Emerson Roc827 Instruction Manual

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Form Number A6175
Part Number D301217X012
March 2006

ROC827 Remote Operations Controller
Instruction Manual

Flow Computer Division

Revision Tracking Sheet
March 2006
This manual may be revised periodically to incorporate new or updated information. The
revision date of each page appears at the bottom of the page opposite the page number. A change
in revision date to any page also changes the date of the manual that appears on the front cover.
Listed below is the revision date of each page (if applicable):

Page
Initial issue

Revision
Mar-06

ROCLINK is a trademark of one of the Emerson Process Management companies. The Emerson logo is a trademark
and service mark of Emerson Electric Co. All other marks are the property of their respective owners.
© Fisher Controls International, LLC. 2006. All rights reserved. Printed in the U.S.A.
www.EmersonProcess.com/flow
While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee
satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty
or guarantee, express or implied, regarding the performance, merchantability, fitness or any other matter with respect
to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls
reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.

Issued Mar-06

Contents
Chapter 1 – General Information
1.1
1.2

1.3
1.4

1.5
1.6
1.7
1.8

Scope of Manual...............................................................................................................1-1
Hardware ..........................................................................................................................1-2
1.2.1
Central Processor Unit (CPU) ............................................................................1-5
1.2.2
Processor and Memory ......................................................................................1-6
1.2.3
Real-Time Clock (RTC) ......................................................................................1-6
1.2.4
Diagnostic Monitoring.........................................................................................1-7
1.2.5
Options ...............................................................................................................1-7
FCC Information ...............................................................................................................1-8
Firmware...........................................................................................................................1-8
1.4.1
Historical Database and Event & Alarm Log ....................................................1-11
1.4.2
Meter Runs and Stations..................................................................................1-12
1.4.3
Flow Calculations .............................................................................................1-12
1.4.4
Automatic Self Tests ........................................................................................1-13
1.4.5
Low Power Modes............................................................................................1-13
1.4.6
Proportional, Integral, and Derivative (PID) .....................................................1-14
1.4.7
Function Sequence Table (FST) ......................................................................1-14
ROCLINK 800 Configuration Software...........................................................................1-15
DS800 Development Suite Software..............................................................................1-16
Expanded Backplane......................................................................................................1-17
Related Specification Sheets..........................................................................................1-18

Chapter 2 – Installation and Use
2.1

2.2
2.3

2.4

2.5

2.6

2.7

1-1

2-1

Installation Requirements .................................................................................................2-1
2.1.1
Environmental Requirements .............................................................................2-2
2.1.2
Site Requirements..............................................................................................2-2
2.1.3
Compliance with Hazardous Area Standards ....................................................2-3
2.1.4
Power Installation Requirements .......................................................................2-4
2.1.5
Grounding Installation Requirements.................................................................2-4
2.1.6
I/O Wiring Requirements ....................................................................................2-5
Required Tools .................................................................................................................2-5
Housing.............................................................................................................................2-5
2.3.1
Removing and Replacing End Caps ..................................................................2-6
2.3.2
Removing and Installing Wire Channel Covers..................................................2-6
2.3.3
Removing and Installing Module Covers............................................................2-7
Mounting the ROC827 on a DIN Rail ...............................................................................2-7
2.4.1
Installing the DIN Rail.........................................................................................2-9
2.4.2
Securing the ROC827 on the DIN Rail...............................................................2-9
2.4.3
Removing the ROC827 from the DIN Rail .......................................................2-10
ROC800-Series Expanded Backplane (EXP) ................................................................2-10
2.5.1
Attaching an Expandable Backplane ...............................................................2-11
2.5.2
Removing an Expandable Backplane ..............................................................2-12
Central Processor Unit (CPU) ........................................................................................2-13
2.6.1
Removing the CPU Module..............................................................................2-16
2.6.2
Installing the CPU Module................................................................................2-16
License Keys ..................................................................................................................2-17
2.7.1
Installing a License Key....................................................................................2-18
2.7.2
Removing a License Key..................................................................................2-19

Issued Mar-06

iii

2.8

Startup and Operation ....................................................................................................2-19
2.8.1
Startup ..............................................................................................................2-20
2.8.2
Operation..........................................................................................................2-20

Chapter 3 – Power Connections
3.1

3.2
3.3
3.4
3.5

3.6

3-1

Power Input Module Descriptions.....................................................................................3-1
3.1.1
12-Volt DC Power Input Module (PM-12)...........................................................3-1
3.1.2
24-Volt DC Power Input Module (PM-24)...........................................................3-3
3.1.3
Auxiliary Output (AUX+ and AUX–)....................................................................3-4
3.1.4
Switched Auxiliary Output (AUXSW+ and AUXSW–) ........................................3-6
Determining Power Consumption.....................................................................................3-7
3.2.1
Tuning the Configuration ..................................................................................3-11
Removing a Power Input Module ...................................................................................3-20
Installing a Power Input Module .....................................................................................3-21
Connecting the ROC827 to Wiring .................................................................................3-21
3.5.1
Wiring the DC Power Input Module..................................................................3-22
3.5.2
Wiring the External Batteries............................................................................3-23
3.5.3
Replacing the Internal Battery ..........................................................................3-25
Related Specification Sheets..........................................................................................3-26

Chapter 4 – Input/Output Modules

4-1

4.1
4.2

I/O Module Overview ........................................................................................................4-1
Installation.........................................................................................................................4-3
4.2.1
Installing an I/O Module......................................................................................4-4
4.2.2
Removing an I/O Module....................................................................................4-5
4.2.3
Wiring I/O Modules.............................................................................................4-6
4.3 Analog Input Modules.......................................................................................................4-6
4.4 Analog Output Modules ....................................................................................................4-8
4.5 Discrete Input Modules.....................................................................................................4-9
4.6 Discrete Output Modules ................................................................................................4-10
4.7 Discrete Output Relay Modules......................................................................................4-11
4.8 Pulse Input Modules .......................................................................................................4-12
4.9 RTD Input Modules.........................................................................................................4-14
4.9.1
Connecting the RTD Wiring..............................................................................4-15
4.10 J and K Type Thermocouple Input Modules ..................................................................4-16
4.11 Related Specification Sheets .........................................................................................4-21

Chapter 5 – Communications
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

5-1

Communications Ports and Modules Overview ...............................................................5-1
Installing Communication Modules ..................................................................................5-3
Removing a Communications Module .............................................................................5-4
Wiring Communications Modules ....................................................................................5-5
Local Operator Interface (LOI) .........................................................................................5-5
5.5.1
Using the LOI .....................................................................................................5-7
Ethernet Communications................................................................................................5-7
EIA-232 (RS-232) Serial Communications ......................................................................5-9
EIA-422/485 (RS-422/485) Serial Communications Module .........................................5-10
5.8.1
EIA-422/485 (RS-422/485) Jumpers & Termination Resistors ........................5-11

Issued Mar-06

5.9
5.10
5.11
5.12

Dial-up Modem Communications Module......................................................................5-12
Multi-Variable Sensor (MVS) Interface Modules............................................................5-14
HART Interface Module .................................................................................................5-16
Related Specification Sheets .........................................................................................5-20

Chapter 6 – Troubleshooting
6.1
6.2

6.3

Guidelines.........................................................................................................................6-1
Checklists .........................................................................................................................6-2
6.2.1
Serial Communications ......................................................................................6-2
6.2.2
I/O Point..............................................................................................................6-2
6.2.3
Software .............................................................................................................6-3
6.2.4
Powering Up .......................................................................................................6-3
6.2.5
MVS Module .......................................................................................................6-3
Procedures .......................................................................................................................6-4
6.3.1
Preserving Configuration and Log Data .............................................................6-4
6.3.2
Restarting the ROC827 ......................................................................................6-4
6.3.3
Troubleshooting Analog Input Modules..............................................................6-5
6.3.4
Troubleshooting Analog Output Modules...........................................................6-7
6.3.5
Troubleshooting Discrete Input Modules............................................................6-7
6.3.6
Troubleshooting Discrete Output Modules.........................................................6-8
6.3.7
Troubleshooting Discrete Output Relay Modules...............................................6-8
6.3.8
Troubleshooting Pulse Input Modules................................................................6-8
6.3.9
Troubleshooting RTD Input Modules .................................................................6-9
6.3.10 Troubleshooting J and K Type Thermocouple Input Modules .........................6-10

Chapter 7 – Calibration
7.1
7.2

6-1

7-1

Calibration.........................................................................................................................7-1
Preparing for Calibration...................................................................................................7-1

Appendix A – Glossary
Index

Issued Mar-06

A-1
I-1

Issued Mar-06

ROC827 Instruction Manual

Chapter 1 – General Information
This manual focuses on the hardware aspects of the ROC827 Remote
Operations Controller (the “ROC827”) and the ROC800-Series expanded
backplanes (“EXPs”). For information about the software, refer to the
ROCLINK™ 800 Configuration Software User Manual (Form A6121).
This chapter details the structure of this manual and provides an overview
of the ROC827 and its components.
In This Chapter
1.1
1.2

1.3
1.4

1.5
1.6
1.7
1.8

Scope of Manual......................................................................................1-1
Hardware .................................................................................................1-2
1.2.1 Central Processor Unit (CPU)........................................................1-5
1.2.2 Processor and Memory..................................................................1-6
1.2.3 Real-Time Clock (RTC)..................................................................1-6
1.2.4 Diagnostic Monitoring ....................................................................1-7
1.2.5 Options...........................................................................................1-7
FCC Information ......................................................................................1-8
Firmware ..................................................................................................1-8
1.4.1 Historical Database and Event & Alarm Log................................1-12
1.4.2 Meter Runs and Stations .............................................................1-12
1.4.3 Flow Calculations.........................................................................1-12
1.4.4 Automatic Self Tests ....................................................................1-13
1.4.5 Low Power Modes .......................................................................1-14
1.4.6 Proportional, Integral, and Derivative (PID) .................................1-14
1.4.7 Function Sequence Table (FST)..................................................1-15
ROCLINK 800 Configuration Software ..................................................1-15
DS800 Development Suite Software .....................................................1-17
Expanded Backplane.............................................................................1-18
Related Specification Sheets.................................................................1-19

The ROC827 Remote Operations Controller is a microprocessor-based
controller that provides the functions required for a variety of field
automation applications. The ROC827 is ideal for applications requiring
general logic and sequencing control; historical data archiving; multiple
communication ports; Proportional, Integral, and Derivative (PID) control;
and flow measurement on up to twelve meter runs. When attached to the
ROC827, the ROC800-Series expanded backplanes provide the ROC827
with increased I/O capabilities.

1.1

Scope of Manual
This manual contains the following chapters:
Chapter 1
General Information

Issued Mar-06

Provides an overview of the hardware and
specifications for the ROC827 and the ROC800-Series
expanded backplane.

General Information

1-1

ROC827 Instruction Manual
Chapter 2
Installation and Use

Provides information on installation, tools, wiring,
mounting the ROC827, and other essential elements of
the ROC827 and EXPs.

Chapter 3
Power Connections

Provides information on the Power Input modules
available for the ROC827 and EXPs and provides
worksheets to help determine power requirements for
the ROC827 configurations.

Chapter 4
Input/Output (I/O)
Modules

1.2

Provides information for the Input/Output (I/O) modules
available for the ROC827 and EXPs.

Chapter 5
Communications

Provides information for the built-in communications
and the optional communication modules available for
the ROC827.

Chapter 6
Troubleshooting

Provides information on diagnosing and correcting
problems for the ROC827.

Chapter 7
Calibration

Provides information for calibrating Analog Inputs,
HART Inputs, RTD Inputs, and MVS Inputs for the
ROC827.

Glossary

Provides definitions of acronyms and terms.

Index

Provides an alphabetic listing of items and topics
contained in this manual.

Hardware
The ROC827 is highly innovative and versatile with an integrated
backplane to which the central processor unit (CPU), Power Input module,
communication modules, and I/O modules connect. The ROC827 has
three I/O module slots.
The ROC800-Series expanded backplane (EXP) attaches to the ROC827.
Each EXP provides six additional I/O module slots. The ROC827 can
support up to four EXPs, for a total of 27 I/O module slots in a fully
configured ROC827 (six slots per EXP plus the three I/O slots on the
ROC827 itself).
The ROC827 uses a Power Input module to convert external input power
to the voltage levels required by the ROC827’s electronics and to monitor
voltage levels to ensure proper operation. Two Power Input modules—12
Volts dc (PM-12) and 24 Volts dc (PM-24)—are available for the
ROC827. For more information on the Power Input modules, refer to
Chapter 3, Power Connections.
The ROC827 supports a variety of communication protocols: ROC Plus,
Modbus, Modbus TCP/IP, Modbus encapsulated in TCP/IP, and Modbus
with Electronic Flow Measurement (EFM) extensions.
Figure 1-1 shows the housing, typical I/O modules, and communication
modules installed in a ROC827. The patented ABS (Acrylonitrile
Butadiene Styrene) plastic housing has wire covers to protect the wiring
terminals. The housing includes DIN rail mounts for mounting the
ROC827 on a panel or in a user-supplied enclosure.

Issued Mar-06

General Information

1-2

ROC827 Instruction Manual

Power Supply Module

I/O Module (1 of 3)

CPU
Wire Channel Cover
LOI (Local Port)
EIA-232 (RS-232D)
Right End Cap
Built-in Ethernet (Comm1)
Built-in EIA-232 (RS-232C)
(Comm2)

Figure 1-1. ROC827 Base Unit (without Expanded Backplane)
The ROC827’s CPU contains the microprocessor, the firmware, a
connector to the backplane, three built-in communication ports, a LightEmitting Diode (LED) low power wakeup button, a RESET button, the
application license key connectors, a STATUS LED indicating system
integrity, diagnostic LEDs for two of the communications ports, and the
main processor.

Issued Mar-06

General Information

1-3

ROC827 Instruction Manual

Figure 1-2 shows a typical expanded backplane (EXP) populated with a
full complement of six I/O modules. Each EXP is composed of the same
plastic housing as the ROC827, contains six I/O slots, and has a powered
backplane that easily attaches to the ROC827 and other EXPs.

Figure 1-2. ROC827 with One Expanded Backplane
The ROC827 and EXPs support nine types of Input/Output (I/O) modules,
which can satisfy a wide variety of field I/O requirements (refer to Chapter
4, Input/Output Modules). I/O modules include:

Issued Mar-06

Analog Inputs (AI).
Analog Outputs (AO).
Discrete Inputs (DI).
Discrete Outputs (DO).
Digital Relay Outputs (DOR).
HART Inputs/Outputs.
Pulse Inputs (PI) – High/Low Speed.
Resistance Temperature Detector Inputs (RTD).
J and K Type Thermocouple (T/C) Inputs.

General Information

1-4

ROC827 Instruction Manual

The ROC827 holds up to six communication ports (refer to Chapter 5,
Communications). Three communication ports are built-in:

Local Operator Interface (LOI) – Local Port EIA-232 (RS-232D).
Ethernet – Comm1 Port for use with the DS800 Development Suite
Software.
EIA-232 (RS-232C) – Comm2 Port for point-to-point asynchronous
serial communications.

Communication modules (which install in the ROC827’s Comm3,
Comm4, and Comm5 slots) provide additional ports for communicating
with a host computer or other devices. Modules include:

Hot-Swappable &
Hot-Pluggable

EIA-232 (RS-232C) – Point-to-point asynchronous serial
communications include Data Terminal Ready (DTR) support, Ready
To Send (RTS) support, and radio power control.
EIA-422/EIA-485 (RS-422/RS-485) – Point-to-point (EIA-422) or
multiple-point (EIA-485) asynchronous serial communications.
Multi-Variable Sensor (MVS) – Interfaces with MVS Sensors (up to
two modules per ROC827).
Dial-up modem – Communications over a telephone network (14.4K
V.42 bis with throughput up to 57.6K bps).

Modules—whether I/O or communication—easily install in the
module slots. Modules are both “hot-swappable” (they can be
removed and another module of the same kind installed while the
ROC827 is powered) and “hot-pluggable” (they can be installed
directly into unused module slots with the ROC827 is powered).
Modules are also self-identifying, which means that the ROCLINK
800 Configuration software recognizes the module (although you may
need to configure the module using the software). The modules have
extensive short circuit, overvoltage protection, and are self-resetting
after a fault clears.

1.2.1 Central Processor Unit (CPU)
The CPU contains the microprocessor, the firmware, connectors to the
backplane, the three built-in communication ports (two with LEDs), a
LED low power wakeup button, a RESET button, the application license
key connectors, a STATUS LED indicating system integrity, and the main
processor.
CPU components include:

Issued Mar-06

32-bit microprocessor based on Motorola® MPC862 Quad Integrated
Communications Controller (PowerQUICC™) PowerPC® processor.
SRAM (Static Random Access Memory) with battery backup.
Flash ROM (Read-Only Memory).
SDRAM (Synchronous Dynamic Random Access Memory).
General Information

1-5

ROC827 Instruction Manual

Diagnostic monitoring.
Real-Time Clock.
Automatic self-tests.
Power saving modes.
Local Operator Interface (LOI) EIA-232 (RS-232D) Local Port.
EIA-232 (RS-232C) serial Comm2 port.
Ethernet Comm1 port.

1.2.2 Processor and Memory
The ROC827 uses a 32-bit microprocessor with processor bus clock
frequency at 50 MHz with a watchdog timer. The Motorola MPC862
Quad Integrated Communications Controller (PowerQUICC) PowerPC
processor and the Real-Time Operating System (RTOS) provide both
hardware and software memory protection.

1.2.3 Real-Time Clock (RTC)
You can set the ROC827’s Real-Time Clock (RTC) for year, month, day,
hour, minute, and second. The clock provides time stamping of the
database values. The battery-backed clock firmware tracks the day of the
week, corrects for leap year, and adjusts for daylight savings time (userselectable). The time chip automatically switches to backup power when
the ROC827 loses primary input power.
The internal Sanyo 3-volt CR2430 lithium battery provides backup for the
data and the Real-Time Clock when the main power is not connected. The
battery has a one-year minimum backup life with the battery is installed,
the jumper disengaged, and no power applied to the ROC827. The battery
has a ten-year backup life with the backup battery installed and power
applied to the ROC827 or when the battery is removed from the ROC827.
Note: If the Real-Time Clock does not keep the current time when you

remove power, replace the lithium battery.

Issued Mar-06

General Information

1-6

ROC827 Instruction Manual

1.2.4 Diagnostic Monitoring
The ROC827 has diagnostic inputs incorporated into the circuitry for
monitoring system integrity. Use ROCLINK 800 software to access the
System Analog Inputs. Refer to Table 1-1.
Table 1-1. System Analog Inputs
System AI
Point Number

Function

Normal Range

Battery Input Voltage

11.25 to 16 Volts dc

Charge in Voltage

0 to 18 Volts dc

Module Voltage

11.00 to 14.50 Volts dc

Not Used

On Board Temperature

–40 to 85°C (–40 to
185°F)

1.2.5 Options
The ROC827 allows you to choose from a wide variety of options to suit
many applications.
Optional communication modules include EIA-232 (RS-232) serial
communications, EIA-422/485 (RS-422/485) serial communications,
Multi-Variable Sensor (MVS), and dial-up modem communications (refer
to Chapter 5, Communications).
The ROC827 can handle up to two MVS interface modules. Each module
can provide power and communications for up to six MVS sensors, for a
total of up to 12 MVS sensors per ROC827 (refer to Chapter 5,
Communications).
Optional I/O modules include Analog Inputs (AI), Analog Outputs (AO),
Discrete Inputs (DI), Discrete Outputs (DO), Discrete Output Relays
(DOR), Pulse Inputs (PI), Resistance Temperature Detector (RTD) Inputs,
Thermocouple (T/C) Inputs, and Highway Addressable Remote
Transducers (HART) (refer to Chapter 4, Input/Output Modules).
The optional application license keys provide extended functionality, such
as the use of the DS800 Development Suite Software (the IEC 61131-3
compliant programming environment) and various user programs, and
enables embedded meter runs. For example, you need to install a license
key with the proper license in the ROC827 to perform AGA calculations.
Refer to Section 1.6, “DS800 Development Suite Software.”
The Local Operator Interface (LOI local port) communications terminal
requires the installation of an LOI cable between the ROC827 and your
PC. The LOI port uses an RJ-45 connector with a standard EIA-232
(RS-232D) pin out.

Issued Mar-06

General Information

1-7

ROC827 Instruction Manual

1.3

FCC Information
This equipment complies with Part 68 of the FCC rules. Etched on the
modem assembly is, among other information, the FCC certification
number and Ringer Equivalence Number (REN) for this equipment. If
requested, this information must be provided to the telephone company.
This module has an FCC-compliant telephone modular plug. The module
is designed to be connected to the telephone network or premises’ wiring
using a compatible modular jack that is Part 68-compliant.
The REN is used to determine the quantity of devices that may be
connected to the telephone line. Excessive RENs on the telephone line
may result in the devices not ringing in response to an incoming call.
Typically, the sum of the RENs should not exceed five (5.0). Contact the
local telephone company to determine the total number of devices that
may be connected to a line (as determined by the total RENs).
If this equipment and its dial-up modem causes harm to the telephone
network, the telephone company will notify you in advance that temporary
discontinuance of service may be required. However, if advance notice is
not practical, the telephone company will notify the customer as soon as
possible. In addition, you will be advised of your right to file a complaint
with the FCC if you believe it necessary.
The telephone company may make changes to its facilities, equipment,
operations, or procedures that could affect the operation of the equipment.
If this happens, the telephone company will provide advance notice so you
can make the necessary modifications to maintain uninterrupted service.
If you experience trouble with this equipment or the dial-up modem,
contact Emerson Process Management’s Flow Computer Division (at 641754-3923) for repair or warranty information. If the equipment harms the
telephone network, the telephone company may request that you
disconnect the equipment until the problem is resolved.

1.4

Firmware
The firmware that resides in Flash Read-Only Memory (ROM) contains
the operating system, ROC Plus communications protocol, and application
software. The CPU module provides battery-backed Static Random
Access Memory (SRAM) for saving configurations, storing events,
alarms, and the historical logs.
The ROC800-Series Operating System firmware provides a complete
operating system for the ROC827. The firmware in the ROC827 is fieldupgradeable using a serial connection or the Local Operator Interface
(LOI) local port. For more information, refer to the ROCLINK 800
Configuration Software User Manual (Form A6121).
The firmware supports:

Issued Mar-06

Input/Output Database.
General Information

1-8

ROC827 Instruction Manual

Historical Database.
Event and Alarm Log Databases.
Applications (PID, AGA, FST, and such).
Measurement Station Support.
Determining Task Execution.
Real-Time Clock.
Establishing and Managing Communications.
Self-Test Capability.
The firmware makes extensive use of configuration parameters, which you
configure using ROCLINK 800 software.
RTOS

The ROC800-Series firmware uses a pre-emptive, multi-tasking,
message-based Real-Time Operating System (RTOS) with hardwaresupported memory protection. Tasks are assigned priorities and, at any
given time, the operating system determines which task will run. For
instance, if a lower priority task is executing and a higher priority task
needs to run, the operating system suspends the lower priority task,
allows the higher priority task to run to completion, then resumes the
lower priority task’s execution. This is more efficient than a “time
sliced” architecture type.

TLP

The ROC827 reads data from and writes data to data structures called
“points.” A “point” is a ROC Plus Protocol term for a grouping of
individual parameters (such as information about an I/O channel) or
some other function (such as a flow calculation). Points are defined by
a collection of parameters and have a numerical designation that
defines the type of point (for example, point type 101 refers to a
Discrete Input and point type 103 refers to an Analog Input).
The logical number indicates the physical location for the I/O or the
logical instance for non-I/O points within the ROC827. Parameters are
individual pieces of data that relate to the point type. For instance, the raw
A/D value and the low scaling value are parameters associated with the
Analog Input point type, 103. The point type attributes define the database
point to be one of the possible types of points available to the system.
Together, these three components—the type (T), the logical (L), and the
parameters (P)—can be used to identify specific pieces of data that reside
in a ROC827’s data base. Collectively, this three-component address is
often called a “TLP.”

I/O Database

Issued Mar-06

The Input/Output database contains the input and output points the
operating system firmware supports, including the System Analog
Inputs, Multi-Variable Sensor (MVS) inputs, and Input/Output (I/O)
modules. The firmware automatically determines the point type and
point number location of each installed I/O module. It then assigns
each input and output to a point in the database and includes userdefined configuration parameters for assigning values, statuses, or
identifiers. The firmware scans each input, placing the values into the
General Information

1-9

ROC827 Instruction Manual

respective database point. These values are available for display and
historical archiving.
SRBX

Spontaneous-Report-by-Exception (SRBX or RBX) communication
allows the ROC827 to monitor for alarm conditions and, upon
detecting an alarm, automatically reports the alarm to a host computer.
Any kind of communications link—dial-up modem or serial line—can
perform SRBX as long as the host is set up to receive field-initiated
calls.

Protocols

The firmware supports both the ROC Plus protocol and the Modbus
master and slave protocol. ROC Plus protocol can support serial
communications and radio or telephone modem communications to
local or remote devices, such as a host computer. The firmware also
supports the ROC Plus protocol over TCP/IP on the Ethernet port. The
ROC Plus protocol is similar to the ROC 300/400/500 protocol, since
it used many of the same opcodes. For more information, contact your
local sales representative.
The ROC800-Series firmware also supports Modbus protocol as either
master or slave device using Remote Terminal Unit (RTU) or American
Standard Code for Information Interchange (ASCII) modes. This allows
you to easily integrate the ROC827 into other systems. Extensions to the
Modbus protocol allow the retrieval of history, event, and alarm data in
Electronic Flow Metering (EFM) Measurement applications.
Note: In Ethernet mode, the firmware support Modbus only in slave mode.

Security

The ROCLINK 800 software also secures access to the ROC827. You
can define and store a maximum of 16 case-sensitive user identifiers
(User IDs). In order for the ROC827 to communicate, a case sensitive
log-on ID supplied to the ROCLINK 800 software must match one of
the IDs stored in the ROC827.
The operating system firmware supports the application-specific firmware
supplied in the Flash ROM. The application firmware includes
Proportional, Integral, and Derivative (PID) Control; FSTs; SpontaneousReport-By-Exception (SRBX) Communications Enhancement; optional
American Gas Association (AGA) Flow calculations with station support;
and optional IEC 61131-3 language programs (using DS800 Development
Suite software). Applications reside, so you do not need to re-build and
download the firmware for changes in calculation method.

