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Interior of the old Saia PCD2.M120 automation controller with expansion modules

p.kaczmarek2 297 3

TL;DR

  • Opens the Saia PCD2.M120 base unit of an old Saia programmable controller, including the enclosure, main board, I/O bus, cover, LEDs, display and PGU connector.
  • The motherboard sits above the I/O bus as a separate PCB, with side connectors, DIP memory sockets, and a mode-change jumper.
  • Key parts include the Xilinx XC9572, MC68340 processor, V3022 clock chip, DS75176 RS485 transceiver, and an L4972A-based power section.
  • The unit is over 20 years old, the copy shows broken plastic spacers, and the display is missing, so restoration remains uncertain.
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  • Interior of the old Saia PCD2.M120 automation controller with expansion modules
    Some time ago I presented the interior of the Saia PCD2.C100 extension cassette , today I would like to show its main module, the PCD2.M120 base unit. The PCD2.M120 consists of an enclosure, inside of which is the main board and the bus for the I/O modules, and a cover with LEDs, display and PGU (programming) connector. The connectors for the expansion cards are located on the side:
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    The motherboard sits above the bus as a separate PCB. Immediately striking are the markings and the battery for keeping time. There is no display on my copy.
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    Photo from the other side; you can see the DIP pin sockets on the memory bones along with the jumper for changing the mode.
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    Additional connectors on both sides of the motherboard:
    Interior of the old Saia PCD2.M120 automation controller with expansion modules Interior of the old Saia PCD2.M120 automation controller with expansion modules
    The way the motherboard is connected with the bus on the bottom:
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    Module with 7580 DS75176 - RS485 transceiver:
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    There are further RS485 line control chips nearby - DS14C89 and DS14C88. In addition we have circuits HC30, 74HC14, HC74, 74HC03, LM339D, perhaps from bus control.
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    An interesting component is the TICOMEL visible in the photo - the model is obscured, but you can see an example online - SD-17-0.63-500 0.63A 500UH. This is simply a coil. That whole circuit there is a power section based on an inverter on the L4972A.
    Interior of the old Saia PCD2.M120 automation controller with expansion modules
    After the power section we have the region with the main ICs. There are the Xilinx XC9572 (CPLD), MC68340 (processor with DMA, also of age, 1994) and V3022 (clock chip - you can see the oscillator next to it).
    Interior of the old Saia PCD2.M120 automation controller with expansion modules Interior of the old Saia PCD2.M120 automation controller with expansion modules
    Interior of the old Saia PCD2.M120 automation controller with expansion modules Close-up of a PCB showing a Xilinx XC9572 chip and nearby electronic components
    Let's remove the motherboard now. My copy must have been dropped by someone because there are broken plastic spacers:
    Underside of a green PCB with many traces and solder points on a wooden workbench
    Four I/O modules can be placed on each side of the bus.
    Inside a modular controller: four green PCBs with orange relay blocks, many ICs, and screw terminal strips Black plastic chassis with four metal guide plates and module slots, on a wooden surface Printed circuit board with relays, screw terminals, and a D-sub connector on a wooden surface
    I can still show them in a few pictures, but in general I have already discussed these modules: Interior of the Saia PCD2.C100 expansion cassette from the PCD2 programmable controller
    Three green PCBs with orange relays and screw terminal blocks on a wooden table Close-up of a PCB with DIP switches, ICs, many resistors, and screw terminal blocks Close-up of PCB modules with orange relays, integrated circuits, and blue DIP switches
    Close-up of a PCB with orange relays, IC chips, and blue DIP switches Underside of green PCB assembly with eight modules and a side metal connector on a wooden surface

    In summary, this was over 20 years old industrial equipment. In this section I have shown the base unit, the expansion card was shown separately . Perhaps the copy shown here could be made to work, although I don't know about the display. For now, let's treat the whole thing as a curiosity - in modern times, it's getting harder and harder to find this kind of controller design, separate logic chips, separate memory bones, still in DIP sockets.... and I am not even mentioning their parameters.
    Have you worked with this type of Saia controller? When did you last see them used in practice, in what applications? How do you assess their design and reliability?
    Attachments:
    • PCD1_PCD2_Hardware_Manual_26-737_E.pdf (10.59 MB) You must be logged in to download this attachment.
    • pcd-2.pdf (2.92 MB) You must be logged in to download this attachment.

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    About Author
    p.kaczmarek2
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    p.kaczmarek2 wrote 14295 posts with rating 12175, helped 648 times. Been with us since 2014 year.
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  • #2 21878307
    jerry1960
    Level 37  
    We still have two of these controllers in operation at our site, you could say for 30 years without failure.
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  • #3 21878529
    Kris52
    Level 24  
    A certain industrial robot for receiving parts from the injection moulding machine was also fitted. From what I've heard it still works today. I still have one such working controller without external modules on the shelf.
  • #4 21878605
    DJ MHz
    Level 26  
    Also three conveyor belts in the works. Circa 2003 I think something assembled
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