circuit Status Indicator Label
11. USB Programing Button & Status LED
12. USB Port
13. Spare Fuse Positions
14. Dipswitch
15. Fuse Picker
16. Fault Code/Input Label
17. Digital Switch Input Connector (12-pin)
18. NMEA 2000 Connector (5-pin)
19. Analogue Input Connector

3.4 LED INDICATORS

Figure 3. LED Indicators

1. Circuit Status LED’s

2. Power LED

3. Network Status LED

3.5 LABELLING

The unit is supplied with a blank label panel. The circuit names can be hand- written on this with a marker pen to indicate the circuit name.
Custom polycarbonate labels may be ordered from BEP Marine for a professional looking solution.

Figure 4. Blank Circuit Label

Figure 5. Blank Input Label

3.6 USB PORT

The USB port on the COI allows system software updates and configuration files to be loaded from a USB Memory Stick. This feature is only supported on devices with firmware version 6.11.30.0 or newer.

3.6.1 General Requirements & Tips

• Make sure the USB drive is FAT32 formatted.
• USB drive sizes up to 32GB are recommended.
• Most USB brands have been verified up to 32GB in size, including Strontium, Sandisk, Toshiba, Verbatim, Kingston, Samsung, Apacer etc.
• For USB drives 64GB and above only a limited number of devices from Kingston have been verified for operation.
• It is best, but not necessary, to use an empty USB drive for these operations.

3.6.2 Reading Configuration From Network

To read the existing configuration from the network to the USB drive you must:

1. Insert a USB drive with NO existing (.zcf or .czfwp) files in the root folder.
2. Press the USB button for 5sec or until the LED flashes RED.
3. Wait for the USB LED to turn solid green before removing it. This should take less than 20sec. Once done it will create/update 4 files:
   a) .zcf – The configuration file read from the network
   b) .csv – A spreadsheet listing information about the system and modules connected to the network
   c) CZone.bak – A backup copy of the configuration file. This needs to be present when writing updated configuration back to the network
   d) CZone USB Result.txt – A text file describing the result of the last operation performed, as well as these instructions

3.6.3 Writing Configuration To Network

To write the system configuration from the USB to the network you must:

1. Insert a USB drive in to the COI. The following files must present in the root folder:
   a) CZone.bak – This config file backup must match the existing system config before a config update can occur. This file is generated by copying the existing configuration to the USB as above.
   b) .zcf – A single configuration file to be written to the network. If more than one file is present no update will occur.
   c) No firmware update files (.czfwp).

2. Press the USB button for 5sec or until the LED flashes RED.

3. Wait for the USB LED to turn solid green before removing it. This should take less than 20sec.

4. Once the system configuration has been updated the following files will be created/updated:
   a) *.csv – A basic spreadsheet listing information about the system and modules connected to the network.
   b) CZone USB Result.txt – A text file describing the result of the last operation performed, as well as these instructions.

3.6.4 Updating Device Firmware

To update firmware of devices on the network you must:

1. Insert a USB drive with the following files in the root folder: The following files must be present in the root folder:
   a) .czfwp – A single CZone firmware update file to be used to update devices in the system.
   b) No configuration files (.zcf).

2. Press the USB button for 5sec or until the LED flashes RED.

3. Wait for the USB LED to turn solid green before removing it, this operation can take 10-40minutes depending on the number of different module types in the system. The COI channel LEDs will sweep back and forth when looking for devices of a particular type to update. Once devices of a particular type are found and are being updated, the LEDs will indicate progress for this update.

4. Once the firmware has been updated the following files will be created/updated:
   a) *.csv – A basic spreadsheet listing information about the system and modules connected to the network.
   b) CZone USB Result.txt – A text file describing the result of the last operation performed, as well as these instructions.

3.7 SYSTEM EXAMPLE

Figure 6. CZone COI & Masterbus System Example

INSTALLATION

4.1 THINGS YOU NEED

• COI Module & Top Cover (included)
• Deutsch Connector Kit (included with part # 80-911-0119-00)
• COI Cable Cover & fasteners (optional part # 80-911-0123-00)
• COI Digital Switch Breakout and Cable (optional, refer to page 23 for part numbers)
• 4 x 8G or 10G (4mm or 5mm) self-tapping screws or bolts for mounting COI to surface
• HDT-48-00 Deutsch crimp tool for crimping 0.5mm-4mm (20-12AWG) wire
• Duratool D03008 crimp tool or similar for crimping 6mm (10AWG) wire (optional)
• Appropriately rated ATC fuses for all circuits
• NMEA2000 drop cable and T-connector
• Screw driver and drill bits
• Electrical Tools