Input Module
Addressing

Issued Mar-06

The ROC800-Series firmware, by default, supports 16 addressable
points per module slot. However, to accommodate all the ROC827’s
expanded input capabilities (up to 27 module slots), you must set the
firmware to support eight (8) addressable points per module slot.
(Accomplish this using ROCLINK 800 and selecting ROC >
Information. On the Device Information screen’s General tab, click
the 8-Points Per Module radio button in the Logical Compatibility
Mode frame.)

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The difference between 16-point and 8-point addressing becomes critical
when you have a host device reading data from specific TLPs. For
example, under 16-point addressing, channel 2 for a DI module in slot 2 is
referenced by TLP 101,33,3. Under 8-point addressing, channel 2 for a DI
module in slot 2 is referenced by TLP 101,17,23. Table 1-2 illustrates the
difference between 8-point and 16-point addressing.
Table 1-2. 16-Point vs. 8-Point Addressing
Slot Number
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Logicals (16 pt)
0–15
16–31
32–47
48–63
64–79
80–95
96–111
112–127
128–143
144–159
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

Logicals (8 pt)
0–7
8–15
16–23
24–31
32–39
40–47
48–55
56–63
64–71
72–79
80–87
88–95
96–103
104–111
112–119
120–127
128–135
136–143
144–151
152–159
160–167
168–175
176–183
184–191
192–199
200–207
208–215
216–223

Note: 16-point addressing is the default for the ROC800-Series firmware.

To maximize the expanded input capabilities of the ROC827, you must
use ROCKLINK 800 to modify the firmware addressing to use 8-points
per module.

1.4.1 Historical Database and Event & Alarm Log
The historical database provides archiving of measured and calculated
values for either on-demand viewing or saving to a file. It provides an
historical record in accordance with API Chapter 21.1. You can configure
each of up to 200 points in the historical database to archive values under
various schemes, such as averaging or accumulating, as appropriate for the
type of database point.

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The historical database is maintained in 11 segments. You can configure
each segment in the database to archive selected points at specified time
intervals. The segments can continuously archive or can be turned on and
off.
You can distribute history points among history segments 1 through 10
and the general history segment. For each history segment, you can
configure the number of periodic history values archived, the frequency of
archiving periodic values, the number of daily values archived, and the
contract hour. The number of minute values is fixed at 60. The 200 points
provide a total of over 197,000 entries (equal to more than 35 days of 24hour data for 200 points).
The Event Log records the last 450 parameter changes, power on and off
cycles, calibration information, and other system events. The event is
recorded along with a date and time stamp. The Alarm Log records the last
450 configured occurrences of alarms (set and clear). You can view the
logs, save them to a disk file, or print them using ROCLINK 800 software.

1.4.2 Meter Runs and Stations
You can group similarly configured meter runs into stations, which
provide great benefits during configuration and reporting. You can also
configure each meter run, which eliminates redundant meter run data
within a station and enables faster data processing.
You can group meter runs among the maximum of twelve stations in any
combination. Meter runs belong in the same station when they have the
same gas composition data and calculation methods. Stations allow you to:

Set contract hours differently for each station.
Designate several individual meter runs as part of a station.
Configure one to twelve meter runs for each station.

1.4.3 Flow Calculations
Gas and liquid calculation methods include:

AGA and API Chapter 21 compliant for AGA linear and differential
meter types.
AGA 3 – Orifice Plates for gas.
AGA 7 – Turbine Meters (ISO 9951) for gas.
AGA 8 – Compressibility for Detailed (ISO 12213-2), Gross I (ISO
12213-3), and Gross II for gas.
ISO 5167 – Orifice Plates for liquid.
API 12 – Turbine Meters for liquid.

ROC827 firmware completes full calculations every second on all
configured runs (up to 12) for AGA 3, AGA 7, AGA 8, ISO 5167, and
ISO 9951.
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AGA 3 calculations conform to the methods described in American Gas
Association Report No. 3, Orifice Metering of Natural Gas and Other
Related Hydrocarbon Fluids. Based on the second and third editions, the
calculation method is 1992 AGA 3.
The AGA 7 calculations conform to methods described in American Gas
Association Report No. 7, Measurement of Gas by Turbine Meters, and
use the AGA 8 method for determining the compressibility factor.
The AGA 8 method calculates the compressibility factor based on the
physical chemistry of the component gasses at specified temperatures and
pressures.
The firmware supports liquid calculation methods ISO 5167 and API 12.
Factors for API 12 correction must be supplied through a Function
Sequence Table (FST) or user program. For more information, refer either
to the Function Sequence Table (FST) User Manual (Form A4625) or the
ROCLINK 800 Configuration Software User Manual (Form A6121).

1.4.4 Automatic Self Tests
The operating system firmware supports diagnostic tests on the ROC827
hardware, such as RAM integrity, Real-Time Clock operation, input
power voltage, board temperature, and watchdog timer.
The ROC827 periodically performs the following self-tests:

Voltage tests (battery low and battery high) ensure the ROC827 has
enough power to run while not allowing the battery to be overcharged.
The ROC827 operates with 12 Volts dc (nominal) power. The LEDs
become active when input power with the proper polarity and startup
voltage (9.00 to 11.25 Volts dc) is applied to the BAT+ / BAT–
connectors. Refer to Table 1-1.
The CPU controls the software “watchdog.” This watchdog checks the
software for validity every 2.7 seconds. If necessary, the processor
automatically resets.
The ROC827 monitors Multi-Variable Sensor(s), if applicable, for
accurate and continuous operation.
A memory validity self-test is performed to ensure the integrity of
memory.

1.4.5 Low Power Modes
The ROC827 uses low power operation under predetermined conditions
and supports two low power modes, Standby and Sleep.

Issued Mar-06

Standby
The ROC827 uses this mode during periods of inactivity. When the
operating system cannot find a task to run, the ROC827 enters Standby
mode. This mode keeps all peripherals running and is transparent to

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ROC827 Instruction Manual

the user. The ROC827 wakes from Standby mode when it needs to
perform a task.
Sleep
The ROC827 uses this mode if it detects a low battery voltage. The
System AI Battery Point Number 1 measures the battery voltage and
compares it to the LoLo Alarm limit associated with this point. (The
default value for the LoLo Alarm limit is 10.6 Volts dc.) When in
Sleep mode, AUXsw is turned off. For information on configuring
alarms and System AI points, refer to the ROCLINK 800
Configuration Software User Manual (Form A6121).
Note: Sleep mode applies only to ROC827s using the 12 V dc Power

Input module (PM-12).

1.4.6 Proportional, Integral, and Derivative (PID)
The PID Control applications firmware provides Proportional, Integral,
and Derivative (PID) gain control for the ROC827 and enables the stable
operation of 16 PID loops that employ a regulating device, such as a
control valve.
The firmware sets up an independent PID algorithm (loop) in the
ROC827. The PID loop has its own user-defined input, output, and
override capability.
The typical use for PID control is to maintain a Process Variable at a
setpoint. If you configure PID override control, the primary loop is
normally in control of the regulating device. When the change in output
for the primary loop becomes less or greater (user-definable) than the
change in output calculated for the secondary (override) loop, the override
loop takes control of the regulating device. When the switchover
conditions are no longer met, the primary loop regains control of the
device. Parameters are also available to force the PID into either loop or
force it to stay in one loop.

1.4.7 Function Sequence Table (FST)
The Function Sequence Table (FST) applications firmware gives analog
and discrete sequencing control capability to the ROC827. This
programmable control is implemented in an FST, which defines the
actions the ROC827 performs using a series of functions. To develop
FSTs, you use the FST Editor in the ROCLINK 800 Configuration
software.
The function is the basic building block of an FST. You organize
functions in a sequence of steps to form a control algorithm. Each function
step can consist of a label, a command, and associated arguments. Use
labels to identify functions and allow branching to specific steps within an
FST. You select commands from a library of mathematical, logical, and
other command options. Command names consist of up to three characters
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or symbols. Finally, arguments provide access to process I/O points and
retrieve real-time values. A function may have zero, one, or two
arguments.
The FST Editor provides a workspace into which you can enter—for each
FST—either a maximum of 500 lines or a maximum of 3000 bytes. Since
the total amount of memory each FST uses is based on the number of steps
and the commands used in each step and since different commands
consume different amounts of memory, estimating the memory usage of
an FST is difficult. Only after compiling an individual FST can you
conclusively know its memory usage.
For further information on FSTs, refer to the ROCLINK 800 Configuration
Software User Manual (Form A6121) or the Function Sequence Table
(FST) User Manual (Form A4625).

1.5

ROCLINK 800 Configuration Software
ROCLINK 800 Configuration software (“ROCLINK 800”) is a
Microsoft® Windows®-based program that runs on a personal computer
and enables you to monitor, configure, and calibrate the ROC827.
ROCLINK 800 has a standard, easy-to-use Windows interface. Tree-based
navigation makes accessing features quick and easy.
Many of the configuration screens, such as stations, meters, I/O, and PIDs,
are available while ROCLINK 800 is off-line. This enables you to
configure the system while either on-line or off-line with the ROC827.
The Local Operator Interface (LOI local port) provides a direct link
between the ROC827 unit and a personal computer (PC). The LOI port
uses an RJ-45 connector with standard EIA-232 (RS-232D) pinout. With a
personal computer running ROCLINK 800, you can locally configure the
ROC827, extract data, and monitor its operation.
Remote configuration is possible from a host computer using a serial or
dial-up modem communications line. Configurations can be duplicated
and saved to a disk. In addition to creating a backup, this feature is useful
when you are similarly configuring multiple ROC827s for the first time, or
when you need to make configuration changes off-line. Once you create a
backup configuration file, you can load it into a ROC827 by using the
Download function.
Access to the ROC827 is restricted to authorized users with correct User
ID and password.
You can build custom displays for the ROC827 that combine both graphic
and dynamic data elements. The displays can monitor the operation of the
ROC827 either locally or remotely.
You can archive historical values for any numeric parameter in the
ROC827. For each parameter configured for historical archiving, the

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system keeps time-stamped minute, periodic, and daily data values as well
as yesterday’s and today’s daily minimum and maximum values.
You can collect history values from the ROC827 using ROCLINK 800 or
another third-party host system. You can view history directly from the
ROC827 or from a previously saved disk file. For each history segment,
you can configure the number of periodic history values archived, the
frequency of archiving the periodic values, the number of daily values
archived, and the contract hour.
ROCLINK 800 can create an EFM (Electronic Flow Measurement) report
file that contains all the configuration, alarms, events, periodic and daily
history logs, and other history logs associated with the stations and meter
runs in the ROC827. This file then becomes the custody transfer audit
trail.
The SRBX (Spontaneous-Report-By-Exception) alarming feature is
available for the host communication ports (Local and dial-up modem
ports). SRBX allows the ROC827 to contact the host to report an alarm
condition.
Use ROCLINK 800 to:

1.6

Configure and view Input/Output (I/O) points, flow calculations, meter
runs, PID control loops, system parameters, and power management
features.
Retrieve, save, and report historical data.
Retrieve, save, and report events and alarms.
Perform five-point calibration on Analog Inputs and Multi-Variable
Sensor Inputs.
Perform three-point calibration on RTD Inputs.
Implement user security.
Create, save, and edit graphical displays.
Create, save, edit, and debug Function Sequence Tables (FSTs) of up
to 500 lines each.
Set up communication parameters for direct connection, telephone
modems, and other communications methods.
Configure Modbus parameters.
Set up radio power control.
Update the firmware.

DS800 Development Suite Software
DS800 Development Suite software allows you to program in any one of
the five IEC 61131-3 languages. You can download DS800 applications to
a ROC827 over the Ethernet port, independently of the ROCLINK 800
software.

Issued Mar-06

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DS800 Development Suite software allows programming in all five of the
IEC 61131-3 languages:

Ladder Logic Diagrams (LD).
Sequential Function Chart (SFC).
Function Block Diagram (FBD).
Structured Text (ST).
Instruction List (IL).

A Flow Chart language provides a sixth programming language. With
these six languages, FSTs, and built-in functionality, you can configure
and program the ROC827 in an environment in which you are
comfortable.
You can download and implement programs developed in the DS800
Development Suite software in the ROC827 in addition to—or as an
alternative to—FST programs. DS800 software has definite benefits for
programmers who prefer to use the IEC 61131-3 languages, who desire to
multi-drop units in a distributed architecture, or who desire enhanced
program diagnostics capabilities.
Additional DS800 Development Suite software features include:

1.7

Cross-reference (bindings) between variables in separate ROC827
units.
Variable Dictionary.
Off-line simulation for diagnostics and testing.
On-line modification of programs.
On-line debugging of programs.
Locking and forcing of variables.
User developed functions and function blocks.
User defined templates.
Creation and support of user defined libraries.

Expanded Backplane
The expanded backplane is a key component to the ability of the ROC827
to expand its I/O capabilities to meet your needs. The ROC827 base unit
can accommodate up to four additional expanded backplanes, which easily
snap together. This increases the total number of available I/O slots to 27.
Refer to Chapter 2, Installation and Use, for instructions on adding
backplanes to the ROC827 base unit. Refer to Chapter 3, Power
Connections, to assess the power requirements for any particular I/O
configuration.

Issued Mar-06

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1.8

Related Specification Sheets
For technical details on the ROC827 and the ROC800-Series expanded
backplane, refer to the specification sheet 6:ROC827. The most current
version of this specification sheet is available at
www.EmersonProcess.com/flow.
Note: Since the expanded backplanes accommodate the same I/O modules

as the ROC827 base unit, the firmware specifications for the expanded
backplane are identical to those for the ROC827. However, because of the
opportunity for different configurations, power requirements differ. Refer
to Chapter 3, Power Connections, for specific information.

Issued Mar-06

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Chapter 2 – Installation and Use
This chapter describes the ROC827 housing (case), its backplane
(electronic connection board at the back of the housing), the ROC800Series CPU (central processing unit), and the ROC800-Series Expanded
Backplane (EXP). This chapter provides a description and specifications
of these hardware items and explains installation and startup of the
ROC827.
In This Chapter
2.1

2.2
2.3

2.4

2.5

2.6

2.7

2.8

2.1

Installation Requirements ........................................................................2-1
2.1.1 Environmental Requirements ........................................................2-2
2.1.2 Site Requirements .........................................................................2-2
2.1.3 Compliance with Hazardous Area Standards ................................2-3
2.1.4 Power Installation Requirements ...................................................2-4
2.1.5 Grounding Installation Requirements ............................................2-4
2.1.6 I/O Wiring Requirements................................................................2-5
Required Tools ........................................................................................2-5
Housing....................................................................................................2-5
2.3.1 Removing and Replacing End Caps..............................................2-6
2.3.2 Removing and Installing Wire Channel Covers .............................2-6
2.3.3 Removing and Installing Module Covers .......................................2-7
Mounting the ROC827 on a DIN Rail ......................................................2-7
2.4.1 Installing the DIN Rail ....................................................................2-9
2.4.2 Securing the ROC827 on the DIN Rail ..........................................2-9
2.4.3 Removing the ROC827 from the DIN Rail ...................................2-10
ROC800-Series Expanded Backplane (EXP)........................................2-10
2.5.1 Attaching an Expandable Backplane ...........................................2-11
2.5.2 Removing an Expandable Backplane..........................................2-12
Central Processor Unit (CPU) ...............................................................2-13
2.6.1 Removing the CPU Module .........................................................2-16
2.6.2 Installing the CPU Module ...........................................................2-16
License Keys .........................................................................................2-17
2.7.1 Installing a License Key ...............................................................2-18
2.7.2 Removing a License Key .............................................................2-19
Startup and Operation ...........................................................................2-19
2.8.1 Startup..........................................................................................2-20
2.8.2 Operation .....................................................................................2-20

Installation Requirements
The ROC827’s design makes it highly adaptable to a wide variety of
installations. Consequently, this manual cannot cover all possible
installation scenarios. Contact your local sales representative if you
require information concerning a specific installation not described in this
manual.
Planning is essential to a good installation. Because installation
requirements depend on many factors (such as the application, location,

Issued Mar-06

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ROC827 Instruction Manual

ground conditions, climate, and accessibility), this document only
provides generalized guidelines.

2.1.1 Environmental Requirements
Always install the ROC827 in a user-supplied enclosure, as the ROC827
requires protection from direct exposure to rain, snow, ice, blowing dust or
debris, and corrosive atmospheres. If you install the ROC827 outside a
building, it must be placed in a National Electrical Manufacturer’s
Association (NEMA) 3 or higher rated enclosure to ensure the necessary
level of protection.
Note: In salt spray environments, it is especially important to ensure that

the enclosure—including all entry and exit points—is sealed properly.
The ROC827 operates over a wide range of temperatures. However, in
extreme climates it may be necessary to provide temperature-controlling
devices to maintain stable operating conditions. In extremely hot climates,
a filtered ventilation system or air conditioning may be required. In
extremely cold climates, it may be necessary to provide a thermostatically
controlled heater in the same enclosure as the ROC827. To maintain a
non-condensing atmosphere inside the ROC827 enclosure in areas of high
humidity, it may be necessary to add heat or dehumidification.

2.1.2 Site Requirements
When locating the ROC827 on the site, careful consideration can help
reduce future operational problems. Consider the following items when
choosing a location:

Issued Mar-06

Local, state, and federal codes often place restrictions on locations and
dictate site requirements. Examples of these restrictions are fall
distance from a meter run, distance from pipe flanges, and hazardous
area classifications. Ensure that all code requirements are met.

Choose a location for the ROC827 to minimize the length of signal
and power wiring.

Locate ROC827s equipped for radio communications so the antenna
has an unobstructed signal path. Antennas should not be aimed into
storage tanks, buildings, or other tall structures. If possible, antennas
should be located at the highest point on the site. Overhead clearance
should be sufficient to allow the antenna to be raised to a height of at
least twenty feet.

To minimize interference with radio communications, choose a
location for the ROC827 away from electrical noise sources, such as
engines, large electric motors, and utility line transformers.

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Choose a location for the ROC827 away from heavy traffic areas to
reduce the risk of being damaged by vehicles. However, provide
adequate vehicle access to aid monitoring and maintenance.

The site must comply with class limits of Part 15 of the FCC rules.
Operation is subject to the following two conditions: (1) The device
may not cause harmful interference, and (2) the device must accept
any interference received, including interference that may cause
undesired operation.

2.1.3 Compliance with Hazardous Area Standards
The ROC hazardous location approval is for Class I, Division 2, Groups
A, B, C, and D. The Class, Division, and Group terms include:

Class defines the general nature of the hazardous material in the
surrounding atmosphere. Class I is for locations where flammable
gases or vapors may be present in the air in quantities sufficient to
produce explosive or ignitable mixtures.

Division defines the probability of hazardous material being present in
an ignitable concentration in the surrounding atmosphere. Division 2
locations are locations that are presumed to be hazardous only in an
abnormal situation.

Group defines the hazardous material in the surrounding atmosphere.
Groups A to D are:
o Group A: Atmosphere containing acetylene.
o Group B: Atmosphere containing hydrogen, gases, or vapors of
equivalent nature.
o Group C: Atmosphere containing ethylene, gases, or vapors of
equivalent nature.
o Group D: Atmosphere containing propane, gases, or vapors of
equivalent nature.

For the ROC827 to be approved for hazardous locations, it must be
installed in accordance with the National Electrical Code (NEC)
guidelines or other applicable codes.
Caution

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2.1.4 Power Installation Requirements
Be sure to route power away from hazardous areas, as well as sensitive
monitoring and radio equipment. Local and company codes generally
provide guidelines for installations. Adhere rigorously to all local and
National Electrical Code (NEC) requirements.
The removable terminal blocks accept 12 American Wire Gauge (AWG)
or smaller wiring.
Although the ROC827 can operate on different DC voltages based on the
installed Power Input module, it is good practice when using a batterybacked system to install a low-voltage cutoff device to help protect
batteries and other devices the ROC827 does not power. Similarly, when
the ROC827 uses a PM-24 Power Input module with a 24 V dc batterybacked system, it is a good practice to install an appropriate low voltage
cutoff device to protect the battery back-up.

2.1.5 Grounding Installation Requirements
If your company has no specific grounding requirements, install the
ROC827 as a floating system (unconnected to ground). Otherwise, follow
your company’s specific grounding practices. However, if you are making
a connection between a grounded device and the ROC827 EIA-232 (RS232) port, ground the ROC827 Power Input module either by connecting
the PM-12’s BAT– to ground or by connecting either of the PM-24’s
negative Power Inputs to ground.
The National Electrical Code (NEC) governs the ground wiring
requirements. When the equipment uses a DC voltage source, the
grounding system must terminate at the service disconnect. All equipment
grounding conductors must provide an uninterrupted electrical path to the
service disconnect. This includes wire or conduit carrying the power
supply conductors.

The National Electrical Code Article 250-83 (1993), paragraph c,
defines the material and installation requirements for grounding
electrodes.

The National Electrical Code Article 250-91 (1993), paragraph a,
defines the material requirements for grounding electrode conductors.

The National Electrical Code Article 250-92 (1993), paragraph a,
provides installation requirements for grounding electrode conductors.

The National Electrical Code Article 250-95 (1993) defines the size
requirements for equipment grounding conductors.

Improper grounding or poor grounding practice can often cause problems,
such as the introduction of ground loops into your system. Proper
grounding of the ROC827 helps to reduce the effects of electrical noise on
the ROC827’s operation and protects against lightning.
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Install a surge protection device at the service disconnect on DC voltage
source systems to protect against lightning and power surges for the
installed equipment. All earth grounds must have an earth to ground rod or
grid impedance of 25 ohms or less as measured with a ground system
tester. You may also consider a telephone surge protector for the dial-up
modem communications module.
A pipeline with cathodic protection is not a good ground. Do not tie
common to the cathodic part of the pipeline.
When connecting shielded cable, be sure to tie the shielded cable to earth
ground at the end of the cable attached to the ROC827 only. Leave the
other end of the shielded cable open to avoid ground loops.

2.1.6 I/O Wiring Requirements
I/O wiring requirements are site- and application-dependent. Local, state,
and NEC requirements determine the I/O wiring installation methods.
Direct buried cable, conduit and cable, or overhead cable are all options
for I/O wiring installations.
Shielded, twisted-pair cable is recommended for I/O signal wiring. The
twisted-pair minimizes signal errors caused by Electro-Magnetic
Interference (EMI), Radio Frequency Interference (RFI), and transients.
Use insulated, shielded, twisted-pair wiring when using MVS signal lines.
The removable terminal blocks accept 12 AWG or smaller wire.

2.2

Required Tools
Use the following tools to perform installation and maintenance
procedures on the ROC827. For tools required for installation or
maintenance of accessories, refer to the ROC/FloBoss Accessories
Instruction Manual (Form A4637).

2.3

Philips screwdriver, size 0.

Flat blade screwdriver, size 2.5 mm (0.1 inch).

Flat blade screwdriver, large, or other prying instrument.

Housing
The housing case is made of a patented Acrylonitrile Butadiene Styrene
(ABS) plastic (U.S. Patent 6,771,513) and the wire channel covers are
made of polypropylene plastic.

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2.3.1 Removing and Replacing End Caps
Normal use and maintenance of the ROC827 does not typically require
you to remove the end caps on the housing. Follow these procedures in
case removal is necessary.
To remove the end caps:
1. Place the tip of a flat-blade screwdriver into the top pry hole of the end

cap and loosen the end cap by pulling the handle of the screwdriver
away from the backplane.
Note: The pry holes are located on the sides of the end caps.
2. Place the tip of a flat-blade screwdriver into the bottom pry hole of the

end cap and loosen the end cap by pulling the handle of the
screwdriver away from the backplane.
3. Pivot the front end cap away from the back edge of the housing.

To replace the end caps:
1. Align the back edge of the end cap on the housing.
2. Rotate the end cap towards the housing and snap the end cap into

place.

2.3.2 Removing and Installing Wire Channel Covers
Install the wire channel covers over the wiring channels once the wiring of
the terminal blocks is complete. Wire channel covers are located on the
front of the ROC827 housing.
To remove a wire channel cover:
1. Grasp the wire channel cover at both the top and bottom.
2. Start at the top or bottom and pull the wire channel cover out of the

wire channel.
To replace a wire channel cover:
1. Align the wire channel cover over the wire channel, allowing

unobstructed wire access.
2. Press the wire channel cover into place until it snaps.
Note: The tabs on the left side of the wire channel cover should rest in the

slots on the left edge of the channel.

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2.3.3 Removing and Installing Module Covers
Before you insert an I/O or communications module, remove the module
cover over the empty module slots in which you intend to install the
modules. Although you are not required to remove the power to the
ROC827 to perform this procedure, caution is always advisable when
working with a powered ROC827.
Caution

To avoid circuit damage when working inside the unit, use appropriate
electrostatic discharge precautions (such as wearing a grounded wrist
strap).
When working on units located in a hazardous area (where explosive
gases may be present), make sure the area is in a non-hazardous state
before performing procedures. Performing these procedures in a
hazardous area could result in personal injury or property damage.

To remove a module cover:
1. Remove the wire channel cover.
2. Unscrew the two captive screws on the face of the cover.
3. Using the tab at the left side of the removable terminal block, pull the

module cover straight out from the ROC827 housing.
Note: If you remove a module for an extended period, install a module

cover plate over the empty module slot to keep dust and other matter from
getting into the ROC827.
To install a module cover:
1. Place the module cover over the module slot.
2. Screw the two captive screws on the module cover plate.
3. Replace the wire channel cover.

2.4

Mounting the ROC827 on a DIN Rail
When choosing an installation site, be sure to check all clearances.
Provide adequate clearance for wiring and service. The ROC827 mounts
on Type 35 DIN rails and requires two strips of DIN rail. Refer to Figures
2-1, 2-2, and 2-3.
Note: English measurement units (inches) appear in brackets in the

following figures.

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Figure 2-1. Side View of the ROC827

Figure 2-2. Bottom View of the ROC827

Note: The distance from the mounting panel to the front of the ROC827 is

174mm (6.85”). If you mount the ROC827 inside an enclosure and want to
connect a cable to the LOI or Ethernet port, ensure adequate clearance for
the cable and the enclosure door. For example, a molded RJ-45 CAT 5
cable can increase the clearance requirement for the enclosure by 25mm
(1”).

