1. Product Overview

Product Name: MAQ20 Backbone Expansion Cable
Model: MAQ20-XCA02
Series: MAQ20 Data Acquisition and Control System
Article Number: MAQ20-XCA02
Manufacturer: Dataforth Corporation

The MAQ20-XCA02 is a 2-meter backbone expansion cable designed for use within the Dataforth MAQ20 modular data acquisition and control system. It serves as an interconnection accessory that enables distributed or expanded system configurations by linking multiple MAQ20 backbones together. The cable facilitates both power and communication distribution between system segments, allowing for flexible installation layouts and remote module placement. As part of the MAQ20 ecosystem, the MAQ20-XCA02 ensures reliable, high-integrity signal and power transmission across extended distances while maintaining the system’s modularity and ease of configuration.

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2. Key Features

- Purpose-Built for MAQ20 Systems: Specifically engineered to connect MAQ20 backbones, enabling distributed installations and system expansion.
- 2-Meter Length: Provides a convenient interconnection distance for local or semi-remote module groupings within control panels or racks.
- Power and Communication Distribution: Transmits both system power and RS-485 communication signals between backbone segments.
- Plug-and-Play Connectivity: Utilizes mechanical male/female pluggable terminal blocks for quick, secure, and tool-free connection between backbones.
- Supports Modular Expansion: Allows the main communication module and I/O modules to be installed in separate physical locations while maintaining full system functionality.
- High Reliability: Incorporates durable, vibration-resistant contacts designed for industrial environments.
- Reverse Installation Protection: Mechanical keying prevents incorrect connection orientation, ensuring safe and error-free installation.
- DIN Rail Integration: Compatible with MAQ20 backbones mounted on standard 35 × 7.5 mm gull-wing DIN rails.
- Industrial-Grade Design: Built to operate in harsh environments with wide temperature and humidity tolerances.
- Compliance Ready: Designed to meet CE and ATEX heavy industrial standards, with UL Class I, Division 2 certification pending.

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3. Technical Specifications

| Parameter | Specification |
|----------------|-------------------|
| Model Number | MAQ20-XCA02 |
| Product Type | Backbone Expansion Cable |
| System Compatibility | MAQ20 Data Acquisition and Control System |
| Cable Length | 2 meters |
| Maximum Expansion Distance | Up to 100 ft (30 m) when used with multiple cables |
| Connection Type | Mechanical male/female pluggable terminal blocks |
| Signal Type | RS-485 inter-module communication |
| Power Distribution | System power bus integrated through cable |
| Circuitry | Passive |
| Mounting Interface | Connects between DIN rail-mounted backbones |
| Operating Temperature Range | –40°C to +85°C |
| Storage Temperature Range | –40°C to +85°C |
| Relative Humidity | 0 to 95% non-condensing |
| Certifications | CE (Heavy Industrial), ATEX (Pending), UL Class I, Division 2, Groups A, B, C, D (Pending) |
| Manufacturer Quality System | ISO 9001:2008 Registered QMS |

The MAQ20-XCA02 is designed to maintain the same electrical and mechanical integrity as the backbone connectors it extends, ensuring consistent performance across distributed system segments.

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4. Functionality

The MAQ20-XCA02 functions as an expansion link between MAQ20 backbones, enabling the distribution of both power and communication signals across multiple DIN rail-mounted module groups. Within a MAQ20 system, the backbone serves as the internal bus that connects the communication module (COM module) to multiple I/O modules. The expansion cable extends this bus, allowing additional backbones to be installed remotely or in separate enclosures while maintaining full system integration.

Operational Principle:
- The MAQ20 communication module interfaces with the host computer or controller via Ethernet or serial communication.
- The backbone distributes power and RS-485 communication signals to each I/O module.
- When additional backbones are required, the MAQ20-XCA02 connects the male and female terminal blocks of adjacent backbones, extending the system bus.
- The communication module automatically detects any newly connected I/O modules through the backbone extension, registers them in the system configuration, and makes them available for immediate use in the host software.

Use Cases and Applications:
- Distributed Data Acquisition: Enables placement of I/O modules closer to sensors or actuators in large installations, reducing wiring complexity.
- Industrial Automation: Supports modular control architectures in manufacturing, process control, and test systems.
- Test and Measurement Systems: Facilitates flexible configuration of measurement channels across multiple racks or panels.
- Remote Monitoring: Allows system expansion into remote enclosures while maintaining centralized communication and power distribution.

Compatibility:
- Fully compatible with all MAQ20 backbones (MAQ20-BKPL4, MAQ20-BKPL8, MAQ20-BKPL16, MAQ20-BKPL24).
- Works seamlessly with MAQ20 communication modules and I/O modules.
- Designed for use with standard 35 × 7.5 mm DIN rails.

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5. Components & Accessories

Included Items:
- One MAQ20-XCA02 backbone expansion cable (2 meters in length).
- Factory-terminated connectors with male/female pluggable terminal blocks for direct backbone connection.

Optional Accessories:
- Additional MAQ20-XCAxx cables for longer or multiple expansion segments (up to 30 m total).
- MAQ20-BKPL backbones (available in 4, 8, 16, and 24 I/O module configurations).
- MAQ20-COM communication modules for system control and data exchange.
- DIN rail mounting hardware and end stops for secure installation.

