Series 625 handbook
Contents
1. e Robust rugged case with 3 5mm screw terminals e DIN rail mounting e Interchangeable cassette modules housing all the active electronics e Full inter channel and system isolation EN60950 e Individually configurable channels scaling features through simple set RS485 communications employing up utility FDTLite MODBUS RTU optional TCP IP MODBUS Contents 1 Unpacking 2 Installation 3 Connecting the inputs and outputs 4 Configuration 5 Operation 6 Fault finding Page 2 of 15 Was 07 01 2008 625Manuallss1 doc 1 Unpacking 1 1 The unit is available in either 8 or 24 channel form The base units are numbered 625 BASE8 and 625 BASE24 respectively 1 2 If you have ordered a base unit complete with I O cassettes these will be installed in the correct slots according to the order If the base units have been ordered separately from the cassettes then these will be packaged separately 1 3 Carefully remove the unit from the packing and inspect for damage If damaged then please inform the Factory within 3 days of receipt so that a replacement can be sent to you Y Page 3 of 15 Vg 07 01 2008 625Manuallss1 doc 2 Installation lt 140 00mm H 75 00mm 90 00mm olol olL S o0oo00000900 0900000000 oO BD 02 0 u Be g oO 0 O w 0 0O m oO Channel 1 8 Sl2. 1 Channel 2 connected together Output smoothing Odd numbered Even numbered capacitors are not employed but it is not advisable to connect the load live as an inrush current can result in damage to a burden resistor Y Page 9of15 Vg 07 01 2008 625Manuallss1 doc 3 7 2 As can be seen outputs are available at channels 2 4 6 8 10 12 14 16 18 20 22 and 24 Voltage outputs Four fully isolated analogue outputs are provided in each slot thus a total of 12 outputs can be provided per unit Since they are isolated they can be combined with all the other I O types The isolated supply voltages of between 15 and 30VDC nominally 24VDC are connected to the odd numbered channels and the outputs are taken from the terminals of the odd and even numbered channels For clarity only one channel will be illustrated but the same connection scheme applies to all other analogue output channels OV 0 10V into The scheme illustrated sources 0 10VDC 24VDC at up to 5mA In this case the voltage output pk appears between the terminals of adjacent channels the positive being the even numbered channel If isolation is not required then all the odd numbered terminals and the odd numbered terminals can be connected together Channel 1 Channel 2 Output smoothing capacitors are not Odd numbered Even numbered employed but it is not advisable to connect the load live as an inrush current can result in
3. when the unit is installed and running in the normal working environment and after sufficient time has elapsed to stabilise any temperature gradients within the cabinet Y Page 7 of 15 Vg 07 01 2008 625Manuallss1 doc When very low level signals such as for type R thermocouples are being used in very noisy electrical environments it is possible that readings may vary slightly due to high series mode signals See elsewhere for adjustable filter time constants 3 4 Analogue inputs linear signals Voltage Input circuit Solid State D O L E Connect direct to the channel aS a terminals observing polarity For very switch low level signals it is recommended that screen cable be used with the screen terminated at the signal source end Current re Input circuit Solid State Current signals are converted to voltage O I a across a burden resistor which should Q O T I be attached directly to the terminals so Burden Resistor L _ that if the cassette is removed the mA Inputs measured on 2V range code 035 switch current loop will not be broken If the unit has been ordered with current inputs specified the burden resistors will be supplied separately If the burden resistors are to be supplied by the customer then they should be at least 0 1 15ppm type If 20mA is to be measured then a 100 ohm resistor should b
4. 625Manuallss1 doc Anville Instruments Ltd Series 625 Data Acquisition System Hardware User Manual QMF 37 Jan 2008 Issue 1 Anville Instruments Ltd Unit 19 Pegasus Court North Lane Aldershot Hants GU12 4QP Tel 01252 351030 Fax 01252 323492 NOTICE The contents of this manual are liable to change without notice Whilst every effort has been made to ensure the accuracy of this manual Anville Instruments Ltd will not be responsible for any errors and omissions or their consequence Windows is a registered trademark of Microsoft Corporation COPYRIGHT This documentation and the equipment described in it are copyrighted with all rights reserved Under copyright laws neither the documentation nor the software may be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form in whole or in part without the written consent of Anville Instruments Ltd Failure to comply with this condition may result in prosecution Y Page 1 of 15 Vg 07 01 2008 625Manuallss1 doc Series 625 Remote Data Acquisition Unit User Manual Description A compact modular data acquisition unit designed to provide accurate and reliable data measurement whilst operating in harshest environments Individually configurable channels Available in 8 16 and 24 channel versions as Analogue Inputs Digital Inputs Analogue Outputs 4 channels per slot or Digital Outputs Key Features