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DIN Rail Mount
DIN Rail Catch

DIN Rail Mount

Figure 2-3. Back View of the ROC827

2.4.1 Installing the DIN Rail
To install the ROC827 using the 35 x 7.5 mm DIN rails:
1. Mount the lower DIN rail onto the enclosure panel.
2. Snap the upper DIN rail into the ROC827 upper DIN rail mounting

blocks.
3. Place the ROC827 onto the lower rail that is mounted to the plane and

ensure that the ROC827 (with the second strip of DIN rail still in its
upper mounting blocks) is seated against the panel.
4. Fasten the upper strip of DIN rail to the panel.
Note: Following this procedure (which uses the ROC827 to provide the

correct DIN rail spacing) ensures that the ROC827 is held securely in
place.

2.4.2 Securing the ROC827 on the DIN Rail
When placed correctly, the DIN rail catches (see Figure 2-3) secure the
ROC to the DIN rail. Place the catches according to the following
configuration:

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ROC827 and one EXP: Place catches on ROC827 and EXP.

ROC827 and two EXPs: Place catches on ROC827 and second EXP.

ROC827 and three EXPs: Place catches on ROC827 and third EXP.

ROC827 and four EXPs: Place catches on ROC827 and second and
fourth EXP.

2.4.3 Removing the ROC827 from the DIN Rail
To remove the ROC827 from DIN rails, gently lever the DIN rail catches
(located on the top of the housing) up approximately 3-4mm (1/8”). Then
tilt the top of the ROC827 away from the DIN rail.

2.5

ROC800-Series Expanded Backplane (EXP)
The expanded backplane has connectors for the central processing unit
(CPU), the power input module, and all the I/O and communication
modules. Once a module is completely inserted into the module slot, the
connector on the module fits into one of the connectors on the backplane.
The backplane does not require any wiring, so no jumpers are associated
with the backplane.

Figure 2-4. ROC827 and Expanded Backplane
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Removing the backplane from the housing is not recommended, as there
are no field serviceable parts. If the backplane requires maintenance,
please contact your local sales representative.

2.5.1 Attaching an Expandable Backplane
To attach an EXP to an existing ROC827 base unit or to another EXP:
1. Remove the right-hand end cap from the ROC827 as described in
Section 2.3.1, “Removing and Replacing End Caps.”
Note: The EXP may not have attached end caps. If it does, remove the

left-hand end cap.
2. Remove the wire channel covers from the ROC827 as described in
Section 2.3.2, “Removing and Installing Wire Channel Covers.”
3. Align and gently press together the front right edge of the EXP against
the front left edge of the ROC827. This aligns the power connector on
the EXP’s backplane with the socket on the ROC827’s backplane (see
Figure 2-5).

Figure 2-5. Power connector on the EXP Backplane
4. Pivot the back edges of the ROC827 and the EXP toward each other
until they click together.
Note: The plastic locking clips at the back of the EXP click when the

two units securely fasten together.
5. Attach an end cap to the right side of the EXP (if it does not have one).
Do not replace the wire channel covers until you finish installing and
wiring the modules in the EXP.
Note: Adding an EXP–and the modules it will hold–may require you to

adjust your ROC827’s power consumption requirements. Refer to Section
3.2, “Determining Power Consumption.”

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2.5.2 Removing an Expandable Backplane
Note: Before you remove an EXP, you must power down the ROC827,

disconnect all wiring from all modules, and remove the entire unit from
the DIN rail. Once the entire ROC827 is free of the DIN rail, you can
detach an individual EXP.
To remove an EXP from an existing ROC827 base unit:
1. Remove the right-hand end cap from the EXP as described in Section
2.3.1, “Removing and Replacing End Caps.”
2. Remove the wire channel covers on either side of the EXP you want to
detach, as described in Section 2.3.2, “Removing and Installing Wire
Channel Covers.”
3. Turn the ROC827 around so that the back of the unit faces you (as
shown in Figure 2-6).
Note: It may be useful to place the ROC827 face-down on a flat

surface with the EXP you want to detach hanging free of the surface’s
edge.

Locking clips and
tabs

Figure 2-6. Plastic Snaps on the Back of the EXP

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4. Using a flat-bladed screwdriver, gently pry the plastic locking clips at
the upper and lower back edge of the EXP housing away from their
securing tabs.
Note: Applying too much pressure breaks the plastic hooks.

5. Once you free the plastic locking clips from their securing tabs, gently
pivot the back of the EXP away from the ROC827.
Note: The EXP detaches quickly. Hold it securely to prevent it from

falling.
6. Place the detached EXP in a secure location.
7. Replace the right-hand end cap.
8. Replace the ROC827 on the DIN rail.
9. Reattach all wiring.
10. Replace the wire channel covers.

2.6

Central Processor Unit (CPU)
The ROC827 uses a standard ROC800-Series central processing unit
(CPU) containing the microprocessor, the firmware, connectors to the
backplane, the three built-in communication ports (two with LEDs), a
LED low power wakeup button, a RESET button, the application License
Key connectors, a STATUS LED indicating system integrity, and the main
processor (refer to Figures 2-5 and 2-6 and Tables 2-1 and 2-2).
The 32-bit microprocessor is based on a Motorola MPC862 Quad
Integrated Communications Controller (PowerQUICC) PowerPC
processor running at 50 MHz.
The internal Sanyo 3-volt CR2430 lithium backup battery provides backup
of the data and the Real-Time Clock when the main power is not
connected.

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Securing Screw

LED Button
LOI – EIA-232 (RS-232D)x
STATUS LED x
LICENSE KEYS x
RESET Button
ETHERNET x

EIA-232 (RS-232C)
Securing Screw

Figure 2-6. CPU Front View

Battery

LED Button
Boot ROM
License Key (at P4)
License Key (at P6)
RESET Button

Figure 2-7. CPU Connectors

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Table 2-1. CPU Connector Locations
CPU Number
J4
P2
P3
P4
P6
SW1
SW2

Definitions
Not Used
LOI Port RJ-45
Ethernet RJ-45
License Key Terminal
License Key Terminal
LED Button
RESET Button

The CPU contains a microprocessor supervisory circuit. This device
monitors the battery voltage, resets the processor, and disables the SRAM
chip if the voltage goes out of tolerance. The CPU has an internal Analog
to Digital Converter (A/D). The A/D monitors the supply voltage and
board temperature (refer to “Automatic Self-Tests” in Chapter 1, General
Information).
The CPU has two buttons, LED and RESET (see Figures 2-6 or 2-7):

RESET: Use this button to reset the ROC827 to system defaults (refer
to “Preserving Configuration and Log Data” in Chapter 6,
Troubleshooting).
Note: First, remove power from the ROC827. Then press and hold in

the RESET button while you re-apply power to the ROC827. Finally,
release the RESET button.

LED: Press to turn on the LEDs on the CPU module, I/O modules,
and communication modules when the ROC827 has timed out.

The STATUS LED helps to indicate the integrity of the ROC827 (refer to
Table 2-2).
Table 2-2. STATUS LED Functions
Status LED
Continually
Lit
Continually
Lit
Flashing
Flashing
Flashing

Color

Definitions

Solution

Green

ROC827 functioning normally.

N/A

Low Battery Voltage alert.
System AI (Point number 1) LoLo
Alarm.
Firmware invalid.
Firmware update in
decompression.
Firmware update is flashing image.

Charge battery.

Red

Apply DC voltage source.

Update firmware.

Do not restart the ROC827.

Green
Green-Green
to Red-Red
Green to Red

To save power, you can enable or disable the LEDs on the ROC827 (with
the exception of the LED on the power module). Using the ROCLINK 800
software, you can define how long the LEDs remains on after you press
the LED button on the CPU module. For instance, with the default setting
of five minutes, all LEDs turn off after five minutes. If you press the LED
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button, LEDs light and stay lit again for five minutes. By entering a 0
(zero) setting, the LED always stays lit.

2.6.1 Removing the CPU Module
To remove the CPU module:
Caution

Failure to exercise proper electrostatic discharge precautions (such as
wearing a grounded wrist strap) may reset the processor or damage
electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive
gases may be present), make sure the area is in a non-hazardous state
before performing procedures. Performing these procedures in a
hazardous area could result in personal injury or property damage.

1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Remove power from the ROC827.
3. Remove the wire channel cover.
4. Unscrew the two small screws on the front of the CPU module and

remove the faceplate.
5. Place a small screwdriver under the ejector clip at the top or bottom of

the CPU module and lightly pry the CPU module out of its socket.
You may find it easiest to carefully pry on the top ejector clip a little,
then carefully pry the bottom ejector (refer toFigure2-5). You will feel
and hear the CPU as it detaches from the backplane.
6. Remove the CPU module carefully. Do not scrape either side of the

module against the ROC827. Make sure not to pull on any cables
attached to the CPU module.

2.6.2 Installing the CPU Module
To install the CPU module:
Caution

1. Slide the CPU module into the slot.
2. Press the CPU firmly into the slot, ensuring the ejector clips rest on the

module rail guides. The connectors at the back of the CPU module fit
securely into the connectors on the backplane.
3. Place the CPU faceplate on the CPU.
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4. Tighten the two screws on the faceplate of the CPU module firmly (see

Figure 2-5).
5. Replace the wire channel cover.
6. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
7. Return power to the ROC827 unit.

2.7

License Keys
License keys with valid license codes grant access to applications or, in
some cases, allow optional firmware functionality to execute. In some
situations, a license key may also be required before you can run the
application. Examples of licensed applications include DS800
Development Suite software, meter run calculations, and various user
programs. You can then configure these applications using ROCLINK 800
or the DS800 Development Suite software.
The term “license key” refers to the physical piece of hardware (refer to
Figure 2-6) that can contain up to seven different licenses. Each ROC827
can have none, one, or two installed license keys. If you remove a license
key after enabling an application, the firmware disables the task from
running. This prevents unauthorized execution of protected applications in
a ROC827.

Figure 2-8. License Key

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2.7.1 Installing a License Key
To install a license key:
Caution

1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Remove power from the ROC827.
3. Remove the wire channel cover.
4. Unscrew the screws from the CPU faceplate.
5. Remove the CPU faceplate.
6. Place the license key in the appropriate terminal slot (P4 or P6) in the

CPU (refer to Figure 2-7).

Incorrect

Correct

Figure 2-9. License Key Installation
Note: If you are installing a single license key, place it in slot P4.
7. Press the license key into the terminal until it is firmly seated. Refer to

Figure 2-8.
8. Replace the CPU faceplate.
9. Replace the screws on the CPU faceplate.
10. Replace the wire channel cover.
11. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
12. Restore power to the ROC827.

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2.7.2 Removing a License Key
To remove a license key:
Caution

1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Remove power from the ROC827.
3. Remove the wire channel cover.
4. Unscrew the screws from the CPU faceplate.
5. Remove the CPU faceplate.
6. Remove the license key from the appropriate terminal slot (P4 or P6)

in the CPU (refer to Figure 2-7).
7. Replace the CPU faceplate.
8. Replace the screws from the CPU faceplate.
9. Replace the wire channel cover.
10. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
11. Restore power to the ROC827.

2.8

Startup and Operation
Before starting the ROC827, perform the following checks to ensure the
unit components are properly installed.

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Make sure the power input module is properly seated in the backplane.

Make sure I/O and communication modules are seated in the
backplane.

Check the field wiring for proper installation.

Make sure the input power has the correct polarity.

Make sure the input power is fused at the power source.

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Check the input power polarity before connecting power to the ROC827.
Incorrect polarity can damage the ROC827.

Caution

2.8.1 Startup
Before you apply power to the ROC827, assess the power requirements
(including the base unit, EXPs, and any installed modules and peripheral
devices) that comprise the total configuration for your ROC827. Refer to
“Determining Power Consumption” in Chapter 3, Power Connections.
Apply power to the ROC827 (refer to “Installing a Power Input Module”
in Chapter 3, Power Connections). The power input BAT+ LED indicator
should light green to indicate that the applied voltage is correct. Then, the
STATUS indicator on the CPU should light to indicate a valid operation.
Depending on the Power Saving Mode setting, the STATUS indicator may
not remain lit during operation (refer to Table 2-2).

2.8.2 Operation
Once startup is successful, configure the ROC827 to meet the
requirements of the application. Once it is configured and you have
calibrated the I/O and any associated Multi-Variable Sensors (MVS,
MVSS, MVSI, and so on), place the ROC827 into operation.
Caution

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Chapter 3 – Power Connections
This chapter discusses the Power Input modules. It describes the modules,
explains how to install and wire them, and provides worksheets to help
you determine—and tune—the power requirements for the I/O and
communications modules you can install in the ROC827 and the EXPs.
In This Chapter
3.1

3.2
3.3
3.4
3.5

3.6

3.1

Power Input Module Descriptions............................................................3-1
3.1.1 12-Volt DC Power Input Module (PM-12) ......................................3-1
3.1.2 24-Volt DC Power Input Module (PM-24) ......................................3-3
3.1.3 Auxiliary Output (AUX+ and AUX–) ...............................................3-4
3.1.4 Switched Auxiliary Output (AUXSW+ and AUXSW–)........................3-6
Determining Power Consumption............................................................3-7
3.2.1 Tuning the Configuration..............................................................3-11
Removing a Power Input Module ..........................................................3-20
Installing a Power Input Module ............................................................3-21
Connecting the ROC827 to Wiring ........................................................3-21
3.5.1 Wiring the DC Power Input Module .............................................3-22
3.5.2 Wiring the External Batteries .......................................................3-23
3.5.3 Replacing the Internal Battery .....................................................3-25
Related Specification Sheets.................................................................3-26

Power Input Module Descriptions
As a ROC800-Series controller, the ROC827 uses a Power Input module
to convert external input power to the voltage levels the ROC827’s
electronics require. The module also monitors voltage levels to ensure
proper operation. Two Power Input modules—12 V dc (PM-12) and 24 V
dc (PM-24)—are available for the ROC827.
The power consumption of a ROC827 and any attached expandable
backplanes determines the current requirements for the external power
supply. Refer to Section 3.2, “Determining Power Consumption” for a
discussion and worksheets on assessing power requirements.
The Power Input module has removable terminal blocks for wiring and
servicing. The terminal blocks can accept wire sizes 12 AWG (American
Wire Gauge) or smaller.

3.1.1 12-Volt DC Power Input Module (PM-12)
Using the PM-12, the ROC827 can accept 12 Volts dc (nominal) input
power from an AC/DC converter or other 12-volt dc supply. The input
source should be fused and connected to the BAT+ and BAT– terminals
(see Figure 3-1). The base system (CPU, power input, and backplane)
requires less than 70 mA. The Power Input module economizes power
consumption using 3.3 Volts dc switching power that provides power to
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the ROC800-Series modules via the backplane. The ROC827 requires
11.25 to 14.25 Volts dc for proper operation.

VOK LED

BAT+ / BAT–
CHG+ / CHG–
AUX+ / AUX–

VOFF LED

AUXSW+ / AUXSW–

VOVER LED
TEMP LED

Figure 3-1. 12 Volt dc Power Input Module
The CHG+ and CHG– terminals comprise an Analog Input channel that
allows you to monitor an external voltage between 0 to 18 volts dc. For
example, you can connect a solar panel upstream of the solar regulator to
monitor the output of the solar panel. This allows you to compare the
System AI Point Number 2 for the charging voltage (CHG+) to the actual
battery voltage (BAT+) System AI Point Number 1 and take action as
required. The ROC827 has a low-voltage cut-off circuit built-in to guard
against draining power supply batteries. Refer to “Automatic Self Tests”
in Chapter 1, General Information.
Use the AUX+ / AUX– terminals to supply reverse polarity protected
source voltage to external devices, such as a radio or solenoid. Use the
AUXSW+ / AUXSW– terminals to provide switched power for external
devices. The AUXSW+ is turned off when the ROC827 detects a software
configurable voltage at the BAT+ / BAT– terminals.
Table 3-1 details the specific connection information for the 12 volt dc
(PM-12) Power Input module. Table 3-2 indicates the LED fault
indicators.

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Table 3-1. 12 Volt dc Power Input Terminal Block Connections
Terminal Blocks
BAT+ and BAT–

CHG+ and CHG–
AUX+ and AUX–
AUXSW+ and AUXSW–

Definition
Accepts 12 Volts dc nominal from an
AC/DC converter or other 12 Volts dc
supply.
Analog Input used to monitor an external
charging source.
Supplies reverse polarity protected source
voltage to external devices. Fused.
Supplies switched power for external
devices.

Volts DC
Absolute Maximum: 11.25 to 16 Volts
dc

Recommended Operating Range:
11.25 to 14.25 Volts dc

0 to 18 Volts dc

BAT+ minus ∼0.7 Volts dc

0 to 14.25 Volts dc

Table 3-2. 12 Volt DC Power Input LED Fault Indicators
Signal

LED

VOK
VOFF

Green LED on when voltage is in tolerance on BAT+ and BAT–.
Fault – Red LED on when the AUXSW+ output are disabled by
the CPU control line.
Fault – Red LED on when AUXSW+ is disabled due to excess
voltage on BAT+.
Fault – Red LED on when AUXSW+ output are disabled due to
the excess temperature of the Power Input module.

VOVER
TEMP

3.1.2 24-Volt DC Power Input Module (PM-24)
Using the PM-24, the ROC827 can accept 24 Volts dc (nominal) input
power from an AC/DC converter or other 24 Volts dc supply connected
to the + and – terminals. Connect the input power to either or both of the
+ and – channels. The 24 V dc Power Input module (PM-24) does not
have CHG terminals for monitoring a charging voltage, and does not
monitor the input voltage for alarming, sleep mode, or other monitoring
purposes. The module has two LEDs that indicate voltage is received at
the backplane and the CPU (see Figure 3-2 and Tables 3-3 and 3-4).
The base system (CPU, power input, and backplane) requires less than 70
mA. The Power Input module economizes power consumption using 3.3
Volts dc switching power that provides power to the I/O and
communications modules installed in the ROC827 and any expanded
backplanes. With this Power Input module installed, the ROC827 requires
20 to 30 Volts dc for proper operation.
Use the AUX+ and AUX– terminals to supply reverse polarity protected
source voltage to external devices, such as a radio or solenoid.

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V12 LED
+/–
V3 LED

AUX+ / AUX–

Figure 3-2. 24 Volt dc Power Input Module
Table 3-3. 24 Volt dc Power Input Terminal Block Connections
Terminal Blocks
+ and –
AUX+ and AUX–

Definition
Accepts 24 Volts dc nominal from an AC/DC converter
or other 24 Volts dc supply.
Supplies reverse polarity protected source voltage to
external devices. Fused.

Volts DC
18 to 30 Volts dc
+12 Volts dc minus ∼0.7 Volts
dc

Table 3-4. 24 Volt dc Power Input LED Indicators
Signal
V12
V3.3

LED
Green LED on when voltage is provided to backplane.
Green LED on when voltage is provided to CPU.

3.1.3 Auxiliary Output (AUX+ and AUX–)
You can use the AUX+ and AUX– terminals to supply reverse polarity
protected source voltage to external devices, such as a radio or a solenoid.
All module terminal blocks accept 12 AWG or smaller wiring. Refer to
Figures 3-3 and 3-4.
For the 12-volt dc Power Input module (PM-12), the auxiliary output
follows the voltage located at BAT+ minus ~0.7 Volts dc, which is the
protection diode voltage drop. For example, if the BAT+ voltage is 13
volts dc, then AUX+ is ~12.3 Volts dc.
For the 12-volt dc Power Input module, AUX+ / AUX– is always on and
is current-limited by a fast acting glass 2.5 Amp x 20 mm fuse. In the
event that the fuse blows, CSA requires that you replace the 2.5 Amp
fast-acting fuse with a Little Fuse 217.025 or equivalent. Refer to
“Automatic Self Tests” in Chapter 1, General Information.
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For the 24 volt Power Input module (PM-24), the AUX voltage is always
12 Volts dc minus ~0.7 Volts. AUX+ / AUX– is internally current-limited
by a 0.5 Amp Positive Temperature Coefficient (PTC).
If you need to cycle power to the radio or other device to reduce the load
on the power source (a recommended practice when using batteries), use
a Discrete Output (DO) module to switch power on and off. Refer to the
ROCLINK 800 Configuration Software User Manual (Form A6121).
Power Supply
Terminal Block
AUXsw
–
+

Other Equipment
2.5 Amps Maximum
Current On. Non-switched

AUX
–
+

–
2 Amp or less
Fast ActingFuse

Other Equipment
14.5 Volts DC Maximum @ 0.5 Amps
–
Switched Power
809AUX.DSF

Figure 3-3. 12 Volt dc Auxiliary Power Wiring
Power Supply
Terminal Block

Other Equipment
12 Volts DC Maximum @ 0.5 Amps
Current-Limited Always On

AUX
–
+

–
0.5 Amp or less
Fast Acting Fuse

809AUX24.DSF

Figure 3-4. 24 Volt dc Auxiliary Power Wiring
Removing the
Auxiliary Output Fuse

To remove the auxiliary output fuse:
1. Perform the procedure described in Section 3.3, “Removing a Power

Input Module.”
2. Remove the fuse located at F1 on the Power Input module.

Installing the Auxiliary
Output Fuse

To re-install the auxiliary output fuse:
1. Replace the fuse located at F1 on the Power Input module.
2. Perform the procedure described in Section 3.4, “Installing a Power

Input Module.”
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3.1.4 Switched Auxiliary Output (AUXSW+ and AUXSW–)
The AUXSW+ and AUXSW– terminals on the 12 volt dc Power Input
module (PM-12) provide switched power for external devices, such as
radios. AUXSW+ is current-limited for protection of the power input and
the external device via a 0.5 Amp nominal Positive Temperature
Coefficient (PTC). The AUXSW+ and AUXSW– terminals provide
voltages from 0 to 14.25 Volts dc. AUXSW+ is turned off when the
ROC827 detects a software configurable voltage (LoLo Alarm) at the
BAT+ and BAT– terminals. All module terminal blocks accept 12 AWG
or smaller wiring. Refer to Figure 3-3.
If the source voltage falls to a level below which reliable operation cannot
be ensured, the hardware circuitry on the Power Input module
automatically disables the AUXSW+ outputs. This activity occurs at
approximately 8.85 Volts dc, and is based on the LoLo Alarm limit set for
the System Battery Analog Input Point Number 1. The low input voltage
detect circuit includes approximately 0.75 Volts dc of hysteresis between
turn-off and turn-on levels.
The presence of high input voltage can damage the linear regulator. If the
dc input voltage at BAT+ exceeds 16 volts, the over-voltage detect circuit
automatically disables the linear regulator, shutting off the unit. For
further information on the STATUS LED functions, refer to Table 2-2 in
Chapter 2, Installation and Use.

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3.2

Determining Power Consumption
Determining the power consumption requirements for a ROC827
configuration involves the following steps:
1. Determine your ideal ROC827 configuration, which includes

identifying all modules, device relays, meters, solenoids, radios,
transmitters, and other devices that may receive DC power from the
complete ROC827 configuration (base unit and EXPs).
Note: You should also identify any devices (such as a touch screen

panel) that may be powered by the same system but not necessarily by
the ROC827.
2. Calculate the “worst-case” DC power consumption for that

configuration by totaling the combined power draw required for all
installed modules, as well as accounting for the power any modules
provide to external devices (through the use of +T).
Note: “+T” describes the isolated power some modules (such as AI,

AO, PI, and HART) may supply to external devices, such as 4–20 mA
pressure and temperature transducers.
3. Verify that the power input module you intend to use can meet the

power requirements calculated in the first step.
This verification helps you identify and anticipate power demands
from +T external devices that exceed the capabilities of the PM-12 or
PM-24 Power Input modules. In this case, you can then make
arrangements to externally power these field devices.
4. “Tune” (if necessary) the configuration by providing external power

or re-assessing the configuration to lessen the power requirements
from the ROC827.
To assist you in this process, this chapter contains a series of worksheets
(Tables 3-5 through 3-16) that help you to identify and assess the power
requirements for each component of your ROC827 system. Table 3-5
identifies the power requirements related to the ROC827 base unit and
summarizes the power requirements you identify on Tables 3-6 through
3-16. (Complete Tables 3-6 through 3-15 to calculate the power
consumption for each of the I/O modules, and then transfer those results
to Table 3-5.) Completing Table 3-5 enables you to quickly determine
whether the power input module you intend to use is sufficient for your
configuration. If the power module is not sufficient, you can then review
individual worksheets to determine how to best “tune” your configuration
and lessen power demands.

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General Calculation
Process

To calculate the power the ROC827 requires:
1. Determine the kind and number of communication modules and the

kind and number of expanded backplanes you are implementing.
Enter those values in the Quantity Used column of Table 3-5.
2. Multiply the PTypical value by the Quantity Used. Enter the values in

the Sub-Total column of Table 3-5. Perform this calculation for both
the communications module and the LED.
3. Determine the kind and number of I/O modules you are implementing

and complete Tables 3-6 through 3-15 for those modules. For each
applicable I/O module:
a. Calculate the PTypical values and enter them in the PTypical columns

of each table. Perform this calculation for the I/O modules, LEDs
(if applicable), channels (if applicable), and any other devices.
b. Calculate the Duty Cycle value for each I/O module and each I/O

channel (as applicable). Enter those values in the Duty Cycle
column of Tables 3-6 through 3-15.
c. Multiply the PTypical values by the Quantity Used by the Duty

Cycle on each applicable table. Enter those individual sub-totals
in the Sub-Total column on each table and add the sub-totals to
calculate the Total for the table.
4. Transfer the totals from Tables 3-6 through 3-15 to their respective

lines in the Sub-Total column on Table 3-5.
5. Add the Sub-Total values for Tables 3-6 through 3-15. Enter that

value in the Total for All Modules line on Table 3-5.
6. Add the value from the Total for ROC827 Base Unit to the Total for

All Modules. Enter that result in the Total for ROC827 Base Unit and
All Modules line.
7. Transfer the Other Devices total from Table 3-16 to its respective line

in the Sub-Total column on Table 3-5.
8. Add the values from Total for ROC827 Base Unit, Total for All

Modules, and the total for Other Devices. Enter that value in the Total
for ROC827 Base Unit, All Modules, and Other Devices line.
9. Multiply the value in the Total for ROC827 Base Unit, Total for All

Modules, and Other Devices by 0.25. Enter the result in the Power
System Safety Factor (0.25) line.
Note: This value represents a safety factor to the power system to

account for losses and other variables not factored into the power
consumption calculations. This safety factor may vary depending on
external influences. Adjust the factor value up or down accordingly.