Figure 7. Deutsch HDT-48-00 Crimp Tool

4.2 ENIVRONMENT

Obey the following stipulations during installation:

• Ensure the COI is located in an easily accessible location for quick access to fuses
• Ensure indicator LED’s are visible for troubleshooting
• Ensure circuit label is fitted and all channels labelled correctly
• The COI must be mounted at least 50mm away from high current carrying conductors such as anchor winches, bow thruster cables, speakers, transformers and other high inductive loads.
• Ensure COI is mounted either vertically or horizontally
• Ensure the bulkhead that the unit will be attached to is sufficiently strong to take the weight of the unit.
• Ensure there is sufficient clearance above the COI to allow the cover to be removed.
• Ensure there is at least 10mm clearance around the sides and top of the COI

4.3 PLANNING

• Make a list of all inputs and outputs to be wired to the COI and take note of the output channel ratings and functions as shown in Figure 8. Ensure loads are wired to the appropriate channel for the functionality required.
• All 25A channels have the option to alarm on detection of external voltage, useful for circuits such as Bilge Pumps with an external or “automatic” supply from a float switch. This feature reduces wiring by allowing control and feedback from a single wire. See Figure 9 for a Bilge Pump wiring example.
• For loads with a continuous current exceeding max channel current it is possible to parallel output channels up to 80A for OUT-H connector and 100A for OUT-L connector (do not parallel outputs between connectors).

Figure 8. Output Channel Specifications

Figure 9. COI Bilge Pump Wiring Example

4.4 DEUTSCH CONNECTOR KIT

If you have purchased the COI module that includes the Deutsch connector kit (part # 80-911-0119-00), check all components are in the bag before proceeding.

Figure 10. COI Deutsch Connector Kit Parts

4.5 MOUNTING

Figure 11. Mounting Screw Locations

1. Remove the COI top cover and locate the 4 mounting screw locators as shown in Figure 11
2. Place the COI on a solid, flat surface.
3. Screw the COI to the surface with 4 x 8G or 10G (4mm or 5mm) self-tapping screws or bolts.

4.6 CONNECTIONS

Figure 12. COI Connections

1. Connect High-Current Outputs (OUT-H)

1. . Referring to the load list, strip and crimp the High Current cables with the appropriate Deutsch contact and crimp tool.
2. Insert the contacts into the DTP06-4S plug following the plugs position numbers and secure using the locking wedge.
3. Any unused pins in the connector should be plugged with sealing plugs to maintain the IPX5 rating.
4. Insert the connector into the COI and lock into place.
5. Load negatives are not connected to the COI, they must be connected to a common negative bus. Best wiring practice is to locate the negative connections close to the COI so positive & negative wires run together minimizing magnetic fields.
6. Secure and neaten up the cables against the bulkhead to reduce the strain on the connectors.

2. Connect Low-Current Outputs (OUT-L):

1. Referring to the load list, strip and crimp the Low Current cables with the appropriate Deutsch contact and crimp tool.
2. Insert the contacts into the DT06-12SA plug following the plugs position numbers and secure using the locking wedge.
3. Any unused pins in the connector should be plugged with sealing plugs to maintain the IPX5 rating.
4. Insert the connector into the COI and lock into place.
5. Load negatives are not connected to the COI, they must be connected to a common negative bus. Best wiring practice is to locate the negative connections close to the COI so positive & negative wires run together minimizing magnetic fields.
6. Secure and neaten up the cables against the bulkhead to reduce the strain on the connectors.

3. Connect Analogue Inputs (IN-A)

1. The analogue inputs can be used to connect mechanical switches to control outputs (switch to pos or switch to neg) or analogue sensors (0-32V, 0-1000Ω or 4-20mA). CZone will convert analogue sensor values into NMEA 2000 digital sentences.
2. Referring to the input list, strip and crimp the Analogue Input cables with the appropriate Deutsch contact and crimp tool.
3. Insert the contacts into the DT06-08SA plug following the plugs position numbers and secure using the locking wedge.
4. Any unused pins in the connector should be plugged with sealing plugs to maintain the IPX5 rating.
5. Insert the connector into the COI and lock into place.
6. Secure and neaten up the cables against the bulkhead to reduce the strain on the connectors.

4. Connect NMEA2000 network

1. Connect an NMEA2000 drop cable from the COI to an NMEA2000 backbone.
2. Ensure the NMEA2000 network is properly terminated and connected to a 12V power source (Do not power up network yet).