Connectors:
- Industrial-grade pluggable terminal connectors with keyed mechanical alignment.
- Designed for repeated connection cycles without degradation of contact integrity.
- Provides both power and RS-485 signal continuity between backbones.

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6. Installation & Setup

Requirements:
- Compatible MAQ20 backbone modules and communication module.
- Standard 35 × 7.5 mm DIN rail for backbone mounting.
- Proper grounding and power supply per MAQ20 system specifications.

Installation Steps:
1. Mount the MAQ20 backbones on the DIN rail using the integrated spring clips.
2. Ensure the communication module is installed on the primary backbone.
3. Connect the MAQ20-XCA02 cable between the male and female connectors of adjacent backbones.
4. Verify mechanical alignment and secure connection; the keyed design prevents reverse installation.
5. Apply system power. The communication module will automatically detect all connected I/O modules.
6. Configure the system using the MAQ20 host software or communication interface.

Configuration:
- No manual addressing or configuration required; modules are hot-swappable and auto-detected.
- The communication module updates the system configuration record dynamically when modules are added or removed.
- The expansion cable requires no calibration or software setup.

Mounting Options:
- Supports both local (adjacent DIN rails) and remote (separate enclosures) installations.
- Maximum total expansion distance: 100 ft (30 m) using one or more cables.

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7. Performance & Capabilities

Speed and Communication:
- Utilizes RS-485 differential signaling for robust, noise-immune communication between modules.
- Maintains full data throughput and synchronization across extended backbone segments.
- Supports real-time data acquisition and control applications without latency degradation.

Capacity:
- Each backbone supports one communication module and up to 24 I/O modules.
- Multiple backbones can be interconnected using MAQ20-XCA02 cables to achieve higher channel counts or distributed layouts.

Efficiency:
- Passive circuitry ensures minimal signal loss and power drop across the cable.
- High-quality connectors maintain low contact resistance and long-term reliability.
- Designed for continuous operation in industrial environments.

Limitations:
- Maximum total expansion distance limited to 30 m (100 ft).
- Cable length fixed at 2 m; longer distances require multiple cables or custom configurations.
- Must be used exclusively with MAQ20 system components to ensure compatibility and performance.

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8. Standards & Compliance

Certifications and Compliance:
- CE (Heavy Industrial): Complies with European EMC and safety directives for industrial environments.
- ATEX (Pending): Designed for use in potentially explosive atmospheres, pending certification.
- UL Class I, Division 2 (Pending): Suitable for hazardous locations, Groups A, B, C, and D.
- ISO 9001:2008 Registered QMS: Manufactured under a certified quality management system ensuring consistent product quality and reliability.

Industry Standards:
- DIN Rail Compatibility: Conforms to IEC 60715 standard for 35 mm DIN rail mounting.
- RS-485 Communication Standard: Ensures interoperability and robust data transmission.
- Environmental Standards: Designed for operation in wide temperature and humidity ranges typical of industrial environments.

Safety and Reliability:
- Mechanical keying prevents reverse connection, protecting modules and system integrity.
- Vibration-resistant contacts ensure stable operation in high-vibration environments.
- Passive design eliminates active components, reducing failure points and maintenance requirements.

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9. Additional Information

Warranty:
- Standard manufacturer’s warranty provided by Dataforth Corporation (details available upon request).
- Covers defects in materials and workmanship under normal operating conditions.

Support:
- Technical support available via Dataforth’s engineering and customer service teams.
- Comprehensive documentation, including the MA1040 – MAQ20 Communications Module Hardware User Manual, available for download at [www.dataforth.com/maq20_download.aspx](https://www.dataforth.com/maq20_download.aspx).

Maintenance:
- No routine maintenance required.
- Periodic inspection of connectors recommended to ensure secure mechanical engagement and cleanliness.
- Cable should be protected from excessive bending or mechanical stress.

Updates and Compatibility:
- Fully compatible with all current and future MAQ20 system modules and backbones.
- Firmware or software updates for the communication module automatically recognize and support backbone expansion configurations.

Manufacturer Information:
- Dataforth Corporation
3331 E. Hemisphere Loop, Tucson, Arizona, USA
Phone: 800-444-7644
Website: [www.dataforth.com](https://www.dataforth.com)
©1995–2014 Dataforth Corporation. All Rights Reserved. ISO9001:2008 Registered QMS.

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Summary

The Dataforth MAQ20-XCA02 Backbone Expansion Cable (2 m) is a critical accessory for extending and distributing the MAQ20 system backbone, enabling flexible, modular, and distributed data acquisition and control architectures. Engineered for industrial reliability, it provides seamless power and RS-485 communication continuity between MAQ20 backbones, supporting up to 30 m total expansion distance. With its rugged construction, keyed connectors, and plug-and-play functionality, the MAQ20-XCA02 simplifies system wiring, enhances scalability, and ensures dependable operation in demanding environments. It is an essential component for engineers and system integrators seeking to design scalable, high-performance MAQ20 installations across diverse industrial and test applications.