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10. Add the values for the Power System Safety Factor (0.25) to the Total

for ROC827 Base Unit, All Modules, and Other Devices to determine
the total estimated power consumption for the configured ROC827
system.

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Table 3-5. Estimated Power Consumption
Device

Power Consumption (mW)
Description

PTYPICAL

Power Input Module PM-12

110 mA @ 12 volts dc

1320 mW

Power Input Module PM-24

55 mA @ 24 volts dc

1320 mW

1.5 mA

18 mW

4 mA @ 12 volts dc

48 mW

Per Active LED – Maximum 4

1.5 mA

18 mW

EIA-422/485 (RS-422/485) Module

112 mA @ 12 volts

1344 mW

Per Active LED – Maximum 2

1.5 mA

18 mW

95 mA @ 12 volts dc

1140 mW

1.5 mA

18 mW

70 mA @ 12 volts dc

840 mW

35 mA @ 24 volts dc

840 mW

Quantity
Used

Sub-Total
(mW)

CPU and ROC827 Backplane

Per Active LED – Maximum 10
EIA-232 (RS-232) Module

Dial-up Modem Module
Per Active LED – Maximum 4
Expanded Backplanes

Total for ROC827 Base Unit
AI Modules

Total (from Table 3-6)

AO Modules

Total (from Table 3-7)

DI Modules

Total (from Table 3-8)

DO Modules

Total (from Table 3-9)

DOR Modules

Total (from Table 3-10)

PI Modules

Total (from Table 3-11)

MVS Modules

Total (from Table 3-12)

RTD Modules

Total (from Table 3-13)

Thermocouple Modules

Total (from Table 3-14)

HART Modules

Total (from Table 3-15)
Total for All Modules

Total for ROC827 Base Unit and All Modules

Total (from Table 3-16)

Total for ROC827 Base Unit, All Modules, and
Other Devices

Power System Safety Factor (0.25)

Total for Configured ROC827

Other Devices

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3.2.1 Tuning the Configuration
The PM-12 Power Input module can supply a maximum of 36 W (36000
mW) to the backplane, which includes the +T overhead. The PM-24,
when operating between –40°C to 55°C, can supply a maximum of 30 W
(30000 mW) to the backplane. Across its entire operating range (–40°C to
85°C) the PM-24 can supply 24 W (24000 mW).
Refer to Table 3-5 and the value you entered in the Total for ROC827
Base Unit and All Modules line. That is the value against which you
“tune” your configuration to accommodate your Power Input module. If
your configuration requires more power than the Power Input module you
intend to use, you need to modify your I/O module configuration to
reduce your power requirements.
Tuning Hints

Review the content of Tables 3-6 through 3-15. Suggestions to help
you better align the configuration of your ROC827 with the capability
of the Power Input module you intend to use include:

Reduce the +T usage by providing an external power supply for as
many transmitters or field devices needed to reduce the value in the
Total for ROC827 Base Unit and All Modules line on Table 3-5 to
below the capability of the Power Input module you intend to use.

Reduce the +T usage by reducing the number of transmitters or field
devices.

Reduce the total number of I/O modules by consolidating transmitters
or field devices onto as few I/O modules as possible.

Note: Tuning your I/O module configuration may require several

iterations to rework the content of Tables 3-6 through 3-15 until your
power requirements match the capability of the Power Input module you
intend to use.

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Table 3-6. Power Consumption of the Analog Input Modules

I/O Module

Power Consumption (mW)
Description

ANALOG INPUT
84 mA @ 12 volts dc
AI Module Base
Jumper set for +T @ 12 volts dc
Channel’s mA current
Channel 1
draw from +T * 1.25 * 12
Channel 2

Channel’s mA current
draw from +T * 1.25 * 12

Channel 3

Channel’s mA current
draw from +T * 1.25 * 12

Channel 4

Channel’s mA current
draw from +T * 1.25 * 12

PTYPICAL

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

1008 mW

Jumper set for +T @ 24 volts dc
Channel’s mA current
Channel 1
draw from +T * 2.50 * 12
Channel 2

Channel’s mA current
draw from +T * 2.50 * 12

Channel 3

Channel’s mA current
draw from +T * 2.50 * 12

Channel 4

Channel’s mA current
draw from +T * 2.50 * 12
Table Total

Duty Cycle

The duty cycle is based on the average current flow compared to the
full-scale current flow value. To approximate the duty cycle, estimate
the average current consumption in relation to its maximum range. For
example, if an AI channel’s current averages 16 mA:

Duty Cycle = Average mA output ÷ Maximum mA Output = (16 ÷ 20) = 0.80

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Table 3-7. Power Consumption of the Analog Output Modules
Power Consumption (mW)

I/O Module

Description
100 mA @ 12 volts dc
AO Module Base
Jumper set for +T @ 12 volts dc
Channel’s mA current
Channel 1
draw from +T * 1.25 * 12
Channel 2

Channel’s mA current
draw from +T * 1.25 * 12

Channel 3

Channel’s mA current
draw from +T * 1.25 * 12

Channel 4

Channel’s mA current
draw from +T * 1.25 * 12

PTYPICAL

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

1200 mW

Jumper set for +T @ 24 volts dc
Channel 1

Channel’s mA current
draw from +T * 2.50 * 12

Channel 2

Channel’s mA current
draw from +T * 2.50 * 12

Channel 3

Channel’s mA current
draw from +T * 2.50 * 12

Channel 4

Channel’s mA current
draw from +T * 2.50 * 12
Table Total

Duty Cycle

Duty Cycle = Average mA output ÷ Maximum mA Output = (12 ÷ 20) = 0.60

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Table 3-8. Power Consumption of the Discrete Input Modules
Power Consumption (mW)

I/O Module

Description
19 mA @ 12 volts dc No
Channels Active
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc
3.2 mA @ 12 volts dc

DI Module Base
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Channel 8
Per Active LED –
Maximum 8

1.5 mA

PTYPICAL

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

228 mW
38.4 mW
38.4 mW
38.4 mW
38.4 mW
38.4 mW
38.4 mW
38.4 mW
38.4 mW
18 mW
Table Total

Duty Cycle

The duty cycle is the time on divided by the total time, and is
essentially the percent of time that the I/O channel is active
(maximum power consumption).

Duty Cycle = Active time ÷ (Active time + Inactive time)

For example, if a Discrete Input is active for 15 seconds out of every 60
seconds:
Duty Cycle = 15 seconds ÷ (15 seconds + 45 seconds) = 15 seconds ÷ 60 seconds = 0.25

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Table 3-9. Power Consumption of the Discrete Output Modules
Power Consumption (mW)

I/O Module

Description
DO Module
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Per Active LED –
Maximum 5

PTYPICAL

20 mA @ 12 volts dc No
Channels Active
1.5 mA
1.5 mA
1.5 mA
1.5 mA
1.5 mA

18 mW
18 mW
18 mW
18 mW
18 mW

1.5 mA

18 mW

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

240 mW

Table Total

Duty Cycle

The duty cycle is the time on divided by the total time, and is
essentially the percent of time that the I/O channel is active
(maximum power consumption).

Duty Cycle = Active time ÷ (Active time + Inactive time)

For example, if a Discrete Output is active for 15 seconds out of every 60
seconds:
Duty Cycle = 15 seconds ÷ (15 seconds + 45 seconds) = 15 seconds ÷ 60 seconds = 0.25

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Table 3-10. Power Consumption of the Discrete Output Relay Modules
I/O Module

Power Consumption (mW)
Description

DOR Module
Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Per Active LED –
Maximum 5

6.8 mA @ 12 volts dc
No Channels Active
150 mA for 10 mSec
during transition
150 mA for 10 mSec
during transition
150 mA for 10 mSec
during transition
150 mA for 10 mSec
during transition
150 mA for 10 mSec
during transition
1.5 mA

PTYPICAL

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

81.6 mW
1800 mW
for 10 mSec
1800 mW
for 10 mSec
1800 mW
for 10 mSec
1800 mW
for 10 mSec
1800 mW
for 10 mSec
18 mW for
10 mSec
Table Total

Duty Cycle

The duty cycle is:

[((Number of Transitions in some time period) * 0.01 sec)] ÷ (Seconds in the period) = Duty Cycle

For example, if a DOR channel changes state 80 times per hour:
80 = Number of transitions.
Hour is the time period.
An hour contains 3600 seconds.
Calculate the duty cycle as:
Duty Cycle = [(80 * 0.01) ÷ 3600] = 0.0002

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Table 3-11. Power Consumption of the High and Low Speed Pulse Input Modules
Power Consumption (mW)

I/O Module

Description
PI Module
Channel 1
Channel 2
Per Active LED –
Maximum 4
Jumper set to +T @ 12
volts dc
Jumper set to +T @ 24
volts dc

PTYPICAL

21 mA @ 12 volts dc No
Channels Active
7.4 mA
7.4 mA

88.8 mW
88.8 mW

1.5 mA

18 mW

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

252 mW

1.25 * Measured Current
Draw at +T Terminal
2.5 * Measured Current
Draw at +T Terminal
Table Total

Duty Cycle

The duty cycle is the time on divided by the total time, and is
essentially the percent of time that the I/O channel is active
(maximum power consumption).

Duty Cycle = [Active Time * (Signals Duty Cycle)] ÷ (Total Time Period)

For example, if a Pulse Input receives a signal for 6 hours over a 24-hour
time period and the signal’s wave form is on time for 1/3 of the signal’s
period:
Duty Cycle = [6 hours * (1 ÷ 3)] ÷ (24 hours) = 0.0825

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Table 3-12. Power Consumption of the MVS Modules
Power Consumption (mW)

I/O Module
MVS Module
Per Active LED – Maximum 2
Power provided by the module
for the MVS sensors

Description

PTYPICAL

112 mA @ 12 volts dc

1344 mW

1.5 mA

18 mW

Quantity
Used

1.25 * Measured
Current Draw at +
Terminal

Duty
Cycle

Sub-Total
(mW)

1
Table Total

Note: For an MVS sensor, the typical mW per MVS is about 300 mW.
Duty Cycle

The duty cycle is the time on divided by the total time. For an MVS,
the sensor is always drawing power, so enter the duty cycle as “1” for
the MVS power calculations. The LEDs can also have an associated
duty cycle, which is essentially the percent of time that the LEDs are
active.

Duty Cycle = Active time ÷ (Active time + Inactive time)

For example, if the LEDs are on approximately 20 minutes a day:
Duty Cycle = 20 minutes ÷ (24 * 60 minutes in a day) = 20 ÷ 1440 = 0.014

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Table 3-13. Power Consumption of the RTD Modules
Power Consumption (mW)

I/O Module

Description

PTYPICAL

65 mA @ 13.25 volts dc

RTD Module

Duty Cycle

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

1
Table Total

An RTD has no associated duty cycle. Consequently, always set “1”
as the duty cycle value.

Table 3-14. Power Consumption of the Thermocouple Modules
Power Consumption (mW)

I/O Module

Description
TYPE J OR K THERMOCOUPLE MODULE
84 mA @ 12 volts dc
T/C Module

Duty Cycle

PTYPICAL

1008 mW

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

1
Table Total

A thermocouple has no associated duty cycle. Consequently, always
set “1” as the duty cycle value.

Table 3-15. Power Consumption of the HART Modules
Other Device
HART Module Base
Each Channel

Power Consumption (mW)
Description

PTYPICAL

110 mA @ 12 volts dc
Channel’s mA current
draw from +T * 2.50 * 12

1320 mW

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

Table Total

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Table 3-16. Power Consumption of Other Devices
Other Device

Power Consumption (mW)
Description

PTYPICAL

Quantity
Used

Duty
Cycle

Sub-Total
(mW)

Total

Although Tables 3-5 and Tables 3-6 through 3-15 take into account the
power the ROC827 supplies to its connected devices, be sure to add the
power consumption (in mW) of any other devices (such as radios or
solenoids) used with the ROC827 in the same power system, but which
are not accounted for in Tables 3-6 through 3-15.
Enter that Total value in the Other Devices line of Table 3-5.

3.3

Removing a Power Input Module
To remove the Power Input module:
Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.
When working on units located in a hazardous area (where explosive
gases may be present), make sure the area is in a non-hazardous state
before performing procedures. Performing these procedures in a
hazardous area could result in personal injury or property damage.

1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Remove power from the ROC827.
3. Remove the wire channel cover.
4. Unscrew the two captive screws on the front of the Power Input

module.
5. Remove the Power Input module.
Note: If you intend to store the ROC827 for an extended period, also

remove the internal backup battery.

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3.4

Installing a Power Input Module
To install the Power Input module:
Caution

Note: Remove the plastic module cover and wire channel cover, if

present.
1. Slide the Power Input module into the slot.
2. Press the module firmly into the slot. Make sure the connectors at the

back of the Power Input module fit into the connectors on the
backplane.
3. Tighten the two captive screws on the front of the Power Input

module firmly (refer to Figures 3-1 and 3-2).
4. Replace the wire channel cover.
5. Review “Restarting the ROC827” in Section 6, Troubleshooting.
6. Return power to the ROC827.

3.5

Connecting the ROC827 to Wiring
The following paragraphs describe how to connect the ROC827 to power.
Use the recommendations and procedures described in the following
paragraphs to avoid damage to equipment.
Use 12 American Wire Gauge (AWG) wire or smaller for all power
wiring.
Caution

Always turn off the power to the ROC827 before you attempt any type of
wiring. Wiring of powered equipment could result in personal injury or
property damage.
To avoid circuit damage when working with the unit, use appropriate
electrostatic discharge precautions, such as wearing a grounded wrist
strap.

To connect the wire to the removable block compression terminals:
1. Bare the end (¼ inch maximum) of the wire.
2. Insert the bared end into the clamp beneath the termination screw.
3. Tighten the screw.
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The ROC827 should have a minimum of bare wire exposed to prevent
short circuits. Allow some slack when making connections to prevent
strain.

3.5.1 Wiring the DC Power Input Module
Use 12 American Wire Gauge (AWG) wire or smaller for all power
wiring. It is important to use good wiring practice when sizing, routing,
and connecting power wiring. All wiring must conform to state, local, and
NEC codes.
Verify the hook-up polarity is correct.
To make DC power supply connections:
1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Install a surge protection device at the service disconnect.
3. Remove all other power sources from the ROC827.
4. Install a fuse at the input power source.
5. Remove the terminal block connector from the socket.
6. Insert each bared wire end from either the:

12 Volts dc source into the clamp beneath the appropriate BAT+ /
BAT– termination screw.

24 Volts dc source into the clamp beneath the appropriate BAT+ /
BAT– termination screw. The + terminal should have a similar
fuse to the 12 Volts dc Power Input Module.
– CHG+ – BAT+

5 Amp Fuse

12 Volt DC Battery Bank
AC to 12 Volt DC Power Supply
24 Volt DC/12 Volt DC Power Converter
Other 12 Volt DC Nominal Source
BATWIRE.DSF

Figure 3-5. 12 Volts dc Power Supply and BAT+ / BAT– Wiring
7. Screw each wire into the terminal block.
8. Plug the terminal block connector back into the socket.
9. If you are monitoring an external charge voltage (12 Volts dc Power

Input Module only), wire the CHG+ and CHG– terminal block
connector. Refer to Figure 3-6.
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+

Solar
–
Regulator

–

Solar
Panel

Batteries
+

Power Supply
Terminal Block

–

– CHG+ – BAT+

5 Amp Fuse
5 Amp Fuse

809CHG.DSF

Figure 3-6. 12 Volt dc Power Supply and CHG+ and CHG– Wiring
10. Replace all other power sources (if necessary) to the ROC827.
11. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
Note: Refer to Table 3-2 concerning LEDs.

3.5.2 Wiring the External Batteries
You can use external batteries as the main source of power for the
ROC827 with the 12 volts dc Power Input module (PM-12). The
maximum voltage that can be applied to the BAT+ / BAT– terminals is
16 volts dc before damage may occur. The recommended maximum
voltage is 14.5 volts dc (refer to Table 3-2 concerning LEDs).
It is important that you use good wiring practices when sizing, routing,
and connecting power wiring. All wiring must conform to state, local, and
NEC codes. Use 12 American Wire Gauge (AWG) or smaller wire for all
power wiring.
Batteries should be rechargeable, sealed, gel-cell, lead-acid batteries.
Connect batteries in parallel to achieve the required capacity (refer to
Figure 3-6). The amount of battery capacity required for a particular
installation depends upon the power requirements of the equipment and
days of reserve (autonomy) desired. Calculate battery requirements based
on power consumption of the ROC827 and all devices powered by the
batteries.

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Battery Reserve

Battery reserve is the amount of time that the batteries can provide
power without discharging below 20% of their total output capacity.
The battery reserve should be a minimum of five days, with ten days
of reserve preferred. Add 24 hours of reserve capacity to allow for
overnight discharge. Space limitations, cost, and output are all factors
that determine the actual amount of battery capacity available.
To determine the system capacity requirements, multiply the system
current load on the batteries by the amount of reserve time required, as
shown in the following equation:

System Requirement = Current Load in Amps * Reserve Hours = _____ Amp Hours

Caution

When using batteries, apply in-line fusing to avoid damaging the ROC827.

To make battery connections:
1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
2. Remove the BAT+ and BAT– terminal block connector from the

socket.
3. Install a fuse at the input power source.
4. Insert each bared wire end into the clamp beneath the BAT+ and

BAT– termination screws (refer to Figure 3-5).
5. Screw each wire into the terminal block.
6. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
7. Re-apply power to the ROC827.
Note: Refer to Table 3-2 concerning LEDs.

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3.5.3 Replacing the Internal Battery
The internal Sanyo 3 volt CR2430 lithium backup battery located on the
CPU provides backup of the data and the Real-Time Clock when the
main power is not connected. The battery has a one-year minimum
backup life while the battery is installed and no power is applied to the
ROC827. The battery has a ten-year backup life while the backup battery
is installed and power is applied to ROC827 or when the battery is
removed from the ROC827.
Recommended replacement Lithium/Manganese Dioxide batteries
include:
Table 3-17. Replacement Battery Types
Part

Battery, Lithium, 3V

Size

24 mm (0.94 in) diameter x 3 mm (0.12 in) height

Type

Coin Type

Capacity

280 mAh minimum

Acceptable Types

Duracell DL2430
Eveready CR2430
Sanyo CR2430
Varta CR2430

Note: Remove the internal backup battery if you intend to store the

ROC827 for an extended period.
Caution

When working on units located in a hazardous area (where explosive
gases may be present), make sure the area is in a non-hazardous state
before performing these procedures. Performing these procedures in a
hazardous area could result in personal injury or property damage.
To avoid circuit damage when working inside the unit, use appropriate
electrostatic discharge precautions, such as wearing a grounded wrist
strap.

1. Perform the backup procedure described in “Preserving Configuration

and Log Data” in Chapter 6, Troubleshooting.
Note: Removing the battery erases the contents of the ROC827’s
RAM.
2. Remove all power from the ROC827.
3. Remove the wire channel cover.
4. Remove the two screws on the CPU faceplate.
5. Remove the CPU faceplate.
6. Remove the CPU (as described in “Removing the CPU Module” in

Chapter 2, Installation and Use).
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Power Connections

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ROC827 Instruction Manual
7. Insert a plastic screwdriver behind the battery and gently push the

battery out of the battery holder. Note how the battery is oriented:
the negative side of the battery (–) is placed against the CPU and the
positive (+) towards the + label on the battery holder.
8. Insert the new battery in the battery holder paying close attention to

install the battery with the correct orientation.
9. Reinstall the CPU (as described in “Installing the CPU Module” in

Chapter 2, Installation and Use).
10. Replace the CPU faceplate.
11. Replace the two screws to secure the CPU faceplate.
12. Replace the wire channel cover.
13. Review “Restarting the ROC827” in Chapter 6, Troubleshooting.
14. Apply power to the ROC827.

3.6

Related Specification Sheets
Refer to the following specification sheets (available at
www.EmersonProcess.com/flow) for additional and most-current
information on the Power Input modules for the ROC827.
Table 3-18. Power Input Module Specification Sheets

Name
Power Input Modules (ROC800-Series)

Issued Mar-06

Form Number
6.3:PIM

Power Connections

Part Number
D301192X012

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ROC827 Instruction Manual

Chapter 4 – Input/Output Modules
This chapter describes the Input/Output (I/O) modules used with the
ROC827 and expandable backplanes and contains information on
installing, wiring, and removing the I/O modules.
In This Chapter
4.1
4.2

I/O Module Overview ...............................................................................4-1
Installation................................................................................................4-3
4.2.1 Installing an I/O Module .................................................................4-4
4.2.2 Removing an I/O Module ...............................................................4-5
4.2.3 Wiring I/O Modules ........................................................................4-6
4.3 Analog Input Modules ..............................................................................4-6
4.4 Analog Output Modules ...........................................................................4-8
4.5 Discrete Input Modules ............................................................................4-9
4.6 Discrete Output Modules .......................................................................4-10
4.7 Discrete Output Relay Modules.............................................................4-11
4.8 Pulse Input Modules ..............................................................................4-12
4.9 RTD Input Modules................................................................................4-14
4.9.1 Connecting the RTD Wiring .........................................................4-15
4.10 J and K Type Thermocouple Input Modules..........................................4-16
4.11 Related Specification Sheets.................................................................4-21

4.1

I/O Module Overview
The I/O modules typically consist of a terminal block for field wiring and
connectors to the backplane. The ROC827 base unit supports up to three
I/O modules. Each expandable backplane (EXP) can accommodate up to
six I/O modules, and a fully configured ROC827 can handle up to 27 I/O
modules (three on the base unit and six modules on each of up to four
expandable backplanes). Each I/O module electrically connects to field
wiring by a removable terminal block. Refer to Figures 4-1 and 4-2.
Note: Figure 4-2 represents a ROC827 with one EXP.

Issued Mar-06

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4-1

ROC827 Instruction Manual

DOC0513A

Front View

Side View

Figure 4-1. Typical I/O Module
I/O Slot #4
I/O Slot #1 or
Comm 3
I/O Slot #7

I/O Slot #5
I/O Slot #2 or
Comm 3 or 4

I/O Slot #8

I/O Slot #6
I/O Slot #3 or
Comm 3, 4, or 5
I/O Slot #9

Figure 4-2. Optional I/O Module Locations (ROC827 with one EXP)
I/O modules for the ROC827 include:

Issued Mar-06

Analog Input (AI) modules that provide the ability to monitor various
analog field values.

Discrete Input (DI) and Pulse Input (PI) modules that provide the
ability to monitor various discrete and pulse input field values.
Input/Output Modules

4-2

ROC827 Instruction Manual

Analog Output (AO), Discrete Output (DO), and Discrete Output
Relay (DOR) modules that provide the ability to manage various
control devices.

The RTD Input and Thermocouple Input (T/C) modules that provide
the ability to monitor various analog temperature field values.

The Highway Addressable Remote Transducer (HART) interface
modules that enable the ROC827 to communicate with HART devices
using the HART protocol as either Analog Inputs or Analog Outputs.

Each module rests in a module slot at the front of the ROC827 base unit or
EXP housing. You can easily install or remove I/O modules from the
module slots while the ROC827 is powered up (hot-swappable). Modules
may be installed directly into unused module slots (hot-pluggable), and
modules are self-identifying in the software. All modules have removable
terminal blocks to make servicing easy. I/O modules can be added in any
module slot.
The I/O modules acquire power from the backplane. Each module has an
isolated DC/DC converter that provides logic, control, and field power as
required. The ROC827 has eliminated the need for fuses on the I/O
modules through the extensive use of current-limited short-circuit
protection and over voltage circuitry. Isolation is provided from other
modules and the backplane, power, and signal isolation. The I/O modules
are self-resetting after a fault clears.

4.2

Installation
Each I/O module installs in the ROC827 in the same manner. You can
install any I/O module into any module socket, whether empty or in place
of another module.
Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.
When installing units in a hazardous area, make sure all installation
components selected are labeled for use in such areas. Installation and
maintenance must be performed only when the area is known to be nonhazardous. Installation in a hazardous area could result in personal injury
or property damage.

You can insert or remove the I/O modules while power is connected to the
ROC827. If the ROC827 is powered, exercise caution while performing
the following steps to install a module.
Note: After you install a new I/O module or replace an existing I/O

module, it may be necessary to reconfigure the ROC827. To change
configuration parameters, use ROCLINK 800 software to make changes to
the new module. Any added modules (new I/O points) start up with
Issued Mar-06

Input/Output Modules

4-3

ROC827 Instruction Manual

default configurations. Refer to the ROCLINK 800 Configuration Software
User Manual (Form A6121).

4.2.1 Installing an I/O Module
To install an I/O module in either the ROC827 or the EXP:
1. Remove the wire channel cover.
Note: Leaving the wire channel cover in place can prevent the module

from correctly connecting to the socket on the backplane.
2. Perform one of the following:

If there is a module currently in the slot, unscrew the captive
screws and remove that module (refer to “Removing an I/O
Module”).

If the slot is currently empty, remove the module cover.

3. Insert the new I/O module through the module slot on the front of the

ROC827 or EXP housing. Make sure the label on the front of the
module faces right side up (refer to Figure 4-3). Gently slide the
module in place until it contacts properly with the connectors on the
backplane.
Note: If the module stops and will not go any further, do not force the

module. Remove the module and see if the pins are bent. If the pins are
bent, gently straighten the pins and re-insert the module. The back of
the module must connect fully with the connectors on the backplane.

Issued Mar-06

Input/Output Modules

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ROC827 Instruction Manual

Figure 4-3. Installing an I/O Module
4. Tighten the captive screws on the front of the module.
5. Wire the I/O module (refer to “Wiring I/O Modules”).
6. Replace the wire channel cover.

Caution

Never connect the sheath surrounding shielded wiring to a signal ground
terminal or to the common terminal of an I/O module. Doing so makes the
I/O module susceptible to static discharge, which can permanently
damage the module. Connect the shielded wiring sheath only to a suitable
earth ground.

7. Connect to ROCLINK 800 software and login. The I/O modules are

self-identifying after re-connecting to ROCLINK 800 software.
8. Configure the I/O point.