5. are isolated from each other and the system thus two connections are required for each channel IC _ Ov Y Page 4 of 15 Vg 07 01 2008 625Manuallss1 doc 2 7 2 7 1 2 7 2 2 7 3 2 8 2 8 1 2 8 2 Power Supply Voltage is 24 VDC 10 70mA Isolation 500 VDC The 70mA load only applies when a 24 channel digital output unit is used and all 24 channels are ON The unit is fitted with an internal diode to protect against reverse polarity and to prevent voltages greater than 27VDC being applied As can be seen from the illustration below two sets of power terminals are provided so that a series of units can be strung together without the need for two connections per terminal lo A we sy Xs Cs ay N ay A f an at Dw Www Ye amp POW Ww WY oS pees 13 2 a ar sr 6 7 oz 103 117 127 195 145 155 167 DATA ACQUISITION UNIT Sans a oF Pa 8 ANVILLE INSTRUMENTS PQOAOGOCCO ODD AGO OOQO0O 24VDC in 24VDC to next unit OV in OV to next unit Two ground terminals WD amp WD are also provided This is not safety ground but is used to increase immunity to noisy inputs RS485 communications The unit is equipped with an isolated RS485 communications port The unit is shipped as standard with 4 wire RS485 selected Please see below for changing to 2 wire configuration It is recommended that Belden 9502 or s
6. connection error on one channel can affect all PRT channels Y Page 15 of 15 Vg 07 01 2008
7. damage 4 Configuration 4 1 4 1 1 4 1 3 Hardware configuration The unit automatically senses the configuration of the I O on power up That is how many and where the inputs and outputs have been installed If it is required to increase the number of channels in an 8 channel unit a 24 channel base must be used but the existing cassette and the new one can be installed in the 24 channel base This feature makes spares holding very simple To change a board power down the unit remove the cassette lever up the lid with a small screwdriver and change the board Replace the cassette The unit will reconfigure itself on power up Y Page 10 of 15 Vg 07 01 2008 625Manuallss1 doc 4 1 4 2 1 4 2 4 4 2 5 Vs i LLL Addressing MODBUS Protocol 1 start bit 8 data bits 1 stop bit no parity Each unit on the loop must be given a unique base address Addressing is hexadecimal in the range 00 to FF Function codes 01 to 08 15 16 amp 17 are supported Function code 01 or 02 Read n bits Function code 03 or 04 Read n words Function code 05 Write 1 bit Function code 06 Write 1 word Function code 07 Read Exception Function code 08 Loopback Function code 15 Write n bits Function code 16 Write n registers Function code 17 Report ID Block read functions are supported for both analogue values and digital status All 24 channels can be read in one message The base address is set in hexadecimal f
8. e used with the 2V range selected 3 5 Analogue inputs platinum resistance thermometers PRT or RTD The system is designed for 3 wire PRT100s These are measured in a bridge configuration where lead 1 and 2 resistances appear in the lower two arms Connect lead 1 to channel lead 2 to channel terminal Three PRT Rtn terminals are provided one for each slot The third wire should be connected to one of these terminals Take care not to confuse the three wires of the PRT or else unpredictable readings will be obtained 2 wire sensors can be used by connecting the PRT to the and channel terminals and linking the terminal to the PRT Rtn terminal 4 wire sensors are measured as 3 wire units by ignoring the fourth wire and connecting as 3 wire PRTs Y Page 8 of 15 Vg 07 01 2008 625Manuallss1 doc Solid State Make sure all connections are tight and a that the three wires have the same MNI 4 hd j ji resistance and are affected by the same O m p lt 4 ij external influences such as hot pipes and electrical interference ech If several PRTs are being used it is PRT convenient to common the Lead 3 s to a Rtn A local bus arrangement and run a single fairly heavy gauge wire back to one of the Internal Current Source PRT Rtn terminals 3 6 Digital outputs transistor Excitation Source Load Output circuit Although the output te
9. g illuminated for 0 1s in 2s indicates a fatal error If cycling the power does not cure the problem the board needs replacing 5 Not illuminated at all check that power is ON and that the fuse is intact 6 This is accessible by removing the processor cassette and replacing the fuse located on the base board It must be replaced with the correct value 200mA or else damage may be caused to the unit and the power Supply 6 2 No unit in the loop responds Ensure that the units and computer protocols match Check each unit s address and make sure the channels are configured correctly Ensure that the Baud rate is the same for the computer and all units on the loop Check that power is applied to the RS232 comms loop converter if used Ensure that all communications LEDs are on and that they dim or flicker as data passes Check the connections between the computer RS232 port and the RS232 comms loop converter if used Check the communications loop connections most faults arise from this cause Check RS232 RS485 converter by looping back and running a terminal emulator O akRWNM CON Y Page 14 of 15 Vg 07 01 2008 625Manuallss1 doc 6 3 Communications errors Check the wiring of the Belden cable carefully Check routing of the communications loop try to avoid sources of HF noise Check that no unit has a spur connection longer than Try terminating the transmit loop of the con