5. Connect the Digital Switch Breakout (IN-D) (Optional)

Figure 13. COI Digital Switch Breakout Connections

1. The digital switch input can be used to connect up to 6 CZone digital switches (Push Button or Rocker) to the COI with the optional Digital Switch Breakout. Refer to Page 23 for part numbers. If no digital switches are required, ensure the blanking cap is fitted to maintain the IPX5 rating.
2. Mount the switches in the desired location.
3. Mount the DSB interface as close to the switches as possible.
4. Run the supplied 2M lead (or optional 5M) from the DSB to the COI.

6. Connect DC Negative

1. Connect a 2.5mm² (12AWG) cable from the battery negative terminal or main negative bus to the COI’s M6 negative stud.
2. Ensure supplied spring washer is installed and M6 nut is torqued to 4-5Nm (35-44 in lbs.) torque max.

7. Connect DC Positive

1. Connect an appropriately sized and fused cable from the battery positive terminal to the COI’s M8 positive stud.
2. The positive cable must be of sufficient size to carry the maximum current of all loads connected to the COI and have a fuse/circuit breaker rated to protect the cable, volt drop should be kept to a minimum.
3. Maximum recommended cable size is 70mm² (2/0). Cables larger than 70mm² (2/0) should be connected to a positive stud first with a link to the COI.
4. It is possible to connect two positive cables “back to back” on the positive stud for linking the supply on 2 or more COI’s.
5. Ensure supplied spring washer is installed and M8 nut is torqued to 8-10 (70-88 in lbs.) torque max.

4.7 LABELS & FUSES 

1. Label the Circuits

1. Using a marker pen, write the output names (1-16) on the supplied label matching the load list and physical plug connections.

2. Label the Inputs

1. Using a marker pen, write the analogue and digital input names matching the input list and physical plug connections.
2. Write the COI module number and location (i.e. COI01 – Engine Room). This should match the module name in the configuration.
3. Mark the dipswitch setting of the COI. This is usually assigned automatically when writing the configuration and needs to be unique for each module on the CZone system.

4.8 INSERT FUSES

Figure 14. Fuses In Normal Operation

1. Insert appropriately rated ATC fuses into the NORMAL operation (bottom) position of all fuse holders.
2. The ATC fuse should be rated one size above the software fuse rating

4.9 SET DIPSWITCH

• Using a small screwdriver carefully set the dipswitch on the COI. The dipswitch number must be unique for all modules on the CZone network and must match the dipswitch setting in the configuration to function correctly.
  The example in Figure 15 shows a dipswitch number of 01101100 where 0 = Off and 1 = On

Figure 15. Setting Dipswitch

4.10 INITIAL POWER UP

1. Check all plugs are securely seated and connections are tight.
2. Ensure the COI’s top cover is clipped securely in place and gasket is seated properly around fuses.
3. Power up the NMEA2000 network.
4. Check that the NMEA2000 Network LED lights up. It may also be flashing if other devices are present and transmitting data.
5. Turn the switch/circuit breaker on supplying the COI’s main positive stud.
6. Check that the Power indicator LED is green.
7. Check the circuit’s status LED’s for each individual circuit. Refer to LED codes to diagnose any faults which need to be rectified.
8. Check the software version on the COI with the CZone Configuration Tool and update if necessary.
9. Write configuration file to the COI and the rest of the CZone modules on the system (Refer to the CZone Configuration Tool Instructions for details on how to configure the COI).
10. Test all inputs and outputs for configured functionality.

SPECIFICATIONS

5.1 TECHNICAL SPECIFICATIONS

5.2 NMEA 2000 PGN’S

NMEA 2000 PGN’s sent from the COI

5.4 DIMENSIONS

Figure 16. COI Dimensions no covers

Figure 17. COI Dimensions with covers

ORDERING INFORMATION

COI Part Numbers and Accessories

*Includes 80-911-0131-00 – CZone COI Deutsch Connector Kit
** Includes 2M DSB to COI Cable

EC DELCARATION OF CONFORMITY

We,
Power Products LLC
Mailing Address:
BEP Marine LTD
PO Box 101-739 NSMC
Auckland 0632, New Zealand

Street Address:
42 Apollo Drive
Rosedale,
Auckland, 0632, New Zealand

Declare under our sole responsibility that the products:

• 80-911-0119-00 CZone COI C/W Connectors
• 80-911-0120-00 CZone COI No Connectors

To which this declaration related, is in conformity with the following standards or other normative documents:-

EMC : EN 60945:2002:2002

FCC 47 Code of Federal Regulations
Part 15 – Radio Frequency Devices
Subpart A and B – Unintentional Radiators

Albany, New Zealand, 11 August 2016

Chris Wilkins
R & D Manager

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