4.2.2 Removing an I/O Module
To remove an I/O module:
1. Remove the wire channel cover.
2. Unscrew the two captive screws holding the module in place.
3. Gently pull the module’s lip out and remove the module from the slot.

You may need to gently wiggle the module.
4. Install a new module or install the module cover.
5. Screw the two captive screws to hold the module or cover in place.
Issued Mar-06

Input/Output Modules

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ROC827 Instruction Manual
6. Replace the wire channel cover.

4.2.3 Wiring I/O Modules
All modules have removable terminal blocks for convenient wiring and
servicing. The terminal blocks can accommodate a wide range of wire
gauges (12 AWG or smaller).
Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

The ROC827 should have a minimum of bare wire exposed to prevent
short circuits. Allow some slack when making connections to prevent
strain.
Note: All modules have removable terminal blocks for convenient wiring

and servicing. Twisted-pair cable is recommended for I/O signal wiring.
The removable terminal blocks accept 12 AWG or smaller wire.

4.3

Analog Input Modules
The four Analog Input (AI) channels are scalable, but typically measure
either:

4- to 20-mA analog signal, with the use of a precision resistor
(supplied).

1 to 5 Volts dc signal.

If required, you can calibrate the low end of the analog signal to zero.
You can configure the AI (+T) module as either 12 or 24 Volt dc using
jumper J4 on the I/O module (see Figure 4-4). The AI modules can
provide isolated +12 Volt dc or +24 Volt dc field transmitter power on a
per-module basis. For example, one module can provide +12 Volts dc for
powering low power analog transmitters, while another module in the
same ROC827 can provide +24 Volts dc for powering conventional 4- to
20-mA transmitters. Refer to Figure 4-5:

Issued Mar-06

Input/Output Modules

4-6

ROC827 Instruction Manual

+T 12 / 24 V dc
Jumper

Precision
Resistor

Figure 4-4. Analog Input Jumper J4 – Set to +24V

+
OUT SIGNAL
COM

+
-

1-5 VOLT DEVICE
EXTERNALLY POWERED

CURRENT LOOP DEVICE 4-20mA
ROC809 POWERED

DOC0506A

Figure 4-5. Analog Input Module Field Wiring
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.

Issued Mar-06

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ROC827 Instruction Manual

4.4

Analog Output Modules
The 16-bit Analog Output (AO) module has four channels that provide a
current output for powering analog devices. Analog Outputs are analog
signals the ROC827 generates to regulate equipment, such as control
valves or any device requiring analog control.
Each channel on this module provides a 4- to 20-mA current signal for
controlling analog current loop devices. The AO module isolation includes
the power supply connections.
Note: AO modules (Part Number W38199) with front labels that read AO-

16 are an earlier version that controls the low side current. AO modules
(Part Number W38269) with front labels that read AO are the newer
version (January 2005 and later) and control the high side current.
You can configure the AO module as either 12 or 24 Volts dc via jumper
J4 on the I/O module (see Figure 4-6). The AO module can provide
isolated +12 Volts dc or +24 Volts dc field transmitter power on a per
module basis. For example, one module can provide +12 Volts dc for
powering low-power analog transmitters, while another module in the
same ROC827 can provide +24 Volts dc for powering conventional 4- to
20-mA transmitters. Refer to Figure 4-7.

+T 12 / 24 V dc
Jumper

Figure 4-6. Analog Output Jumper J4 (Shown Set to +12V)

Issued Mar-06

Input/Output Modules

4-8

ROC827 Instruction Manual
Representative
Internal Circuit

Field Wiring

CURRENT LOOP
CONTROL

+
-

I
CURRENT LOOP
CONTROL

CURRENT LOOP DEVICE 4-20mA
ROC800 POWERED

CURRENT LOOP
CONTROL
+V

CURRENT LOOP
CONTROL

250

+
-

1-5 VOLT CONTROL DEVICE

DOC0505A

Figure 4-7. Analog Output Module Field Wiring
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.

4.5

Discrete Input Modules
The eight-channel Discrete Input (DI) modules monitor the status of
relays, open collector/open drain type solid-state switches, and other twostate devices. Discrete Inputs come from relays, switches, and other
devices, which generate an on/off, open/close, or high/low signal.
The DI module provides a source voltage for dry relay contacts or for an
open-collector solid-state switch.
The DI module’s LEDs light when each input is active.
Each DI channel can be software-configured to function as a momentary
or latched DI. A latched DI remains in the active state until reset. Other
parameters can invert the field signal and gather statistical information on
the number of transitions and the time accumulated in the on- or off-state.
Caution

The Discrete Input module operates with non-powered discrete devices,
such as “dry” relay contacts or isolated solid-state switches. Use of the DI
module with powered devices may cause improper operation or damage.

The DI module senses the current flow, which signals the ROC827
electronics that the relay contacts have closed. The opening of the contacts
interrupts the current flow and the DI module signals the ROC827
electronics that the relay contacts have opened. A ROC827 can read a DI a
maximum of 20 times per second (50 millisecond scan).
Issued Mar-06

Input/Output Modules

4-9

ROC827 Instruction Manual

The left side of Figure 4-8 displays the internal circuitry while the right
side displays possible field wiring.
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.
DI
+

2
6.6KW

DRY CONTACT
ROC800 POWERED

3
4
5
6
7

8
C OM

OPEN COLLECTOR
OR
OPEN DRAIN TYPE DEVICE
EXTERNALLY POWERED

8 CHAN

DOC0507A

Figure 4-8. Discrete Input Module Field Wiring

4.6

Discrete Output Modules
The five-channel Discrete Output (DO) module provides two-state outputs
to energize solid-state relays and power small electrical loads. These are
solid-state relays. A Discrete Output may be set to send a pulse to a
specified device. Discrete Outputs are high and low outputs used to turn
equipment on and off.
DO modules can be software-configured as latched, toggled, momentary,
or Timed Duration Outputs (TDO). The DO can be configured to either
retain the last value on reset or use a user-specified fail-safe value.
The DO module provides LEDs that light when each output is active.
When a request is made to change the state of a DO, the request is
immediately sent to the DO module. There is no scan time associated with
a DO. Under normal operating conditions, the DO channel registers the
change within 2 milliseconds.
If the DO is in momentary or toggle mode, you can enter a minimum timeon of 4 milliseconds.
Figure 4-9 displays the field wiring connections to the output circuit of the
DO module.

Issued Mar-06

Input/Output Modules

4-10

ROC827 Instruction Manual

The Discrete Output module only operates with non-powered discrete
devices, such as relay coils or solid-state switch inputs. Using the module
with powered devices may cause improper operation or damage.

Caution

DO modules draw power for the active circuitry from the backplane, and
are fused for protection against excessive current.
Note: When using the Discrete Output module to drive an inductive load

(such as a relay coil), place a suppression diode across the input terminals
to the load. This protects the module from the reverse Electro-Motive
Force (EMF) spike generated when the inductive load is switched off.
Representative
Internal Circuit

Field Wiring

DO
1+
COM

+V
s

+
-

CONTROL

2+
COM

DISCRETE DEVICE
- EXTERNALLY POWERED +

COM

5+
COM

5 CHAN

DOC0508A

Figure 4-9. Discrete Output Module Field Wiring
Note: All I/O modules are isolated on the field side. Be aware that you can
induce ground loops by tying commons from various modules together.

4.7

Discrete Output Relay Modules
The five-channel DO Relay (DOR) module provides LEDs that light when
each output is active. DOR modules use dual-state latching relays to
provide a set of normally open, dry contacts capable of switching 2 A at
32 Volts dc across the complete operating temperature. You can configure
the module as latched, toggled, momentary, or Timed Duration Outputs
(TDO). The DOR can either retain the last value on reset or use a userspecified fail-safe value.
Figure 4-10 displays the field wiring connections to the output circuit of
the DO Relay module.

Issued Mar-06

Input/Output Modules

4-11

ROC827 Instruction Manual
Note: The Discrete Output Relay module operates only with discrete

devices having their own power source.
When a request is made to change the state of a DOR, the request is
immediately sent to the DOR module. There is no scan time associated
with a DOR. Under normal operating conditions, the DOR channel
registers the change within 12 mSecs. If the DOR is in momentary or
toggle mode, DOR channels register the change within 48 mSecs.
The DOR modules draw power for the active circuitry from the backplane.
Note: On power up or reset, the DO Relay module’s LEDs enter

indeterminate state for a few seconds as the module self-identifies. The
LEDs may flash, stay on, or stay off for a few seconds.

DO RELAY
R

CONTROL

CH 3

LATCHING RELAY
NOTE: S = SET
R = RESET

CH 2

CH 1

CH 5

CONTROL

CH 4

DISCRETE DEVICE
SELF- POWERED

+
+

DISCRETE DEVICE
- EXTERNALLY POWERED +

+
-

5 CHAN

DOC0509A

Figure 4-10. Discrete Output Relay Module Field Wiring
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.

4.8

Pulse Input Modules
The Pulse Input (PI) module provides two channels for measuring either a
low speed or high speed pulse signal. The PI module processes signals
from pulse-generating devices and provides a calculated rate or an
accumulated total over a configured period. Supported functions are slowcounter input, slow rate input, fast counter input, and fast rate input.

Issued Mar-06

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ROC827 Instruction Manual

The PI is most commonly used to interface to relays or open
collector/open drain type solid-state devices. The Pulse Input can be used
to interface to either self-powered or ROC827-powered devices.
The high speed input supports signals up to 12 kHz while the low speed
input is used on signals less than 125 Hz.
You can configure the PI module as either 12 or 24 Volts dc using jumper
J4 on the I/O module (see Figure 4-11). The PI modules can provide
isolated +12 Volt dc or +24 Volt dc field transmitter power on a permodule basis. For example, one module can provide +12 Volt dc power,
while another module in the same ROC827 can provide +24 Volt dc
power. Refer to Figures 4-12 and 4-13.
The PI module provides LEDs that light when each input is active.
Caution

The Pulse Input module only operates with non-powered devices, such as
“dry” relay contacts or isolated solid-state switches. Use of the PI module
with powered devices may cause improper operation or damage.

The PI modules draw power for the active circuitry from the backplane.
Input signals are optically isolated.
Note: Do not connect wiring to both the Low and High speed selections

for a given channel. This results in unpredictable operation of the PI
module.

+T 12 / 24 V dc
Jumper

Figure 4-11. Pulse Input J4 Jumper (Set to +12 V)

Issued Mar-06

Input/Output Modules

4-13

ROC827 Instruction Manual
Representative
Internal Circuit

Field Wiring

12KHz PI FILTER &
LEVEL DETECTION

+
-

OPEN DRAIN TYPE
OR
OPEN COLLECTOR DEVICE
EXTERNALLY POWERED

+
-

CONTACT-CLOSURE DEVICE
EXTERNALLY POWERED

DOC0510A

Figure 4-12. Externally Powered Pulse Input Module Field Wiring

+T
L

OPEN COLLECTOR
OR
OPEN DRAIN TYPE DEVICE
ROC800 POWERED
-

METER COIL

COM

CH 2

COM

12KHz PI FILTER &
LEVEL DETECTION

Field Wiring

PI
CH 1

Representative
Internal Circuit

2 CHAN

DOC0511A

Figure 4-13. ROC800-Powered Pulse Input Module Field Wiring
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.

4.9

RTD Input Modules
The Resistance Temperature Detector (RTD) module monitors the
temperature signal from an RTD source. The module can accommodate
input from a two-, three-, or four-wire RTD source.
The active element of an RTD probe is a precision, temperature-dependent
resistor made from a platinum alloy. The resistor has a predictable positive
temperature coefficient, meaning its resistance increases with temperature.

Issued Mar-06

Input/Output Modules

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ROC827 Instruction Manual

The RTD input module works by supplying a small consistent current to
the RTD probe and measuring the voltage drop across it. Based on the
voltage curve of the RTD, the ROC827 firmware converts the signal to
temperature.
The RTD input module monitors the temperature signal from a resistance
temperature detector (RTD) sensor or probe. A two-channel 16-bit RTD
module is available. The RTD module isolation includes the power supply
connections.
The RTD modules draw power for the active circuitry from lines on the
backplane.
It may be more convenient to perform calibration before connecting the
field wiring. However, if the field wiring between the ROC827 and the
RTD probe is long enough to add a significant resistance, then perform
calibration in a manner that considers this.

4.9.1 Connecting the RTD Wiring
Temperature can be input through the Resistance Temperature Detector
(RTD) probe and circuitry. An RTD temperature probe mounts directly to
the piping using a thermowell. Protect RTD wires either by a metal sheath
or by conduit connected to a liquid-tight conduit fitting. The RTD wires
connect to the four screw terminals designated “RTD” on the RTD
module.
The ROC827 provides terminations for a four-wire 100-ohm platinum
RTD with a DIN 43760 curve. The RTD has an alpha equal to 0.00385 or
0.00392Ω/Ω°C. You can use a two-wire or three-wire RTD probe instead
of a four-wire probe, but they may produce measurement errors due to
signal loss on the wiring.
Wiring between the RTD probe and the ROC827 must be shielded wire,
with the shield grounded only at one end to prevent ground loops. Ground
loops cause RTD input signal errors.
Table 4-1. RTD Signal Routing
Signal
CH 1 (REF)
CH 1 (+)
CH 1 (–)
CH 1 (RET)
Not Connected
CH 2 (REF)
CH 2 (+)
CH 2 (–)
CH 2 (RET)
Not Connected

Issued Mar-06

Terminal
1
2
3
4
5
6
7
8
9
10

Input/Output Modules

Designation
Constant Current +
V+ RTD
V– RTD
Constant Current –
N
Constant Current +
V+ RTD
V– RTD
Constant Current –
N/A

4-15

ROC827 Instruction Manual
Note: All I/O modules are isolated on the field side. Be aware that you can

induce ground loops by tying commons from various modules together.
4-Wire RTD

3-Wire RTD

2-Wire RTD

Red

Jumper

Red

Red
Jumper

Figure 4-14. RTD Sensor Wiring Terminal Connections
Figure 4-14 and Table 4-2 display the connections at the RTD terminals
for the various RTD probes.
Table 4-2. RTD Wiring
Terminal
REF
+
–
RET

4-Wire RTD
Red
Red
White
White

3-Wire RTD
Jumper to +
Red, Jumper to REF
White
White

2-Wire RTD
Jumper to +
Red, Jumper to REF
White, Jumper to RET
Jumper to –

Note: The wire colors for the RTD being used may differ.

4.10

J and K Type Thermocouple Input Modules
The five-channel J and K Type Thermocouple Input module monitors
either J or K Type Thermocouple (T/C). J and K refer to the type of
material used to make a bimetallic junction: Type J (Iron/Constantan) and
Type K (Chromel/Alumel). These dissimilar junctions in the thermocouple
junction generate different millivolt levels as a function of the heat to
which they are exposed.
The J and K Type Thermocouple Input module measures the voltage of
the thermocouple to which it is connected. The T/C voltage is measured
and a Cold Junction Compensation (CJC) correction factor is applied to
compensate for errors due to any voltage inducted at the wiring terminals

Issued Mar-06

Input/Output Modules

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ROC827 Instruction Manual

by the junction between the different metal of the T/C wiring and the T/C
module’s terminal blocks.
Note: The use of dissimilar metals is not supported. It will not provide the

correct results, as CJC is applied at the module level.
Thermocouples are self-powered and require no excitation current. The
thermocouple modules use integrated short-circuit protected isolated
power supplies and completely isolates the field wiring side of the module
from the backplane.
Caution
De-calibration

If using the Type J above 750°C (1382°F), abrupt magnetic transformation
causes permanent de-calibration of the T/C wires.

De-calibration can occur in thermocouple wires. De-calibration is the
process of unintentionally altering the makeup of the thermocouple,
usually caused by the diffusion of atmospheric particles into the metal
at the extremes of the operating temperature range. Impurities and
chemicals can cause de-calibration from the insulation diffusing into
the thermocouple wire. If operating at high temperatures, check the
specification of the probe insulation. It is advised to use
thermocouples with insulated junctions to protect against oxidation
and contamination.
Thermocouples use thin wire (typically 32 AWG) to minimize thermal
shunting and increase response times. Wire size used in the thermocouple
depends upon the application. Typically, when longer life is required for
the higher temperatures, select the larger size wires. When sensitivity is
the prime concern, use smaller size wiring. Thin wire causes the
thermocouple to have a high resistance that can cause errors due to the
input impedance of the measuring instrument. If thermocouples with thin
leads or long cables are required, keep the thermocouple leads short and
use a thermocouple extension wire to run between the thermocouple and
measuring instrument.
The thermocouple wires directly to the module’s removable terminal
block. No special terminal or isothermal block is required.

Issued Mar-06

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ROC827 Instruction Manual

+
-

J OR K THERMOCOUPLE
UNGROUNDED SHEATH

DOC0512B

Figure 4-15. Type J and K Thermocouple Wiring
Be sure to use the correct type of thermocouple wire to connect the
thermocouple to the ROC827. Minimize connections and make sure
connections are tight. If you use any dissimilar metals (such as copper
wire) to connect a thermocouple to the ROC827, you can create the
junction of dissimilar metals that can generate millivolt signals and
increase reading errors.
Ensure any plugs, sockets, or terminal blocks used to connect the
extension wire are made from the same metals as the thermocouples and
observe correct polarity.
The thermocouple probe must have sufficient length to minimize the effect
of conduction of heat from the hot end of the thermocouple. Unless there
is insufficient immersion, readings will be low. It is suggested the
thermocouple be immersed for a minimum distance equivalent to four
times the outside diameter of a protection tube or well.
Use only ungrounded thermocouple constructions. Grounded
thermocouples are susceptible to the creation of ground loops. In turn,
ground loops can cause interaction between thermocouple channels on the
thermocouple module.
Note: Use thermocouples as individual sensing devices. All modules are

isolated on the field side. Be aware that you can induce ground loops by
tying module-to-module commons together.

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ROC827 Instruction Manual

Noise Susceptibility

Millivolt signals are very small and are very susceptible to noise.
Noise from stray electrical and magnetic fields can generate voltage
signals higher than the millivolt levels generated from a
thermocouple. The T/C modules can reject common mode noise
(signals that are the same on both wires), but rejection is not perfect,
so minimize noise where possible.
Take care to properly shield thermocouple wiring from noise by separating
the thermocouple wiring runs from signals that are switching loads and
AC signals. Route wires away from noisy areas and twist the two insulated
leads of the thermocouple cable together to help ensure both wires pickup
the same noise. When operating in an extremely noisy environment, use a
shielded extension cable.
+

–

–
TypeKus.dsf

TypeJus.dsf

Figure 4-16. Type J Thermocouple Shielded
Wiring – United States Color Coding

Figure 4-17. Type K Thermocouple Shielded
Wiring – United States Color Coding

United States color-coding for the Type J Thermocouple shielded wiring is
black sheathing, the positive lead is white, and the negative lead is red.
United States color-coding for the Type K Thermocouple shielded wiring
is yellow sheathing, the positive lead is yellow, and the negative lead is
red.
Shielded wiring is recommended. Ground shields only on one end,
preferably at the end device unless you have an excellent ground system
installed at the ROC800-series controller. Do not tie the thermocouple
module to ground.

Caution

Note: It is highly recommended that you use shielded wiring.

Sheathed thermocouple probes are available with one of three junction
types: grounded, ungrounded, or exposed.

unground.dsf

ground.dsf

Figure 4-18. Ungrounded –
Sheathed

exposed.dsf

Figure 4-19. Grounded

Figure 4-20. Exposed,
Ungrounded – Unsheathed
In an ungrounded probe, the thermocouple junction is detached from the
probe wall. Response time slows down from the grounded style, but the
ungrounded probe offers electrical isolation of 1.5 M ½ at 500 Volts dc in
all diameters. The wiring may or may not be sheathed.

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ROC827 Instruction Manual
Note: Only ungrounded probes are supported. It is highly recommended

that you use sheathed probes.
Use an ungrounded junction for measurements in corrosive environments
where it is desirable to have the thermocouple electronically isolated from
and shielded by the sheath. The welded wire thermocouple is physically
insulated from the thermocouple sheath by MgO powder (soft).
At the tip of a grounded junction probe, the thermocouple wires
physically attach to the inside of the probe wall. This results in good heat
transfer from the outside, through the probe wall to the thermocouple
junction. Grounded wiring is not supported.
The thermocouple in the exposed junction protrudes out of the tip of the
sheath and is exposed to the surrounding environment. This type offers the
best response time, but is limited in use to non-corrosive and nonpressurized applications. Exposed junction thermocouples are not
supported.
Note: Avoid subjecting the thermocouple connections and measurement

instrument to sudden changes in temperature.

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4.11 Related Specification Sheets
Refer to the following specification sheets (available at
www.EmersonProcess.com/flow) for additional and most-current
information on each of the I/O modules.
Table 4-3. I/O Module Specification Sheets
Name
AI and AO Modules (ROC800-Series)
DI and PI Modules (ROC800-Series)
DO and DOR Modules (ROC800-Series)
RTD and T/C Modules (ROC800-Series)

Issued Mar-06

Form Number
6.3:IOM1
6.3:IOM2
6.3:IOM3
6.3:IOM4

Input/Output Modules

Part Number
D301163X012
D301175X012
D301181X012
D301182X012

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Chapter 5 – Communications
This section describes the built-in communications and the optional
communication modules used with the ROC827.
In This Chapter
5.1
5.2
5.3
5.4
5.5

Communications Ports and Modules Overview.......................................5-1
Installing Communication Modules..........................................................5-3
Removing a Communications Module.....................................................5-4
Wiring Communications Modules ............................................................5-5
Local Operator Interface (LOI).................................................................5-5
5.5.1 Using the LOI .................................................................................5-7
5.6 Ethernet Communications .......................................................................5-7
5.7 EIA-232 (RS-232) Serial Communications ..............................................5-9
5.8 EIA-422/485 (RS-422/485) Serial Communications Module .................5-10
5.8.1 EIA-422/485 (RS-422/485) Jumpers & Termination Resistors....5-11
5.9 Dial-up Modem Communications Module..............................................5-12
5.10 Multi-Variable Sensor (MVS) Interface Modules ...................................5-14
5.11 HART Interface Module .........................................................................5-16
5.12 Related Specification Sheets.................................................................5-20

5.1

Communications Ports and Modules Overview
The built-in communications and the optional communication modules
provide communications between the ROC827 and a host system or
external devices.
The ROC827 allows up to six communication ports. Three communication
ports are built-in on the CPU. You can add up to three additional ports
with communication modules. Table 5-1 displays the types of
communications available for the ROC827.
Table 5-1. Built-in Communications and Optional Communication Modules
Communications

Built-in on CPU

EIA-232 (RS-232D) Local Operator Interface (LOI)
Ethernet (use with DS800 Configuration Software)
EIA-232 (RS-232C) Serial Communications
EIA-422/485 (RS-422/485) Serial Communications
Modem Communications
MVS Sensor Interface

Local Port
Comm1
Comm2

Optional Module

Comm3 to Comm5
Comm3 to Comm5
Comm3 to Comm5
Comm3 to Comm5

The communication modules consist of a communications module (card),
a communications port, wiring terminal block, LEDs, and connectors to
the backplane. The ROC827 unit can hold up to three communication
modules in the first three module slots. Refer to Figure 5-1.

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ROC827 Instruction Manual

Optional Comm 3
(Slot #1)

Optional Comm 3 or Comm 4
(Slot #2)

LOI (Local Port)
EIA-232 (RS-232D)

Built-in Ethernet (Comm1)

Optional Comm 3 to Comm 5
(Slot #3)

Built-in EIA-232
(RS-232) (Comm2)

Figure 5-1. Communication Ports
Table 5-2. Communication LED Indicator Definitions
Signals

Action

CTS

Clear To Send indicates the modem is ready to send.

Data Carrier Detect (DCD) indicates a valid carrier signal tone detected.

DSR

Data Set Ready for ring indicator communication signal.

DTR

Data Terminal Ready to answer an incoming call. When off, a connection disconnects.

RTS

Ready To Send indicates ready to transmit.

Receive Data (RD) signal is being received.

Transmit Data (TD) signal is being transmitted.

Each communications module has surge protection in accordance with the
CE certification EN 61000. Each communications module is completely
isolated from other modules and the backplane, including power and
signal isolation, with the exception of the EIA-232 (RS-232) module. The
field interface has been designed to protect the electronics in the module.
Filtering is provided on each module to reduce communication errors.

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ROC827 Instruction Manual

5.2

Installing Communication Modules
All communication modules install into the ROC827 in the same way.
You can install or remove communication modules while the ROC827 is
powered up (hot-swappable), you can install modules directly into unused
module slots 1, 2, or 3 (hot-pluggable), and modules are self-identifying in
the software. All modules are self-resetting after a fault clears.
Note: The dial-up modem module is not hot-swappable or hot-pluggable.

When you install a dial-up modem module, you must remove power from
the ROC827.

Figure 5-2. Example RS-485 Communications Module

Caution

Note: You can install communications modules only in slots 1, 2, or 3 of

the ROC827. Refer to Figure 5-1.
1. Remove the wire channel cover.
Note: Leaving the wire channel cover in play can prevent the module

from correctly connecting to the socket on the backplane.
2. Perform one of the following:

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ROC827 Instruction Manual

If there is a module currently in the slot, unscrew the captive
screws and remove that module (refer to “Removing a
Communications Module”).
If the slot is currently empty, remove the module cover.

3. Insert the new module through the module slot on the front of the

ROC827 housing. Make sure the label on the front of the module is
facing right side up. Gently slide the module in place until it contacts
properly with the connectors on the backplane.
Note: If the module stops and will not go any further, do not force the

module. Remove the module and see if the pins are bent. If so, gently
straighten the pins and re-insert the module. The back of the module
must connect fully with the connectors on the backplane.
4. Gently press the module into its mating connectors on the backplane

until the connectors firmly seat.
5. Install the retaining captive screws to secure the module.
6. Wire the module (refer to “Wiring Communications Modules”).
Note: All modules have removable terminal blocks for convenient

wiring and servicing. Twisted-pair cable is recommended for I/O
signal wiring. The removable terminal blocks accept 12 AWG or
smaller wire.
7. For dial-up modem communications, connect the cable to the RJ-11

connector on the communications module.
Note: If you are installing a modem module, it is recommended that

you install a surge protector between the RJ-11 jack and the outside
line.
8. Replace the wire channel cover.
9. Connect to ROCLINK 800 software and login. The modules are self-

identifying after re-connecting to ROCLINK 800 software.