10. imilar be used and that the wires be terminated directly at the terminals in a multi drop parallel loop The screen is connected to the SCR terminal NOT the COM terminal as this is used in three wire RS485 connections Avoid spurs longer than 300mm or else reflections will occur and corrupt the communications From previous TX To next TX From previous TX To next TX From previous RX To next RX From previous RX To next RX Y Page 5 of 15 Vg 07 01 2008 625Manuallss1 doc 2 8 3 It is recommended that a 120 Ohm resistor be connected across the RX terminals of the last unit on the loop once again to prevent reflections 2 8 4 Please remember that when the unit is the first in the loop it will be connected to a master unit This would normally be a computer with an RS485 port 2 8 5 In this case the TX and RX terminals of the master should be connected to the RX and TX terminals respectively of the Series 625 unit Please observe polarity 2 8 6 To change the communications configuration to 2 wire RS485 remove the left hand side cassette flip up the lid and remove the processor lower board Move JP6 from position B to position A Replace the board close the lid and replace the cassette 3 Connecting the inputs and outputs When the units are connected terminals may be live and the removal of parts is li
11. kely to expose live parts The unit must be disconnected from all voltage sources including any potentially hazardous I O leads before it is opened for any replacement maintenance or repair Any adjustment maintenance or repair of the opened unit whilst powered must be avoided It should be carried out only by skilled personnel who are aware of the hazard involved 3 1 Digital inputs Low level 10 30V These are current driven and require about 2mA They are designed to operate from external supplies Although and are specified either AC or DC inputs may be used Do not apply voltages in excess of the specified input range Y Page 6 of 15 Vg 07 01 2008 625Manuallss1 doc If volt free contacts are to be used since the unit is 24VDC powered the supply may be taken from the main supply as all inputs are isolated Opto Isolator Connect the input to the Excitation Source ve O OL appropriate terminals 2 T each input is isolated If t inter channel isolation is not important the terminals can be commoned and connected to the negative of the supply Connect the positive of the supply to the correct side of the switching device and the other to the input terminals Excitation Source ve 3 2 Digital inputs High level 80 240VAC These are current driven and require about 2mA They are designed to operate from external supplies Do not apply voltages in excess of
12. oc 5 Operation There are two LEDs on the processor unit The yellow one marked Fault indicates the health of the unit Upon power up the yellow LED will illuminate for 0 2s in every 2s The Green LED will be illuminated constantly and will extinguish as data passes down the RS485 loop This LED is in the transmit circuit so the unit is answering an interrogation every time it flashes OFF 5 1 The unit can be configured with FDTLite utility Refer to 4 4 1 above for connections Ensure that MODBUS protocol is selected at 9600 Baud 5 2 First of all Identify the unit The address number the unit type and its firmware release number will be displayed Click the Done button 5 3 The unit may now be configured using the Configure button The type of board fitted to each slot is displayed Click on the board of interest and the display will change to a representation of each of the channels Use the drop down menus to select the configuration 5 4 Use the Monitor button to monitor the channels 6 Fault Finding Check that the unit is wired to the power supply and that it is switched on The LEDs should be on 6 1 The Fault Yellow LED 1 When the unit is healthy this will illuminate for 0 2s every 2s 2 If illuminated constantly the unit has not been programmed please contact the Factory 3 Being illuminated for 1s in 2s indicates a watchdog error cycle the power 4 Bein