5.3

Removing a Communications Module
To remove a communications module:
1. Remove the wire channel cover.
2. Unscrew the two captive screws holding the module in place.
3. Gently pull the module’s lip out and remove the module from the slot.

You may need to gently wiggle the module.
4. Install a new module or install the module cover.
5. Screw the two captive screws to hold the module in place.
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ROC827 Instruction Manual
6. Replace the wire channel cover.

5.4

Wiring Communications Modules
Signal wiring connections to the communications are made through the
communications port removable terminal bock connectors and through RJ11 and RJ-45 connectors. All modules have removable terminal blocks for
convenient wiring and servicing. The terminal blocks can accommodate a
wide range of wire gauges (12 AWG or smaller).
Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

and servicing. Twisted-pair cable is recommended for I/O signal wiring.
The removable terminal blocks accept 12 AWG or smaller wire.

5.5 Local Operator Interface (LOI)
The Local Operator Interface (LOI) local port provides direct
communications between the ROC827 and the serial port of an operator
interface device, such as an IBM compatible computer. The interface
allows you to access the ROC827 with a direct connection using
ROCLINK 800 software to configure and transfer stored data.
The LOI uses the Local Port in ROCLINK 800 software.
The LOI terminal (RJ-45) on the CPU provides wiring access to a built-in
EIA-232 (RS-232) serial interface, which is capable of 57.6K baud
operation. The RJ-45 connector pin uses the data terminal equipment
(DTE) in the IEEE standard.
The LOI port supports ROC Plus and Modbus protocol communications.
The LOI also supports the log-on security feature of the ROC827 if you
have enabled the Security on LOI in the ROCLINK 800 software.
Table 5-3 shows the signal routing of the CPU connections. Figure 5-3
shows the RJ-45 pin out.
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Table 5-3. Built-in LOI EIA-232 Signal Routing
Signal

LOI Function

RJ-45 Pins
on ROC827

DTR

Data Terminal
Ready

GND
RX
TX
RTS

Ground
(Common)
Receive
Transmit
Request to Send

Description
Originated by the ROC827 Data Terminal Equipment (DTE) to instruct
the Data Communication Equipment (DCE) to setup a connection.
DTE is running and ready to communicate.
Reference ground between a DTE and a DCE and has a value 0 Volts
dc.
Data received by the DTE.
Data sent by the DTE.
Originated by the DTE to initiate transmission by the DCE.

4
5
6
8

Figure 5-3. RJ-45 Pin Out
The LOI terminal requires the installation of a D-Sub 9 pin (F) to RJ-45
modular converter between the ROC827 and personal computer (PC).
Refer to Table 5-4.
Table 5-4. RJ-45 to EIA-232 (RS-232) Null-modem Cable Signal Routing
EIA-232
(RS-232)
DTE
4
1
6
5
3
2
7
8

ROC800Series
–
–
DTR
GND
TX
RX
–
RTS

RJ-45 Pins
on ROC800Series
1
2
3
4
5
6
7
8

Table 5-5. Using Cable Warehouse 0378-2 D-Sub to Modular Converter 9-Pin to RJ-45 Black

Issued Mar-06

Wire
Color

RJ-45 Pins
on ROC800Series

Blue

Orange

Black

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ROC827 Instruction Manual

Wire
Color

RJ-45 Pins
on ROC800Series

Red

Green

Yellow

Brown

Gray

5.5.1 Using the LOI
1. Plug the LOI cable into the LOI RJ-45 connector of the ROC827.
2. Connect the LOI cable to the D-Sub 9 pin (F) to RJ-45 modular

converter.
3. Plug the modular converter into the COM Port of the personal

computer.
4. Launch ROCLINK 800 software.
5. Click the Direct Connect icon.
6. Configure communications for the other built-in and modular

communications, I/O modules, AGA meter parameters, and other
configuration parameters.

5.6

Ethernet Communications
The Ethernet communications port in the ROC827 allows TCP/IP protocol
communications using the IEEE 802.3 10Base-T standard. One
application of this communications port is to download programs from
DS800 Development Suite Configuration Software.
The Ethernet communications port uses a 10BASE-T Ethernet interface
with an RJ-45 connector. Each Ethernet-equipped unit is called a station
and operates independently of all other stations on the network without a
central controller. All attached stations connect to a shared media system.
Signals are broadcast over the medium to every attached station. To send
an Ethernet packet, a station listens to the medium (Carrier Sense) and
when the medium is idle, the station transmits the data. Each station has an
equal chance to transmit (Multiple Access).
Access to the shared medium is determined by the Medium Access
Control (MAC) mechanism embedded in each station interface. The MAC
mechanism is based on Carrier Sense Multiple Access with Collision
Detection (CSMA/CD). If two stations begin to transmit a packet at the
same instant, the stations stop transmitting (Collision Detection).
Transmission is rescheduled at a random time interval to avoid the
collision.

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ROC827 Instruction Manual

You can link Ethernet networks together to form extended networks using
bridges and routers.
Table 5-6. Ethernet Signal LEDs
Signal
RX
TX
COL
LNK

Function
Lit when currently receiving.
Lit when currently transmitting.
Lit when Ethernet Packet Collision detected.
Lit when Ethernet has linked.

Use a rugged industrial temperature HUB when connecting Ethernet
wiring in an environment that requires it.
The IEEE 802.3 10BASE-T standard requires that 10BASE-T transceivers
be able to transmit over a link using voice grade twisted-pair telephone
wiring that meets EIA/TIA Category four wire specifications. Generally,
links up to 100 meters (328 feet) long can be achieved for unshielded
twisted-pair cable.
For each connector or patch panel in the link, subtract 12 meters (39.4
feet) from the 100-meter limit. This allows for links of up to 88 meters
(288 feet) using standard 24 AWG UTP (Unshielded Twisted-Pair) wire
and two patch panels within the link. Higher quality, low attenuation
cables may be required when using links greater than 88 meters.
The maximum insertion loss allowed for a 10BASE-T link is 11.5 dB at
all frequencies between 5.0 and 10.0 MHz. This includes the attenuation
of the cables, connectors, patch panels, and reflection losses due to
impedance mismatches to the link segment.
Intersymbol interference and reflections can cause jitter in the bit cell
timing, resulting in data errors. A 10BASE-T link must not generate more
than 5.0 nanoseconds of jitter. If your cable meets the impedance
requirements for a 10BASE-T link, jitter should not be a concern.
The maximum propagation delay of a 10BASE-T link segment must not
exceed 1000 nanoseconds.
Crosstalk is caused by signal coupling between the different cable pairs
contained within a multi-pair cable bundle. 10BASE-T transceivers are
designed so that you do not need to be concerned about cable crosstalk,
provided the cable meets all other requirements.
Noise can be caused by crosstalk of externally induced impulses. Impulse
noise may cause data errors if the impulses occur at very specific times
during data transmission. Generally, do not be concerned about noise. If
you suspect noise related data errors, it may be necessary to either reroute
the cable or eliminate the source of the impulse noise.
Multi-pair, PVC 24 AWG telephone cables have an attenuation of
approximately 8 to 10 dB/100 m at 200°C (392°F). The attenuation of
PVC insulted cable varies significantly with temperature. At temperatures
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ROC827 Instruction Manual

greater than 400°C (752°F), use plenum rated cables to ensure that cable
attenuation remains within specification.
When connecting two twisted-pair Medium Attachment Units (MAUs) or
repeaters together over a segment, wire the transmit data pins of one eightpin connector to the receive data pins of the other connector, and vice
versa. There are two methods for accomplishing 10BASE-T crossover
wiring:
Using special cable.
Wiring the 10BASE-T crossover inside the hub.
For a single segment connecting only two devices, provide the signal
crossover by building a special crossover cable, wire the transmit data pins
of one eight-pin connector to the receive data pins of the other connector,
and vice versa. Refer to Figure 5-4.
Signal
Pin 1 TD+
Pin 2 TD–
Pin 3 RD+
Pin 6 RD–

Signal
Pin 1 TD+
Pin 2 TD–
Pin 3 RD+
Pin 6 RD–

Figure 5-4. 10BASE-T Crossover Cable

5.7

EIA-232 (RS-232) Serial Communications
The built-in EIA-232 (RS-232), the LOI, and the communication modules
meet all EIA-232 (RS-232) specifications for single-ended, asynchronous
data transmission over distances of up to 15 meters (50 feet). EIA-232
(RS-232) communication provides transmit, receive, and modem control
signals. The LOI port also meets EIA-232D (RS-232D) specifications.
The EIA-232 (RS-232) communications have the following
communication port designations in ROCLINK 800.

LOI – Local Port EIA-232 (RS-232D). Refer to Section 5.5, “Local
Operator Interface.”.
Built-in – Comm2 EIA-232 (RS-232C).
Module – Comm3 to Comm5 EIA-232 (RS-232C).
EIA-232 (RS-232) uses point-to-point asynchronous serial
communications and is commonly used to provide the physical interface
for connecting serial devices, such as gas chromatographs and radios to
the ROC800-Series. The EIA-232 (RS-232) communication provides
essential hand-shaking lines required for radio communications, such as
DTR and RTS.

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The EIA-232 (RS-232) communications includes LED indicators that
display the status of the Receive (RX), Transmit (TX), Data Terminal
Ready (DTR), and Ready To Send (RTS) control lines.
Table 5-7 defines the built-in EIA-232 (RS-232) terminals at the Comm2
port and their function signals.
Table 5-7. Built-in EIA-232 (RS-232) Signal Routing – Comm2
Signal
RX
TX
RTS
DTR
GND

LED Function
Lit when Comm2 is currently receiving.
Lit when Comm2 is currently transmitting.
Lit when Comm2 ready to send is not active.
Lit when Comm2 data terminal ready is active.
Common.

Terminal
1
2
3
4
5

The EIA-232 (RS-232) communications module provides for EIA-232
(RS-232C) signals on the Comm3, Comm4, or Comm5 port depending on
where the module is installed. Refer to Table 5-8.
Table 5-8. EIA-232 (RS-232) Communication Module Signal Routing – Comm3, Comm4, and Comm5
Signal
RX
TX
RTS
DTR
GND

5.8

LED Function
Lit when module (Comm3, Comm4, or Comm5) is
currently receiving.
Lit when module (Comm3, Comm4, or Comm5) is
currently transmitting.
Lit when module (Comm3, Comm4, or Comm5) is
ready to send is not active.
Lit when module (Comm3, Comm4, or Comm5)
data terminal ready is active.
Common.

Terminal
1
2
3
4
5

EIA-422/485 (RS-422/485) Serial Communications Module
EIA-422/485 (RS-422/485) communication modules meet all EIA422/485 (RS-422/485) specifications for differential, asynchronous serial
communication transmissions of data over distances of up to 1220 meters
(4000 feet). EIA-485 (RS-485) communications are commonly used to
multi-drop units on a serial network over long distances using inexpensive
twisted-pair wiring.
EIA-422 (RS-422) drivers are designed for party-line applications where
one driver is connected to, and transmits on, a bus with up to ten receivers.
EIA-422 (RS-422) allows long distance point-to-point communications
and the drivers are designed for true multi-point applications with up to 32
drivers and 32 receivers on a single bus.
The default values for the EIA-422/485 (RS-422/485) communications are
19200 Baud Rate, 8 Data Bits, 1 Stop Bit, and No Parity. The maximum
rate is 57.6K bps.

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EIA-422/485 (RS-422/485) communication modules include LED
indicators that display the status of receive and transmit activity. Refer to
Tables 5-9 and 5-10.
Table 5-9. EIA-422 (RS-422) Signal Routing – Comm3, Comm4, and Comm5
Signal
A
B
Y
Z
COM

RS-422
RX +
RX –
TX +
TX –
Common

Function
Lit when module (Comm3, Comm4, or Comm5) is currently receiving.
None.
Lit when module (Comm3, Comm4, or Comm5) is currently transmitting.
None.
Ground.

Terminal
1
2
3
4
5

Table 5-10. EIA-485 (RS-485) Signal Routing – Comm3, Comm4, and Comm5
Signal
A
B
Y
Z
COM

RS-485
RX / TX +
RX / TX –
No Connect
No Connect
Common

Function
Lit when module (Comm3, Comm4, or Comm5) is currently receiving.
Lit when module (Comm3, Comm4, or Comm5) is currently transmitting.
None.
None.
Ground.

Terminal
1
2
3
4
5

Note: The EIA-422/485 (RS-422/485) modules are isolated on the field

side. Be aware that you can induce ground loops by tying commons
together.
EIA-422/485 (RS-422/485) communications provides EIA-422/485 (RS422/485) signals on the Comm3, Comm4, or Comm5 port, depending on
where the module is installed. Wiring should be twisted-pair cable, one
pair for transmitting, and one pair for receiving. The EIA-422 (RS-422)
module uses four wires and the EIA-485 (RS-485) uses two wires for
connectivity.

5.8.1 EIA-422/485 (RS-422/485) Jumpers & Termination Resistors
Four jumpers—J3, J4, J5, and J6—are located on the EIA-422/485 (RS422/485) communications module. These jumpers determine the mode in
which the module runs (RS-422 or RS-485) and if the module is
terminated.
Terminations are required on the two EIA-422/485 (RS-422/485)
communication modules located at the extremities of the circuit. That is to
say, the two outside modules require terminations in order to complete the
communications circuit.

Issued Mar-06

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ROC827 Instruction Manual

Figure 5-5. EIA-422/485 (RS-422/485) J4 Jumper
Table 5-11. EIA-422 (RS-422) Module
Terminated

Not Terminated

Jumper
TER
J3
J4
J5
J6

Out

Half

Full
x

TER

Out

Half

Full
x

x
x

Table 5-12. EIA-485 (RS-485) Module
Terminated

Not Terminated

Jumper
TER
J3
J4
J5
J6

5.9

OUT

Half
x

Full

TER

OUT

Half
x

Full

x
x
x

x
x

Dial-up Modem Communications Module
The dial-up modem module interfaces to a Public-Switched Telephone
Network (PSTN) line, and requires a telephone line connection. The
module provides a telephone interface on the host port that is capable of
both answering and originating telephone calls. The module also provides
electronics that conserve power when the phone line is not in use.

Issued Mar-06

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ROC827 Instruction Manual
Note: When installing a dial-up modem module, you must remove power

from the ROC827.
The dial-up modem provides communications with speeds up to 14.4K
bps with V.42 bis and V.42, MNP2-4 and MNP10 error correction, and is
FCC Part 68 approved for use with PSTNs. The FCC label on the module
provides the FCC registration number and the ringer equivalent. The
module supports data compression, error correction, and nonvolatile RAM
for permanent storage of the modem configuration.
Using asynchronous operation, the module interfaces to two-wire, fullduplex telephone lines. It interfaces to a PSTN through an RJ-11 jack.
You control the modem using industry-standard AT command software. A
40-character command line is provided for the AT command set, which is
compatible with EIA document TR302.2/88-08006.
The dial-up modem automatically hangs up after a user-configured period
of communications inactivity and provides automated dial-up alarm
reporting capabilities. Refer to the ROCLINK 800 Configuration Software
User Manual (Form A6121).
Table 5-13. RJ-11 Field Connections
Signal
Tip
Ring

Pin
3
4

LED indicators on the module show the status of the Receive (RX),
Transmit (TX), Ring (RI), and Carrier Detect (CD) control lines.
Table 5-14 displays connector signals and their functions.
Table 5-14. Modem Signal Routing – Comm3, Comm4, and Comm5
Signal
RX
TX
RI
CD

Function
Lit when module (Comm3, Comm4, or Comm5) is currently receiving.
Lit when module (Comm3, Comm4, or Comm5) is currently transmitting (Tip).
Lit when module (Comm3, Comm4, or Comm5) on ring (Ring).
Lit when module (Comm3, Comm4, or Comm5) on carrier detect.

Terminal
1
3
7
9

Notes:

Issued Mar-06

If you are installing a modem module, it is recommended that you
install a surge protector between the RJ-11 jack and the outside line.

The dial-up modem is not hot-swappable or hot-pluggable. When
installing a dial-up modem module, you must remove power from the
ROC827.

Communications

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ROC827 Instruction Manual

5.10 Multi-Variable Sensor (MVS) Interface Modules
The Multi-Variable Sensor (MVS) provides differential pressure, static
pressure, and temperature inputs to the ROC827 unit for orifice flow
calculation.
The MVS module consists of interface electronics that provide the
communications link between the ROC827 and the MVS. The interface
electronics controls communications with the sensor module, provides
scaling of process variables, aids calibration, stores operating parameters,
performs protocol conversion, and responds to requests from the ROC827.
The ROC827 handles up to two MVS interface modules. Each MVS
module provides the communications interface and the isolated, shortcircuit current-limited power required to connect up to six MVS sensors.
The MVS modules create six points automatically for each of the six
possible MVS channels. The points include 1 through 6 and if you have a
second MVS module installed, points 7 through 12 are available. Points
are assigned based on which module is in the first slot. For example, if an
MVS module is in slot three, it automatically assigns the points 1 through
6. If you then install an MVS module into slot one, the points are reassigned so that slot one holds points 1 through 6 and slot three holds
points 7 through 12.
The ROC827 allows six MVS devices to be connected on its
communications bus in a multi-drop connection scheme. You must set the
address of each MVS prior to final wiring of multiple MVS devices. For
proper operation of multiple MVS devices, each MVS device must have a
unique address. None of the addresses can be 240. For details on MVS
configuration, refer to the ROCLINK 800 Configuration Software User
Manual (Form A6121).
Once you set a unique address for each MVS, connect the MVS units in a
multi-drop arrangement. The only requirement for wiring multi-drop
devices is that all like terminals be tied together. This means all the “A”
terminals on the devices are electrically connected to the ROC827’s “A”
terminal and so on. To do this, daisy-chain wire each remote MVS.
Terminations are required on the two MVS modules located at the
extremities of the circuit. That is to say, the two outside modules require
terminations in order to complete the communications circuit. The MVS
termination jumper is located at J4 on the module. Refer to Table 5-15 and
Figure 5-6.
Table 5-15. MVS Termination

Jumper
J4

Issued Mar-06

Terminated
TER
x

Communications

OUT

Not Terminated
TER

OUT
x

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ROC827 Instruction Manual

Figure 5-6. MVS Jumper J4 (Shown Not Terminated)
Four wires run from the MVS module terminal block and connect to the
sensor. The wires should be a minimum size of 22 AWG and a maximum
length of 1220 m (4000 ft).
Note: Insulated, shielded, twisted-pair wiring is required when using MVS

signal lines.
Two of the terminal blocks provide power and the other two terminals
provide a communication path. Table 5-16 identifies the terminals.
Table 5-16. MVS Signal Routing – Comm3, Comm4, and Comm5
Label
A
B
None
+
–

MVS
RX / TX +
RX / TX –
No Connect
Sensor Power
Common

LED
Lit green when receiving
N/A
Lit green when transmitting
N/A
N/A

Terminal
1
2
3
4
5

Notes:

Issued Mar-06

Pay close attention to the connections; do not reverse the power
wires. Make these connections only after removing power from the
ROC827. Double-check connections for the proper orientation before
applying power. If the connections are reversed and power is applied,
you will damage both the MVS module and the ROC800-Series
processor board.

Communications

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ROC827 Instruction Manual

MVS modules are isolated on the field side. Be aware that you can
induce ground loops by tying commons together.

5.11 HART Interface Module
The HART® Interface module allows a ROC827 to communicate with
HART devices using the Highway Addressable Remote Transducer
(HART) protocol. The HART module can receive signals from HART
transmitters or receive and transmit signals from HART transducers. LEDs
provide a visual indication of the status of each HART channel. Refer to
Figure 4-21.
Note: The ROC827 currently supports the HART module only when

installed in slot 1, 2, or 3 of the ROC827 base unit.
The HART module has four analog channels. When configured as an
input, you can configure the channel for use in point-to-point or multidrop mode and typically connects to some type of transmitter, such as for
a temperature reading. When configured as an output, you can configure
the channel for use in point-to-point mode only. The output supports a
Digital Valve Controller (DVC).
Point-to-Point Mode

In point-to-point mode, digital communications are superimposed
using the Frequency Shift Keying (FSK) technique on the 4 to 20
milliAmp analog signal (which can still measure the process variable).
This mode allows communications with one HART device per analog
channel.

Multi-drop Mode

In multi-drop mode, you can connect up to five HART devices (in
parallel) to each analog input channel. As with the point-to-point
mode, digital communications are superimposed on the 4 to 20
milliAmp signal. However, the analog signal is used only to measure
the current consumed by the multi-drop loop. When all four analog
inputs are in the multi-drop mode, the ROC827 can support a
maximum of 20 HART devices. The number of devices per channel is
limited by the static current draw of the devices.
A ROC827 equipped with a HART module is considered to be a HART
Host (primary master) interface with a Class 1 Conformance classification.
Most Universal and some Common Practice commands are supported. For
a list of the commands, refer to the HART Communication Module
specification sheet (6.3:HART). The supported commands conform to
HART Universal Command Specification Revision 5.1 and Common
Practice Command Specification Revision 7, (HCF SPEC 127 and 151).
Refer to www.hartcomm.org for more information on the specifications.
The HART module polls the channels simultaneously. If more than one
device is connected to a channel in a multi-drop configuration, the module
polls one device per channel at a time. The HART protocol allows one

Issued Mar-06

Communications

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ROC827 Instruction Manual

second per poll for each device, so with five devices per channel the
maximum poll time for the channel would be five seconds.
Note: The ROC827 does not support HART devices configured in Burst

mode (in which the device sends information without a prior request). If
you have a HART device configured in Burst mode, use a hand-held Field
Communicator to turn off Burst mode before you connect the device to
the ROC827.
The HART module provides “loop source” power (+T) and four channels
(1+ through 4+) for communications. The +T power is current-limited.
When powered by the ROC827, terminal +T is connected in parallel to the
positive (+) terminal on all of the HART devices, regardless of the channel
to which they are connected. Channel 1+ is wired to the negative (–)
terminal of a single HART device, or in parallel to the negative terminals
of the devices. Likewise, channel 2+ is wired to the negative (–) terminal
of a single HART device, or in parallel to the negative terminals of a
second group of HART devices.
When powered by an external device, the positive (+) terminal from the
power source is connected in parallel to the positive (+) terminal on all of
the HART devices, regardless of the channel to which they are connected.
Channel 1+ on the HART module is wired to the positive (+) terminal of
the HART device. The power source negative (–) terminal is connected to
the channel’s COM terminal and to the negative (–) terminal of a single
HART device, or in parallel to the negative terminals of the HART
devices.
Switches on the module board allow channel-by-channel selection as an
Analog Input (IN) or Analog Output (OUT). The switches for Channel 2
and 4 are located on the front of the module, while the switches for
channel 1 and 3 are located on the back of the module. Use a pin to move
the switches to the desired state (refer to Figures 5-8 and 5-9).
Note: Always set the IN or OUT switches before wiring the switch or

applying power.

Issued Mar-06

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5-17

ROC827 Instruction Manual

Representative
Internal Circuit

Field Wiring

Figure 5-7. HART Interface Module Field Wiring

CH3 I/O Switch

CH1 I/O Switch

Figure 5-8. HART Channels 1 and 3 (back side of board)

Issued Mar-06

Communications

5-18

ROC827 Instruction Manual

CH2 I/O Switch

CH4 I/O Switch

Figure 5-9. HART Channels 2 and 4 (front side of board)

Issued Mar-06

Communications

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ROC827 Instruction Manual

5.12 Related Specification Sheets
Refer to the following specification sheets (available at
www.EmersonProcess.com/flow) for additional and most-current
information on each of the communications modules.
Table 5-17. Related Documentation
Name
Communications Modules (ROC800-Series)

Form Number
6.3:COM

Part Number
D301171X012

MVS205 Multi-Variable Sensor

2.5:MVS205

D301079X012

MVS205R Multi-Variable Sensor (ATEX Version)

2.5:MVSCE

D301204X012

MVS205R Multi-Variable Sensor (SAA Version)
®

HART Communication Module (ROC800-Series)

Issued Mar-06

Communications

2.5:MVSSAA

D301213X012

6.3:HART

D301203X012

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ROC827 Instruction Manual

Chapter 6 – Troubleshooting
This chapter provides generalized guidelines for troubleshooting the
ROC827. Perform the procedures in this chapter before you remove
power from the ROC827 for any reason, after you restore power to the
ROC827, and if you disassemble the ROC827.
Use the following tools for troubleshooting:

IBM-compatible personal computer.

ROCLINK 800 Configuration software (version 1.60 or greater)

Flat-head (size 1/10 inch) and Philips (size 0) screwdrivers.

In This Chapter
6.1
6.2

6.3

6.1

Guidelines................................................................................................6-1
Checklists ................................................................................................6-2
6.2.1 Serial Communications ................................................................6-2
6.2.2 I/O Point .......................................................................................6-2
6.2.3 Software .......................................................................................6-3
6.2.4 Powering Up.................................................................................6-3
6.2.5 MVS Module.................................................................................6-3
Procedures ..............................................................................................6-4
6.3.1 Preserving Configuration and Log Data .......................................6-4
6.3.2 Restarting the ROC827 ................................................................6-4
6.3.3 Troubleshooting Analog Input Modules........................................6-5
6.3.4 Troubleshooting Analog Output Modules.....................................6-7
6.3.5 Troubleshooting Discrete Input Modules......................................6-7
6.3.6 Troubleshooting Discrete Output Modules...................................6-8
6.3.7 Troubleshooting Discrete Output Relay Modules ........................6-8
6.3.8 Troubleshooting Pulse Input Modules..........................................6-9
6.3.9 Troubleshooting RTD Input Modules ...........................................6-9
6.3.10 Troubleshooting J & K Type Thermocouple Input Modules .......6-10

Guidelines
When you are attempting to diagnose a problem with the ROC827:

Remember to write down what steps you have taken.

Note the order in which you remove components.

Note the orientation of the components before you alter or remove
them.

Save the configuration and log data. Refer to “Preserving
Configuration and Log Data” in this chapter.

Read and follow all Cautions in this manual.

When you are done troubleshooting, perform the restart procedure as
described in “Restarting the ROC827” in this chapter.
Issued Mar-06

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6.2

Checklists
If the LEDs do not display:

By default, LEDs on the communication modules and I/O modules
enter Sleep mode after five minutes.

To turn the LEDs on, press the LED button located on the CPU for
one second.

Note: Using the ROCKLINK 800 software, you can disable this feature

so that the LEDs always remain on.

6.2.1 Serial Communications
If you are experiencing troubles with a serial communications connection
(LOI, EIA-232, EIA-422, or EIA-485):

Check to make sure power is applied to the ROC827 unit. Check the
ON/OFF jumper, the wiring connections at CHG+ and CHG–, and the
wiring at the power source.

Check the wiring to the termination block or connector. Refer to
Chapter 5, Communications.

Check the communication port settings using ROCLINK 800
Configuration software. Refer to ROCLINK 800 Configuration
Software User Manual (Form A6121).

6.2.2 I/O Point
If you are experiencing troubles with an I/O point (Analog Input, Analog
Output, Discrete Input, Discrete Output, Pulse Input, RTD Input, or
Thermocouple Input):

Check (using ROCLINK 800 software) to see how the channel is
configured.

If the configuration looks correct, then follow the procedure for
troubleshooting that type of I/O (refer to Chapter 6, sections 3 through
10).

If a module does not function correctly, determine if the problem is
with the field device or the module.

Check a module suspected of being faulty for a short circuit between
its input or output terminals. If a terminal not directly connected to
ground reads 0 (zero) when measured with an ohmmeter, the module
is defective and must be replaced.
Note: Return faulty modules to your local sales representative for

repair or replacement.

Issued Mar-06

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6.2.3 Software
If you are experiencing problems with the ROC827 that appear to be
software-related, try resetting the ROC827.
Note: During a reset and subsequent re-start, the ROC827 loses

configuration and log data. Before you attempt any type of reset, back up
your configuration and log data. Refer to “Preserving Configuration and
Log Data” in this chapter.

Use a Warm Start to restart without losing configuration or log data.
To perform a Warm Start, open ROCLINK 800 software, connect to
the ROC827 unit and select ROC > Flags. Refer to ROCLINK 800
Configuration Software User Manual (Form A6121).

Use a Cold Start to restart without a portion of the configuration, log
data, or programming that may be the trouble. To perform a Cold
Start, open ROCLINK 800 software, connect to the ROC827 and
select ROC > Flags. Refer to ROCLINK 800 Configuration Software
User Manual (Form A6121).

While applying power, firmly press the RESET button on the CPU for
three seconds to restore the unit to factory defaults without connecting
to ROCLINK 800 software.

Note: If none of these methods solve the problem, contact your local sales

representative.

6.2.4 Powering Up
If you are experiencing trouble with powering up the ROC827:

Check the wiring connections at terminations on the Power Input
module and the wiring at the power source.

Check the internal battery for voltage. Refer to Chapter 3, Power
Connections.

Check the external batteries, if applicable, for voltage.

Note: If none of these methods solve the problem, contact your local sales

representative.

6.2.5 MVS Module
If you are experiencing trouble with the MVS module:

Issued Mar-06

If more than one MVS is connected to the ROC827, use the
ROCKLINK 800 Configuration software to ensure that each MVS has
a unique address.

Troubleshooting

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ROC827 Instruction Manual

Reset the MVS module back to factory defaults. Refer to the
ROCLINK 800 Configuration Software User Manual (Form A6121).

Note: If you believe an MVS module is damaged or faulty, contact your

sales representative for repair or replacement.

6.3

Procedures
Use the following procedures to resolve various issues with the I/O
modules.

6.3.1 Preserving Configuration and Log Data
Perform this backup procedure before you remove power from the
ROC827 for repairs, troubleshooting, or upgrades, This procedure
preserves the current ROC827 configuration and log data held in
SDRAM.
Caution

When working on units located in a hazardous area (where explosive
gases may be present), make sure the area is in a non-hazardous state
before performing procedures. Performing these procedures in a
hazardous area could result in personal injury or property damage.
To avoid circuit damage when working inside the unit, use appropriate
electrostatic discharge precautions, such as wearing a grounded wrist
strap.

1. Launch ROCLINK 800 software.
2. Select ROC menu > Flags > Save Configuration. This saves all

configuration settings, including the current states of the ROC827
Flags and calibration values. Click OK.
3. Select ROC menu > Collect Data. Select all check boxes and click

OK. This saves event logs, alarm logs, report data, hourly logs, and
daily logs (you can specify your own file name and path if desired).
4. Select File > Save Configuration. The Save As dialog box appears.
5. Type the desired File name of the backup file.
6. Select the Directory where you desire to store the configuration file.
7. Click Save.

6.3.2 Restarting the ROC827
After removing power to the ROC827 and installing components,
perform the following steps to start your ROC827 and reconfigure your
data.

Issued Mar-06

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ROC827 Instruction Manual

Ensure all input devices, output devices, and processes remain in a safe
state upon restoring power. An unsafe state could result in property
damage.

Caution

Note: The procedure assumes you are using ROCLINK 800 software.
1. Reconnect power to the ROC827 unit.
2. Wait 30 seconds.
3. Launch ROCLINK 800 software, log in, and connect to the ROC827.
4. Verify that the configuration is correct. If major portions or the entire

configuration needs to be reloaded, perform the remaining steps.
5. Select File > Download.
6. Select the backup configuration file (with file extension *.800) from

the Open dialog box.
7. Select the portions of the configuration you desire to download

(restore).
8. Click Download to restore the configuration.
9. Configure other required parameters.

6.3.3 Troubleshooting Analog Input Modules
Before you can determine whether an Analog Input module is operating
properly, you must first know its configuration. Table 6-1 shows typical
configuration values for an Analog Input:
Table 6-1. Analog Input Module Typical Configuration Values
Parameter

Value

Value Read

Adjusted A/D 0 %

819

1 volt dc across the + and the COM terminal by a multimeter

Adjusted A/D 100 %

4095

5 Volts dc across the + and the COM terminal by a multimeter

Low Reading EU

0.0000

EU value with 1 Volt dc

High Reading EU

100.0

EU value with 5 Volts dc

Value

xxxxx

Value read by AI module

Equipment Required:

Issued Mar-06

Multimeter

PC running ROCLINK 800 software

Troubleshooting

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ROC827 Instruction Manual

Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

1. Connect a multimeter across the scaling resistor connected to the +

and COM terminals of the module and set the multimeter to measure
voltage.
2. Connect to ROCLINK 800 software.
3. Select Configuration > I/O > AI Points.
4. Select the correct Analog Input Point Number.
5. Verify the following readings:

When the Value is –25% of span as configured in Table 6-1, it is
an indication of no current flow (0 mA), which can result from
open field wiring or a faulty field device. The multimeter should
show 0 (zero) Volts dc.

When the Value is in excess of 100% of span as configured in
Table 6-1, it is an indication of maximum current flow, which can
result from shorted field wiring or a faulty field device. The
multimeter should show 5 Volts dc.

When the Value is between the Low Reading EU and the High
Reading EU, verify the accuracy of the reading by measuring the
voltage across the terminals with the multimeter.

6. Convert this reading to the Value value:
Value = [((Vmultimeter – 1) ÷ 4) * Span] + Low Reading EU

where Span = High Reading EU – Low Reading EU.
Note: This calculated value should be within one-tenth of one percent

of the Filter value measured by the ROC827.
7. Verify the accuracy by reading the loop current with a multimeter,

setting the multimeter to measure current in mA, and connecting it in
series with current loop. Be sure to take into account that input values
can change rapidly, which can cause a greater error between the
measured value and the calculated value.
8. Calculate the Value from the mAmp reading of the multimeter:
Value = [((mAmpmultimeter* Rscaling resistor – 1) * 4) * Span] + Low
Reading EU

where Span = High Reading EU – Low Reading EU and Rscaling
resistor should be 250 ohms (factory installed scaling resistor value).
Note: If the calculated value and the measured value are the same, the

AI module is operating correctly.
Issued Mar-06

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ROC827 Instruction Manual
9. Remove the test equipment.

6.3.4 Troubleshooting Analog Output Modules
Equipment Required:

Caution

Multimeter.

PC running ROCLINK 800 software.

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

To calibrate the module:
1. Connect a multimeter between the + and – channel terminals of the

module and set the multimeter to measure current in milliamps.
2. Connect to ROCLINK 800 software.
3. Select Configuration > I/O > AO Points.
4. Select the correct Analog Output Point Number.
5. Select Scanning Manual and click Apply.
6. Set the output to the High Reading EU value.
7. Verify a 20 mA reading on the multimeter.
8. Set the output to the Low Reading EU value and click Apply.
9. Verify a 4 mA reading on the multimeter.
10. Calibrate the Low Reading EU value by increasing or decreasing the

Adjusted D/A 0% units value.
11. Select Scanning Enabled and click Apply.
12. Remove the test equipment, and reconnect the field device.
13. If possible, verify the correct operation of the AO module by setting

the High Reading EU and Low Reading EU values as before
(Scanning Disabled) and observing the field device.

6.3.5 Troubleshooting Discrete Input Modules
Equipment Required:

Caution

Jumper wire

PC running ROCLINK 800 software

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

1. Disconnect the field wiring at the DI module terminations.
Issued Mar-06

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ROC827 Instruction Manual
2. Connect to ROCLINK 800 software.
3. Select Configuration > I/O > DI Points.
4. Select the correct Discrete Input Point Number.
5. Place a jumper across a channel input terminal (1-8) and COM.
6. The Status should change to On. With no jumper on the channel

terminal and COM, the Status should change to Off.
7. Remove the test equipment, and reconnect the field device.

6.3.6 Troubleshooting Discrete Output Modules
Equipment Required:

Caution

Multimeter

PC running ROCLINK 800 software

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

1. Verify the load current requirement does not exceed the current limit

value of the module.
2. Verify the module is wired correctly.
3. Remove all wiring from the DO module.
4. Connect the multimeter set up to measure ohms to the channel that

you are testing.
5. Measure the resistance with the DO Status OFF. It should be over 2

megohms.
6. Measure the resistance with the DO Status ON. It should be

approximately 1 ohm.

6.3.7 Troubleshooting Discrete Output Relay Modules
Equipment Required:

Caution

Multimeter

PC running ROCLINK 800 software

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

1. Connect the multimeter set up to measure ohms to the channel that

you are testing.
2. Set the Status to On and click Apply.
Issued Mar-06

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ROC827 Instruction Manual
3. Measure the resistance across terminals + and –. A reading of 0 (zero)

ohms should be obtained. No continuity should be indicated.
4. Measure the resistance across the terminals + and –. The reading

should indicate an open circuit.

6.3.8 Troubleshooting Pulse Input Modules
Equipment Required:

Caution

Pulse Generator

Voltage Generator

Frequency Counter

Jumper wire

PC running ROCLINK 800 software

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

To verify high-speed operation:
1. Disconnect the field wiring at the PI module terminations.
2. Connect to ROCLINK 800 software.
3. Select Configuration > I/O > PI Points.
4. Select the correct Pulse Input Point Number.
5. Connect a pulse generator having sufficient output to drive the

module to terminals L+ or H+ and COM. The pulse generator must
synthesize a square wave signal of 50% for every cycle.
6. Connect a frequency counter across terminals L+ or H+ and COM.
7. Set the pulse generator to a value equal to, or less than 10 KHz.
8. Set the frequency counter to count pulses.
9. Verify, using ROCLINK 800 software, that the count read by the

counter and the ROC827 are the same.
10. Remove the test equipment, and reconnect the field device.

6.3.9 Troubleshooting RTD Input Modules
The RTD module is similar in operation to an Analog Input module and
uses the same troubleshooting and repair procedures.
Equipment Required:

Issued Mar-06

Multimeter

PC running ROCLINK 800 software
Troubleshooting

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ROC827 Instruction Manual

Caution

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

1. Disconnect the field wiring at the RTD module terminations.
2. Connect to the ROCLINK 800 software.
3. Select Configuration > I/O > RTD Point.
4. Select the correct RTD Point Number.
5. If any of the input wires are broken or not connected, the ROCLINK

800 software indicates the Raw A/D Input value is either at minimum
(less than 47974) or maximum (greater than or equal to 61958) as
follows:

An open at terminal + gives a maximum reading.

An open at terminal – gives a minimum reading.

An open at terminal RET gives a minimum reading.

To verify the operation of the RTD module:
6. Connect to the ROCLINK 800 software.
7. Select Configuration > I/O > RTD Point.
8. Disconnect the RTD and connect a jumper between terminals – and

RET of the RTD module.
9. Connect either an accurate resistor or decade resistance box with a

value to give a low end reading across terminals + and –.
Note: Use the temperature-to-resistance conversion chart to determine

the resistance value required for the type of RTD being used.
10. Verify that the Raw A/D Input value changed and reflects the

Adjusted A/D 0% value.
11. Change the resistance to reflect a high temperature as determined by

the temperature-to-resistance conversion chart.
12. Verify that the Raw A/D Input value changed and reflects the

Adjusted A/D 100% value.
13. Remove the test equipment, and reconnect the field device.

6.3.10 Troubleshooting J and K Type Thermocouple Input Modules
Many digital multimeters can generate and measure thermocouple (T/C)
signals. Check your multimeter’s product documentation to see if it
supports thermocouples and how to correctly use the feature if so
equipped. You may require an optional T/C adaptor to use the multimeter.
To test a thermocouple, do not parallel the voltage meter on a
thermocouple that is connected to a ROC827, as it will distort the signal.
Issued Mar-06

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ROC827 Instruction Manual

Do not try to verify a thermocouple that is connected and actively being
monitored by a ROC827 by measuring the voltage at the ROC827
terminal blocks.
It is suggested that you independently verify the process temperature, by
using a certified thermometer in an adjacent thermowell, and then
compare it to what the ROC827 is reading.
Equipment Required:

Caution

Multimeter

PC running ROCLINK 800 software

Failure to exercise proper electrostatic discharge precautions, such as
wearing a grounded wrist strap may reset the processor or damage
electronic components, resulting in interrupted operations.

To test the thermocouple module:
1. Disconnect the thermocouple from the thermocouple module.
2. Generate the correct J or K signal using a multimeter and connect the

wiring from the multimeter to the T/C module in the ROC827.
3. Verify the ROC is reading the generated temperature form the

multimeter.
4. Remove the test equipment, and reconnect the field device.

To test the thermocouple:
1. Disconnect the thermocouple from the ROC827.
2. Connect the thermocouple directly to the multimeter and verify the

reading is correct by comparing it to a certified temperature
measurement device connected to the process temperature the T/C is
measuring.
3. Remove the test equipment, and reconnect the field device.

Unintentional thermocouple junctions cause many measurement errors.
Remember that any junction of two different metals will cause a junction.
To increase the length of the leads from the thermocouple, use the correct
type of thermocouple extension wire. Any connector must be made of the
correct thermocouple material and correct polarity must be observed.
If the reading is off:
1. The type J or K thermocouples are selected on a per channel basis on

the thermocouple module. Verify each channel on the ROC827 and
make sure it is set for the type of thermocouple that you are using.
2. Ensure any plugs, sockets, or terminal blocks used to connect the

extension wire are made from the same metals as the thermocouples
and correct polarity is observed.
3. Verify all connections are tight.
Issued Mar-06

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ROC827 Instruction Manual
4. Verify the thermocouples have the correct construction (ungrounded)

and are not grounded by other means.
5. Verify you are using the correct thermocouple wire all the way from

the thermocouple to the ROC827 with minimal connections.
6. Verify the wiring run is adequately protected from noise.
7. Test the thermocouple reading from the thermocouple to a meter, and

then generate a signal into the ROC827 as described previously.
8. Finally, connect a thermocouple of the same type directly to the

ROC827. If it reads correctly, the problem is likely to be in the wiring
to the field or may be related to a ground loop.

Issued Mar-06

Troubleshooting

6-12

ROC827 Instruction Manual

Chapter 7 – Calibration
This section provides information about calibration procedures for the
Analog Input (AI) modules, HART Input module, RTD Input module,
and Multi-Variable Sensor (MVS) Input module. For the full calibration
procedure, refer to the ROCLINK 800 Configuration Software User
Manual (Form A6121).
In This Chapter
7.1
7.2

7.1

Calibration................................................................................................7-1
Preparing for Calibration..........................................................................7-1

Calibration
Use ROCLINK 800 Configuration software to perform initial calibration
or re-calibration of the inputs on the AI, HART, RTD, and MVS
modules. Re-calibration would occur, for example, after a change in an
orifice plate in the meter run handled by the ROC827. Calibration can be
performed on sensor inputs from either orifice meter runs or turbine meter
runs.
The AI and MVS calibration routines support five-point calibration, with
the three mid-points calibrated in any order. The The low-end or zero
reading is calibrated first, followed by the high-end or full-scale reading.
The three mid-points can be calibrated next, if desired. The RTD
calibration routine supports three-point calibrations.
The HART calibration routine supports two-point calibration. The lowend or zero reading is calibrated first, followed by the high-end or fullscale reading.
The diagnostic System Analog Inputs are not designed to be calibrated.

7.2

Preparing for Calibration
Before calibrating the inputs from a sensor, HART device, or other
device, you should prepare the ROC827 unit.
1. Verify the inputs are correctly wired. For information on wiring the

inputs, refer to Chapter 4, Input/Output Modules.
2. If calibrating a pressure sensor input, be sure to remove the sensor

from the flow as directed in the calibration procedure in the
ROCLINK 800 Configuration Software User Manual (Form A6121).
3. Verify that any external monitoring devices (such as multimeters) are

connected to the ROC827 unit, if they are required for the calibration.

Issued Mar-06

Calibration

7-1

ROC827 Instruction Manual

Issued Mar-06

Calibration

7-2

ROC827 Instruction Manual

Appendix A – Glossary
Note: This is a generalized glossary of terms. Not all the terms may
necessarily correspond to the particular device or software described in
this manual. For that reason, the term “ROC” is used to identify all
varieties of Remote Operations Controllers (including ROC800-Series,
ROC300-Series, FloBoss™ 100-Series, FloBoss 300-Series, FloBoss 500Series, and FloBoss 407 units).

A
A/D

Analog to Digital signal conversion.

ABS

Acrylonitrile Butadiene Styrene.

ADC

Analog to Digital Converter. Used to convert analog inputs (AI) to a format the flow
computer can use.

AGA

American Gas Association. A professional organization that oversees the AGA3 (orifice),
AGA5 (heating value), AGA7 (turbine), AGA8 (compressibility), and AGA11 (ultrasonic)
gas flow calculation standards. See http://www.aga.org.

AWG

American Wire Gauge.

Analog Input.

Analog Output.

Analog

Analog data is represented by a continuous variable, such as an electrical current signal.

Absolute Pressure.

API

American Petroleum Institute. See http://www.api.org.

Area

A user-defined grouping of database entities.

ASCII

American (National) Standard Code for Information Interchange.

Attribute

A parameter that provides information about an aspect of a database point. For example,
the alarm attribute is an attribute that uniquely identifies the configured value of an alarm.

BMV

Base Multiplier Value, used in AGA7 (turbine) calculations.

BPS

Bits Per Second, associated with baud rate.

BTU

British Thermal Unit, a measure of heat energy.

Built-in I/O

I/O channels that are fabricated into the ROC and do not require a separate option. Also
called “on-board” I/O.

C1D2

Class 1, Division 2 hazardous area

CMOS

Complementary Metal Oxide Semiconductor, a type of microprocessor used in a ROC.

Coil

Digital output, a bit to be cleared or set.

COL

Ethernet Packet Collision.

COM

Communications port on a personal computer (PC).

COMM

Communications port on a ROC used for host communications. .

Note: On FloBoss 500-Series and FloBoss 407s, COMM1 is built-in for RS-232 serial
communications.
Issued Mar-06

Glossary

A-1

ROC827 Instruction Manual

C (continued)
Comm Module

Module that plugs into a ROC to provide a channel for communications via a specified
communications protocol, such as EIA-422 (RS-422) or HART.

Compare Flag; stores the Signal Value Discrete (SVD).

Configuration

Refers either to the process of setting up the software for a given system or the result of
performing this process. The configuration activity includes editing the database, building
schematic displays and reports, and defining user calculations. Typically, the software
setup of a device that can often be defined and changed. Can also mean the hardware
assembly scheme.

Configuration
Tree

In ROCLINK 800, the graphical display that appears when a configuration file opens. It is
a hierarchical branching (“tree-style”) method for navigating within the configuration
screens.

CPU

Central Processing Unit.

CRC

Cyclical Redundancy Check error checking.

Crosstalk

The amount of signal that crosses over between the receive and transmit pairs, and
signal attenuation, which is the amount of signal loss encountered on the Ethernet
segment.

CSA

Canadian Standards Association. See http://www.csa.ca.

CSMA/CD

Carrier Sense Multiple Access with Collision Detection.

CTS

Clear to Send modem communications signal.

D/A

Digital to Analog signal conversion.

Database.

Decibel. A unit for expressing the ratio of the magnitudes of two electric signals on a
logarithmic scale.

DCD

Data Carrier Detect modem communications signal. In addition, Discrete Control
Device – A discrete control device energizes a set of discrete outputs for a given setpoint
and matches the desired result against a set of discrete inputs (DI).

DCE

Data Communication Equipment.

Deadband

A value that is an inactive zone above the low limits and below the high limits. The
purpose of the deadband is to prevent a value (such as an alarm) from being set and
cleared continuously when the input value is oscillating around the specified limit. This
also prevents the logs or data storage location from being over-filled with data.

Device Directory

In ROCLINK 800, the graphical display that allows navigation through the PC Comm
Ports and ROC Comm Ports setup screen.

Discrete Input.

Discrete

Input or output that is non-continuous, typically representing two levels (such as on/off).

DMM

Digital multimeter.

Discrete Output.

Download

The process of sending data, a file, or a program from a PC to a ROC.

Differential Pressure.

DSR

Data Set Ready modem communications signal.

DTE

Data Terminal Equipment.

DTR

Data Terminal Ready modem communications signal.

Duty Cycle

Proportion of time during a cycle that a device is activated. A short duty cycle conserves
power for I/O channels, radios, and so on.

Issued Mar-06

Glossary

A-2

ROC827 Instruction Manual

D (continued)
DVM

Digital voltmeter.

DVS

Dual-Variable Sensor. A device that provides static and differential pressure inputs to a
ROC.

EDS

Electronic Static Discharge.

EEPROM

Electrically Erasable Programmable Read-Only Memory, a form of permanent memory
on a ROC.

EFM

Electronic Flow Metering or Measurement.

EIA-232
(RS-232)

Serial Communications Protocol using three or more signal lines, intended for short
distances. Concerning RS232D and RS232C, the letters C or D refer to the physical
connector type. D specifies the RJ-11 connector where a C specifies a DB25 type
connector.

EIA-422
(RS-422)

Serial Communications Protocol using four signal lines.

EIA-485
(RS-485)

Serial Communications Protocol requiring only two signal lines. Can allow up to 32
devices to be connected together in a daisy-chained fashion.

EMF

Electro-Motive Force.

EMI

Electro-Magnetic Interference.

ESD

Electro-Static Discharge.

Engineering Units. Units of measure, such as MCF/DAY.

FCC

Federal Communications Commission. See http://www.fcc.gov.

Firmware

Internal software that is factory-loaded into a form of ROM. In a ROC, the firmware
supplies the software used for gathering input data, converting raw input data values,
storing values, and providing control signals.

FlashPAC
module

ROM and RAM module for a ROC300-Series unit that contains the operating system,
applications firmware, and communications protocol.

Flash ROM

A type of read-only memory that can be electrically re-programmed. It is a form of
permanent memory (requires no backup power). Also called Flash memory.

FloBoss

A microprocess-based device that provides flow calculations, remote monitoring, and
remote control. A FloBoss is a type of ROC.

Factory Mutual.

Force

Write an ON/OFF, True/False, or 1/0 value to a coil.

FPV

Compressibility Factor.

FSK

Frequency Shift Keypad.

FST

Function Sequence Table, a type of user-written program in a high-level language
designed by Emerson Process Management’s Flow Computer Division.

Foot or feet.

GFA

Ground Fault Analysis.

GND

Electrical ground, such as used by the ROC’s power supply.

Gauge Pressure.

Issued Mar-06

Glossary

A-3

ROC827 Instruction Manual

H
HART

Highway Addressable Remote Transducer.

Holding
Register

Analog output number value to be read.

Differential pressure.

Hertz.

I, J
IC

Integrated Circuit. Also, Industry Canada (more recently known as Measurement
Canada), an organization that grants custody transfer approvals on certain ROC units.

Identification.

IEC

Industrial Electrical Code or International Electrotechnical Commission. See
http://www.iec.ch.

IEEE

Institute of Electrical and Electronic Engineers. A professional organization that, in
conjunction with the International Standards Organization (ISO), establishes and
maintains the Open System Interconnection (OSI) reference model and an international
standard for the organization of local area networks (LANs). Refer to http://www.ieee.org.

IMV

Integral Multiplier Value, used in AGA3 (orifice) calculations.

Input

Digital input, a bit to be read.

Input Register

Input numeric value to be read.

Local Port

Also LOI; the serial EIA-232 (RS-232) port on the ROC through which local
communications are established, typically for configuration software running on a PC.

I/O

Input/Output.

I/O Module

Module that plugs into an I/O slot on a ROC to provide an I/O channel.

IRQ

Interrupt Request. Hardware address oriented.

ISO

International Standards Organization. See http://www.iso.ch.

Integral Value.

Kilobytes.

KHz

KiloHertz.

LCD

Liquid Crystal Display.

LDP

Local Display Panel, a display-only device that plugs into ROC300-Series units (via a
parallel interface cable) used to access information stored in the ROC.

LED

Light-Emitting Diode.

Logical Number

The point number the ROC and ROC Plus protocols use for I/O point types are based on
a physical input or output with a terminal location; the point numbers for all other point
types are “logical” and are simply numbered in sequence.

LNK

Ethernet has linked.

LOI

Local Operator Interface (or Local Port). Refers to the serial EAI-232 (RS-232) port on
the ROC through which local communications are established, typically for configuration
software running on a PC.

LPM

Lightning Protection Module; a device that provides lightning and power surge protection
for ROCs.

LRC

Longitudinal Redundancy Checking error checking.

Issued Mar-06

Glossary

A-4

ROC827 Instruction Manual

M
m

Meter.

Milliamp(s); one thousandth of an ampere.

MAC Address

Media Access Control Address; a hardware address that uniquely identifies each node of
a network.

Manual mode

For a ROC, indicates that the I/O scanning has been disabled.

MAU

Medium Attachment Unit.

MCU

Master Controller Unit.

Modbus

A popular device communications protocol developed by Gould-Modicon.

MPU

Micro-Processor Unit.

Millimeter.

MMBTU

Million British Thermal Units.

msec

Millisecond, or 0.001 second.

MVS

Multi-Variable Sensor. A device that provides differential pressure, static pressure, and
temperature inputs to a ROC for orifice flow calculations.

Millivolts, or 0.001 volt.

Milliwatts, or 0.001 watt.

NEC

National Electrical Code.

NEMA

National Electrical Manufacturer’s Association. See http://www.nema.org.

Off-Hook modem communications signal.

Off-line

Accomplished while the target device is not connected (by a communications link). For
example, “off-line configuration” refers to configuring an electronic file that is later loaded
into a ROC.

Ohms

Units of electrical resistance.

On-line

Accomplished while connected (by a communications link) to the target device. For
example, “on-line configuration” refers to configuring a ROC800-Series unit while
connected to it, so that you can view the current parameter values and immediately load
new values.

Opcode

Type of message protocol the ROC uses to communicate with the configuration software,
as well as host computers with ROC driver software.

Operator
Interface

Also LOI or Local Port; the serial EIA-232 (RS-232) port on the ROC through which local
communications are established, typically for configuration software running on a PC.

Orifice meter

A meter that records the flow rate of gas through a pipeline. The flow rate is calculated
from the pressure differential created by the fluid passing through an orifice of a particular
size and other parameters.

P, Q
Parameter

A property of a point that typically can be configured or set. For example, the Point Tag
ID is a parameter of an Analog Input point. Parameters are normally edited by using
configuration software running on a PC.

Personal Computer.

Flowing pressure.

Issued Mar-06

Glossary

A-5

ROC827 Instruction Manual

P, Q (continued)
P/DP

Pressure/Differential Pressure.

Pulse Input.

PID

Proportional, Integral, and Derivative control feedback action.

PIT

Periodic Timer Interrupt.

PLC

Programmable Logic Controller.

Point

Software-oriented term for an I/O channel or some other function, such as a flow
calculation. Points are defined by a collection of parameters.

Point Number

The physical location of an I/O point (module slot and channel) as installed in the ROC.

Point Type

Defines the database point to be a specific type of point available to the system. The
point type determines the basic functions of a point.

Preset

Number value previously determined for a register.

PRI

Primary PID control loop.

Protocol

A set of standards that enables communication or file transfers between two computers.
Protocol parameters include baud rate, parity, data bits, stop bit, and the type of duplex.

PSTN

Public Switched Telephone Network.

Process Temperature.

PTT

Push-to-Talk signal.

Pulse

Transient variation of a signal whose value is normally constant.

Pulse Interface
module

A module that provides line pressure, auxiliary pressure, and pulse counts to a ROC.

Process Variable or Process Value.

Rack

A row of slots on a ROC into which I/O modules can be plugged. Racks are given a letter
to physically identify the location of an I/O channel (such as “A” for the first rack). Built-in
I/O channels are assigned a rack identifier of “A” while diagnostic I/O channels are
considered to be in “E” rack.

RAM

Random Access Memory. RAM is used to store history, data, most user programs, and
additional configuration data.

RBX

Report-by-exception. RBX always refers to Spontaneous RBX in which the ROC contacts
the host to report an alarm condition.

Results Register; stores the Signal Value Analog (SVA).

RFI

Radio Frequency Interference.

Ring Indicator modem communications signal.

ROC

Remote Operations Controller microprocessor-based unit that provides remote
monitoring and control.

ROCLINK 800

Microsoft® Windows®-based software used to configure functionality in ROC units.

ROM

Read-only memory. Typically used to store firmware. Flash memory.

Rotary Meter

A positive displacement meter used to measure flow rate, also known as a Roots meter.

RTC

Real-Time Clock.

RTD

Resistance Temperature Detector.

RTS

Ready to Send modem communications signal.

RTU

Remote Terminal Unit.

RTV

Room Temperature Vulcanizing, typically a sealant or caulk such as silicon rubber.

Issued Mar-06

Glossary

A-6

ROC827 Instruction Manual

R (continued)
RS-232

Serial Communications Protocol using three or more signal lines, intended for short
distances. Also referred to as the EIA-232 standard.

RS-422

Serial Communications Protocol using four signal lines. Also referred to as the EIA-422
standard.

RS-485

Serial Communications Protocol requiring only two signal lines. Can allow up to 32
devices to be connected together in a daisy-chained fashion. Also referred to as the EIA485 standard.

RX or RXD

Received Data communications signal.

SAMA

Scientific Apparatus Maker’s Association.

Script

An uncompiled text file (such as keystrokes for a macro) that a program interprets in
order to perform certain functions. Typically, the end user can easily create or edit scripts
to customize the software.

Soft Points

A type of ROC point with generic parameters that can be configured to hold data as
desired by the user.

Setpoint, or Static Pressure.

SPI

Slow Pulse Input.

SPK

Speaker.

SRAM

Static Random Access Memory. Stores data as long as power is applied; typically backed
up by a lithium battery or supercapacitor.

SRBX

Spontaneous Report-By-Exception. SRBX always refers to Spontaneous RBX in which
the ROC contacts the host to report an alarm condition.

SVA

Signal Value Analog. Stored in the Results Register, it is the analog value that is passed
between functions in an FST.

SVD

Signal Value Discrete. Stored in the Compare Flag, it is the discrete value that is passed
down the sequence of functions in an FST.

System
Variables

Configured parameters that describe the ROC; set using ROCLINK software.

T/C

Thermocouple Input.

TCP/IP

Transmission Control Protocol/Internet Protocol.

TDI

Time Duration Input.

TDO

Time Duration Output.

Flowing temperature.

TLP

Type (of point), Logical (or point) number, and Parameter number.

TX or TXD

Transmitted Data communications signal.

Turbine meter

A device used to measure flow rate and other parameters.

Upload

Send data, a file, or a program from the ROC to a PC or other host.

U
V-Z
V

Issued Mar-06

Volts.

Glossary

A-7

ROC827 Instruction Manual

Issued Mar-06

Glossary

A-8

ROC827 Instruction Manual

Index
Wiring External .............................................. 3-23
Battery
Backup............................................................. 1-6
High ...............................................................1-13
Low ................................................................ 1-13
Storage .......................................................... 3-20
Burst Mode......................................................... 5-17

+
+12 V dc
Analog Input .................................................... 4-6
Pulse Input .................................................... 4-13
+24 V dc
Analog Input .................................................... 4-6
Pulse Input .................................................... 4-13
+T......................................................................... 4-6

C
Calibration............................................................ 7-1
Central Processing Unit
See CPU........................................................ 2-13
Central Processing Unit (CPU) ............................ 1-3
CHG+ and CHG–................................................. 3-2
Clock .................................................................... 1-6
Cold Junction Compensation (CJC) .................. 4-16
Comm1 through Comm5 ..................................... 5-1
Communications
Built-in.............................................................. 5-1
Dial-up modem .............................................. 5-12
EIA-232 (RS-232) module ............................... 5-9
EIA-422/485 (RS-422/485) modules ............. 5-10
Ethernet ........................................................... 5-7
HART Interface module ................................. 5-16
Installing modules............................................ 5-3
Local Port ........................................................ 5-5
Modules ........................................................... 5-1
Port Locations.................................................. 5-1
Removing a module......................................... 5-4
Wiring............................................................... 5-5
Communications modules
Specifications ................................................ 5-20
Configuration, Tuning ........................................ 3-11
CPU ...................................................................2-18
Connector Locations...................................... 2-15
Description....................................................... 1-5
Installing ........................................................ 2-16
Removing ...................................................... 2-16

1
12 Volt dc
Power Input module ........................................ 3-1
2
24 V dc
Power Input module ........................................ 3-3
A
Acrylonitrile Butadiene Styrene (ABS)................. 1-2
Addressing Module Slots................................... 1-10
Alarming
SRBX/RBX .................................................... 1-16
Analog Inputs....................................................... 4-6
+12 and +24 V dc ............................................ 4-6
System............................................................. 1-7
Troubleshooting............................................... 6-5
Analog Outputs .................................................... 4-8
Troubleshooting............................................... 6-7
AT Command..................................................... 5-13
Attaching an EXP............................................... 2-11
Automatic Self Tests.......................................... 1-13
AUX Terminal ...................................................... 3-2
AUX+ and AUX–....................................3-2, 3-3, 3-4
LEDs................................................................ 3-3
Auxiliary
Wiring .............................................................. 3-4
Auxiliary Output ................................................... 3-4
Auxiliary Output Fuse
Installing .......................................................... 3-5
Removing ........................................................ 3-5
AUXSW Terminal................................................... 3-2
AUXSW+ and AUXSW– ...................................3-2, 3-6

D
Detaching an EXP.............................................. 2-12
Determining Power Consumption ........................ 3-7
Diagnostic
Inputs ............................................................... 1-7
Dial-up modem
Communications module ............................... 5-12
LEDs ..............................................................5-13
Wiring............................................................. 5-13
DIN....................................................................... 2-7
Direct Connect ..................................................... 5-7
Discrete Inputs ..................................................... 4-9
LEDs ................................................................ 4-9
Troubleshooting............................................... 6-7

B
Backplane .......................................................... 2-10
Backplane, hardware ........................................... 1-2
BAT Terminal....................................................... 3-2
BAT+ and BAT–................................................... 3-2
Batteries
Replacing Internal ......................................... 3-25
Issued Mar-06

Index

I-1

ROC827 Instruction Manual
Discrete Output Relay
LEDs.............................................................. 4-11
Troubleshooting............................................... 6-8
Discrete Outputs ................................................ 4-10
LEDs.............................................................. 4-10
Relay ............................................................. 4-11
Troubleshooting............................................... 6-8
Dry Relay Contacts.............................................. 4-9
DS800 Development Suite software...........1-16, 5-7
Duty Cycle ........................................................... 3-8
Analog Input .................................................. 3-12
Analog Output ............................................... 3-13
Discrete Input ................................................ 3-14
Discrete Output ............................................. 3-15
Discrete Output Relay ................................... 3-16
MVS............................................................... 3-18
Pulse Input .................................................... 3-17
RTD ............................................................... 3-19
Thermocouple ............................................... 3-19

2-1. Side View, ROC827 ................................. 2-8
2-2. Bottom View, ROC827 ............................. 2-8
2-3. Back View, ROC827................................. 2-9
2-4. ROC827 and Expanded Backplane ....... 2-10
2-5. Power Connector on EXP ...................... 2-11
2-6. CPU Front View...................................... 2-14
2-6. Plastic snaps, EXP ................................. 2-12
2-7. CPU Connectors .................................... 2-14
2-8. License key ............................................ 2-17
3-1. 12 V dc Power Input module .................... 3-2
3-2. 24 V dc Power Input module .................... 3-4
3-3. 12 V dc Auxiliary Power Wiring ................ 3-5
3-4. 24 V dc Auxiliary Power Wiring ................ 3-5
3-5. 12 V dc Power Supply and BAT+ / BAT–
Wiring .......................................................... 3-22
3-6. 12 V dc Power Supply and CHG+ and CHG–
Wiring .......................................................... 3-23
4- 1. Typical I/O Module .................................. 4-2
4- 2. Optional I/O Module Locations................ 4-2
4- 3. Installing an I/O Module .......................... 4-5
4- 4. Analog Input Jumper J4 (at +24V) .......... 4-7
4- 5. Analog Input Module Field Wiring ........... 4-7
4- 6. Analog Output Jumper J4 (at +12 V) ...... 4-8
4- 7. Analog Output Module Field Wiring ........ 4-9
4- 8. Discrete Input Module Field Wiring ....... 4-10
4- 9. Discrete Output Module Field Wiring .... 4-11
4-10. Discrete Output Relay Module Field Wiring
..................................................................... 4-12
4-11. Pulse Input J4 Jumper (at +12V) ......... 4-13
4-12. Externally Powered Pulse Input Module
Field Wiring ................................................. 4-14
4-13. ROC800-Powered Pulse Input Module Field
Wiring .......................................................... 4-14
4-14. RTD Sensor Wiring Terminal Connections416
4-15. Type J and K Thermocouple Wiring..... 4-18
4-16. Type J Thermocouple Shielded Wiring – US
Color Coding ............................................... 4-19
4-17. Type K Thermocouple Shielded Wiring – US
Color Coding ............................................... 4-19
4-18. Ungrounded – Sheathed ...................... 4-19
4-19. Grounded ............................................. 4-19
4-20. Exposed, Ungrounded – Unsheathed .. 4-19
5-1. Communication Ports............................... 5-2
5-2. Example RS-485 Communications Module53
5-3. RJ-45 Pin Out........................................... 5-6
5-4. 10BASE T-Crossover Cable .................... 5-9
5-5. EIA-422/485 (RS-422/485) J4 Jumper... 5-12
5-6. MVS Jumper J4 (shown not terminated) 5-15
5-7. HART Interface Module Field Wiring...... 5-18
5-8. HART Channels 1 and 3 (back side of board)
..................................................................... 5-18
5-9. HART Channels 2 and 4 (front side of board)
..................................................................... 5-19
Firmware .............................................................. 1-8
Flow Calculations............................................... 1-12
Function Sequence Table (FST)........................ 1-14

E
EIA-232 (RS-232) Communications .................... 5-9
Built-in Comm2................................................ 5-9
LEDs................................................................ 5-9
Local Port ........................................................ 5-5
Module Comm3 to Comm5 ............................. 5-9
EIA-422/485 (RS-422/485) Communications
Jumpers and Termination Resistors ............. 5-11
LEDs.............................................................. 5-11
modules ......................................................... 5-10
Selecting 422 or 485 Mode ........................... 5-11
Termination ................................................... 5-11
Enclosure............................................................. 2-2
End Caps ............................................................. 2-6
Environment......................................................... 2-2
Ethernet Communications ................................... 5-7
Ethernet wiring..................................................... 5-8
EUs ...................................................................... 6-6
Event Log........................................................... 1-11
EXP......................................................1-2, 1-4, 2-10
Attaching ....................................................... 2-11
Detaching ...................................................... 2-12
F
FCC Information .................................................. 1-8
Field wiring
Analog Input module ....................................... 4-7
Analog Output module..................................... 4-9
Discrete Input module ................................... 4-10
Discrete Output module................................. 4-11
Discrete Output Relay module ...................... 4-12
HART Interface module................................. 5-18
Pulse Input module (externally powered)...... 4-14
Pulse Input module (ROC800-powered) ....... 4-14
Figures
1-1. ROC827 ................................................... 1-3
1-2. ROC827 and Expanded Backplane ......... 1-4
Issued Mar-06

Index

I-2

ROC827 Instruction Manual
Dial-up Modem .............................................. 5-13
Discrete Inputs................................................. 4-9
Discrete Output Relay ................................... 4-11
Discrete Outputs............................................ 4-10
EIA-232 (RS-232) Communications ................ 5-9
EIA-422/485 (RS-422/485) Communications 5-11
Multi-Variable Sensor .................................... 5-15
Power Input Module..................................3-3, 3-4
Pulse Inputs................................................... 4-13
STATUS ........................................................ 2-15
License Key ....................................................... 2-17
Installing ........................................................ 2-18
Removing ...................................................... 2-19
Light-Emitting Diodes (LED) ................................ 1-5
Local Operator Interface
See Local Port ................................................. 5-5
Local Port............................................................. 5-1
Location ........................................................2-2, 2-3
Logical.................................................................. 1-9
LOI
See Local Port ................................................. 5-5
LOI Port
Using................................................................ 5-7
Low Power Modes ............................................. 1-13

Fuse
Installing .......................................................... 3-5
Removing ........................................................ 3-5
G
Gauges, wire.................................................4-6, 5-5
Ground................................................................. 2-4
H
Hardware ............................................................. 1-2
Hardware Watchdog .......................................... 1-13
HART Interface module ..................................... 5-16
Hazardous Area................................................... 2-3
Historical Database............................................ 1-11
Housing................................................................ 2-5
I
I/O modules ......................................................... 4-1
Analog Inputs .................................................. 4-6
Analog Outputs................................................ 4-8
Discrete Inputs ................................................ 4-9
Discrete Output Relay ................................... 4-11
Discrete Outputs............................................ 4-10
Installation and Setup...................................... 4-3
Installing .......................................................... 4-4
J and K Type Thermocouple Inputs .............. 4-16
Pulse Inputs................................................... 4-12
Removing ........................................................ 4-5
RTD Inputs .................................................... 4-14
Specifications ................................................ 4-21
Wiring .............................................................. 4-6
I/O Wiring............................................................. 2-5
Input/Output ......................................................... 4-1
Installation.....................................................2-1, 2-7
Installing
Auxiliary Output Fuse ...................................... 3-5
Communication modules................................. 5-3
Input/Output modules ...................................... 4-4
Power Input module ...................................... 3-21

M
Memory ................................................................ 1-6
Meter Runs ........................................................ 1-12
Module Cover....................................................... 2-7
Module Slot Addressing..................................... 1-10
Modules
Communications.............................................. 5-1
Input/Output (I/O)............................................. 4-1
Power............................................................... 3-1
Monitoring ............................................................ 1-7
Mounting .............................................................. 2-7
Multi-Variable Sensor
Jumper J4...................................................... 5-14
LEDs ..............................................................5-15
MVS ............................................................... 5-14
Termination.................................................... 5-14
Wiring............................................................. 5-15

J
J and K Type Thermocouple Inputs................... 4-16
Troubleshooting............................................. 6-10
Jumpers
AI +T (+12 or +24)........................................... 4-6
AO +12 or +24................................................. 4-8
EIA-422 (RS-422) module ............................. 5-12
EIA-422/485 (RS-422/485) Communications 5-11
MVS J4 .......................................................... 5-14
Pulse Inputs J4.............................................. 4-13

O
Operation ........................................................... 2-20
Operator Interface Port
See Local Port ................................................. 5-5
P
Parameters .......................................................... 1-9
PID Control ........................................................ 1-14
Point..................................................................... 1-9
Point Type............................................................ 1-9
Polarity ............................................................... 1-13
Power................................................................... 2-4
Connections..................................................... 3-1
Consumption ................................................... 3-7

L
LED .................................................................... 2-15
AUX+ and AUX–.............................................. 3-3
Communications.............................................. 5-2
Issued Mar-06

Index

I-3

ROC827 Instruction Manual
Spontaneous-Report-By-Exception (SRBX)...... 1-16
SRBX/RBX Alarming.......................................... 1-16
Standby Mode.................................................... 1-13
Start ................................................................... 2-19
Stations .............................................................. 1-12
STATUS LED..................................................... 2-15
Storage
Battery ........................................................... 3-20
Switched Auxiliary Output.................................... 3-6
System Analog Inputs.......................................... 1-7

Low Modes .................................................... 1-13
Operating....................................................... 1-13
Requirements .................................................. 3-8
Sleep Mode ................................................... 1-14
Standby Mode ............................................... 1-13
Wiring ............................................................ 3-21
Power Input module............................................. 3-1
12 V dc ............................................................ 3-1
24 V dc ............................................................ 3-3
Installing ........................................................ 3-21
Removing ...................................................... 3-20
Power Input modules
Specifications ................................................ 3-26
Processor and Memory ....................................... 1-6
Proportional, Integral, and Derivative (PID)
See PID Control ............................................ 1-14
Public Switched Telephone Networks
PSTNs ........................................................... 5-12
Pulse Inputs ....................................................... 4-12
+12 and +24 V dc .......................................... 4-13
J4 Jumper...................................................... 4-13
LEDs.............................................................. 4-13
Troubleshooting............................................... 6-9

T
Tables
1-1. System Analog Inputs .............................. 1-7
1-2. 16-point vs. 8-point addressing .............. 1-11
2-1. CPU Connector Locations...................... 2-15
2-2. STATUS LED Functions ........................ 2-15
3- 1. 12 V dc Power Input Terminal Block
Connections .................................................. 3-3
3- 2. 12 V dc Power Input LED Fault Indicators3-3
3- 3. 24 V dc Power Input Terminal Block
Connections .................................................. 3-4
3- 4. 24 V dc Power Input LED Indicators ....... 3-4
3- 5. Estimated Power Consumption............. 3-10
3- 6. Power Consumption, Analog Input module312
3- 7. Power Consumption, Analog Output module
..................................................................... 3-13
3- 8. Power Consumption, Discrete Input module
..................................................................... 3-14
3- 9. Power Consumption, Discrete Output
module......................................................... 3-15
3-10. Power Consumption, Discrete Output Relay
module......................................................... 3-16
3-11. Power Consumption, Pulse Input module 317
3-12. Power Consumption, MVS module ...... 3-18
3-13. Power Consumption, RTD module....... 3-19
3-14. Power Consumption, Thermocouple module
..................................................................... 3-19
3-15. Power Consumption, HART module .... 3-19
3-16. Power Consumption, Other Devices .... 3-20
3-17. Replacement Battery Types................. 3-25
3-18. Power Input Module Specification Sheets 326
4-1. RTD Signal Routing................................ 4-15
4-2. RTD Wiring............................................. 4-16
4-3. I/O Module Specification Sheets ............ 4-21
5- 1. Built-in Communications and Optional
Communications Modules ............................. 5-1
5- 2. Communication LED Indicator Defintions5-2
5- 3. Built-in LOI EIA-232 Signal Routing ........ 5-6
5- 4. RJ-45 to EIA-232 (RS-232) Null-modem
Cable Signal Routing..................................... 5-6
5- 5. Using Cable Warehouse 0378-2 D-Sub to
Modular Converter 9-Pin to RJ-45 Black....... 5-6
5- 6. Ethernet Signal LEDs.............................. 5-8

R
Real-Time Clock .................................................. 1-6
Removing
Auxiliary Output Fuse ...................................... 3-5
Communications module................................. 5-4
I/O modules ..................................................... 4-5
Power Input module ...................................... 3-20
Removing an EXP ............................................. 2-12
Report-By-Exception (RBX)............................... 1-16
RESET............................................................... 2-15
Resistance Temperature Detector
See RTD Inputs............................................. 4-14
Restarting the ROC827 ....................................... 6-4
ROC827............................................................... 1-2
ROCLINK 800 Configuration Software .............. 1-15
RTD Inputs......................................................... 4-14
Troubleshooting............................................... 6-9
Wiring ............................................................ 4-15
S
Security.......................................................1-10, 5-5
Serial Communications
EIA-232 (RS-232)............................................ 5-9
EIA-422/485 (RS-422/485)............................ 5-10
Setup
I/O Modules ..................................................... 4-3
Site....................................................................... 2-2
Sleep Mode........................................................ 1-14
Software Watchdog ........................................... 1-13
Specifications
Communications modules ............................. 5-20
I/O modules ................................................... 4-21
Power Input modules..................................... 3-26
Issued Mar-06

Index

I-4

ROC827 Instruction Manual
5- 7. Built-in EIA-232 (RS-232) Signal Routing –
Comm2........................................................ 5-10
5- 8. EIA-232 (RS-232) Communication Module
Signal Routing – Comm3, Comm4, and Comm5
.................................................................... 5-10
5- 9. EIA-422 (RS-422) Signal Routing – Comm3,
Comm4, Comm5 ......................................... 5-11
5-10. EIA-485 (RS-485) Signal Routing – Comm3,
Comm4, Comm5 ......................................... 5-11
5-11. EIA-422 (RS-422) Module.................... 5-12
5-12. EIA-485 (RS-485) module.................... 5-12
5-13. RJ-11 Field Connections...................... 5-13
5-14. Modem Signal Routing – Comm3, Comm4,
and Comm5................................................. 5-13
5-15. MVS Termination ................................. 5-14
5-16. MVS Signal Routing – Comm3, Comm4,
and Comm5................................................. 5-15
5-17. Communications Modules Related
Documentation ............................................ 5-20
6-1. Analog Input Module Typical Configuration
Values ........................................................... 6-5
TEMP
LED.................................................................. 3-3
Temperature Detector
See J and K Type Thermocouple Inputs....... 4-16
Termination
EIA-422/485 (RS-422/485) Communications 5-11
MVS............................................................... 5-14
Tests
Automatic ...................................................... 1-13
Thermocouple
See J and K Type Thermocouple Inputs....... 4-16
TLP ...................................................................... 1-9
Troubleshooting
Analog Inputs .................................................. 6-5
Analog Outputs................................................ 6-7
Discrete Inputs ................................................ 6-7
Discrete Output Relay ..................................... 6-8
Discrete Outputs.............................................. 6-8
J and K Type Thermocouple Inputs .............. 6-10

Issued Mar-06

Index

Pulse Inputs..................................................... 6-9
RTD Input ........................................................ 6-9
System Analog Inputs...................................... 1-7
Tuning the Configuration ................................... 3-11
U
Using
LOI Port ........................................................... 5-7
UTP...................................................................... 5-8
V
V12
LED.................................................................. 3-4
V3.3
LED.................................................................. 3-4
VOFF
LED...........................................................3-3, 3-4
VOK
LED.................................................................. 3-3
Voltage................................................................. 3-1
VOVER
LED.................................................................. 3-3
W
Watchdog
Software and Hardware................................. 1-13
Wire Channel Covers........................................... 2-6
Wire gauges..................................................4-6, 5-5
Wiring
Auxiliary Power................................................ 3-4
Communications.............................................. 5-5
Dial-up modem .............................................. 5-13
External Batteries .......................................... 3-23
I/O Modules ..................................................... 4-6
I/O Requirements ............................................ 2-5
Multi-Variable Sensor .................................... 5-15
RTD Input ...................................................... 4-15

I-5

ROC827 Instruction Manual

If you have comments or questions regarding this
manual, please direct them to your local sales
representative or contact:
Emerson Process Management
Flow Computer Division
Marshalltown, IA 50158 U.S.A.
Houston, TX 77065 U.S.A.
Pickering, North Yorkshire UK Y018 7JA
Website: www.EmersonProcess.com/flow

Issued Mar-06

Index

I-6

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Emerson Roc827 Instruction Manual

ROC827 53e78454-fa14-41e9-b71b-c7c471d62f23

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