13. ormat between 00 and FF Two rotary switches are accessible by lifting the lid on the processor cassette Left hand side of a 24 channel unit With the processor board at the bottom the left hand side switch selects the most significant digit of the address and the right hand switch selects the least significant digit 01 N EEE EE EA EA E q j4 jad J4 EEEE bal lt gt 12 3 4 5 whe Aho JUMPERS Figure 1 Processor cassette Page 11 of 15 OP 07 01 2008 625Manuallss1 doc 4 2 6 4 2 7 4 2 8 4 3 4 3 1 4 3 2 4 3 3 4 3 4 4 4 4 4 1 4 4 2 Figure 1 above shows a unit has the address 00 do not forget that this is set in hexadecimal To set to address 01 use a small screwdriver and turn the right hand side rotary switch to 1 Power down the unit when powered up the unit will adopt address 01 To set address OE decimal 14 turn the right hand switch to E To set the address to E4 decimal 228 turn the left hand switch to E and the right hand one to 4 Baud rate and protocol selection Figure 1 also shows 5 jumpers jumpers 1 to 3 select the Baud rate between 600 and 76k8 Do not interfere with the other jumpers or incorrect operation may result The unit is shipped from the factory with baud rate set to 9600 and MODBUS protocol selected In the tables that follow a jumper inserted represents a 1 and remo
14. ot 1 Channel 9 16 Slot 2 Cassette L Cassette R 35 00mm Processor amp Comms Channel 17 24 Slot 3 Oo o oO oO oO oO oO oO oO et QVOO000000 900000000 oloo oloo fe Dimensions 90x 140 x 75mm Weight Casing Fixing Protection IP40 Connectors Captive Plus Minus screws M3 5 tinned strip steel Capacity 2 x 2 1 2 2 2 3 2 4 2 5 2 6 500 g average Reinforced Polycarbonate DIN rail symmetrical 35mm EN50022 BS5584 2 5mm solid or 2 x 1 5mm stranded conductor capacity The unit may be installed on 35mm DIN rail or by extending the fixing clips the unit can be panel mounted using 4mm screws The dimensions of the 24 channel unit are shown above The 8 channel unit is half the width i e 7Omm wide Please allow sufficient room to install trunking and make the connections to the unit It is recommended that at least 150mm is allowed between horizontal DIN rail centres The cassettes are keyed to prevent insertion in an inappropriate position 1z 27 a 4 57 6r 7 8 QF 10 11 12 13 14 15 163 AG EF 3s ANVILLE INSTRUMENTS PRT SETETE pe a a e e e To prevent possible mistakes it is recommended that the unit be installed with the cassettes in place to avoid mixing the I O from several units All channels
15. rminals are marked and the so either AC or DC loads may be driven In addition the switching speed is controlled so there is no E gl MOSFET output of the opto isolator is bi directional Excitation Source return 3 7 3 7 1 EMI RFI generation and no snubber network is required The output is rated at 350V at 320mA peak 120mA continuous The device is rated at 400mW and has an ON resistance of 25 Ohms Analogue outputs Four fully isolated analogue outputs are provided in each slot thus a total of 12 outputs can be provided per unit Since they are isolated they can be combined with all the other I O types The isolated supply voltages of between 15 and 30VDC nominally 24VDC are connected to the odd numbered channels and the outputs are taken from the even numbered channels If full isolation is required between analogue output channels then individual supplies will be required Current outputs For clarity only one channel will be illustrated but the same connection scheme applies to all other analogue output channels 24VDC OV The scheme illustrated sources 0 20mA Load and the load it will supply is dependent on the supply voltage used Allow 2V for the 20mA CUrrent constraining circuit so a 24VDc a supply will allow up to 1kohm load to be driven If isolation is not required then all O 4 the odd numbered terminals and the odd numbered terminals can be Channel
16. the specified input range Opto Isolator Connect the input to the l appropriate terminals each input is isolated If inter channel isolation is not important the terminals can be commoned and connected to the neutral of the supply Connect the live of the supply to the correct side of the switching device and the other to the input terminals Excitation Source live _ Excitation Source neutral Please remember that the source of the inputs may render the terminals hazardous as when a thermocouple is connected directly to a heater element The user should take steps to affix warning labels as necessary 3 3 Analogue inputs thermocouples In the circuit schematics below the capacitor is not normally fitted In the event of extremely noisy signals appropriate capacitors and resistors can be fitted at extra charge Input circuit a Automatic cold junction compensation s a0 e is provided so that thermocouples or 16 T 4 L compensation cable should be itch CONnNected directly to the terminals observing the polarity It is recommended that direct connection is made although wire protecting ferrules may be used if desired The CJC sensors are located centrally on all input boards The offset facility is provided to enable errors which might be caused by heat sources in a cabinet to be removed completely Offsets should only be applied
17. ved a 0 Baud rate selection Jumpers 1 to 3 Baud rate Jumper 1 Jumper 2 Jumper 3 600 0 0 0 1200 1 0 0 2400 0 1 0 4800 1 1 0 9600 0 0 1 19200 1 0 1 38400 0 1 1 76800 1 1 1 Channel configuration Referring to Figure 1 there is an RS232 RJ11 socket which is used to configure the unit It is designed for use with a computer running our FDT625 configuration software A suitable 9 way D to RJ11 plug lead is available from Field In the absence of such a lead the computer s RS232 port may be connected to the RS485 port provided that 4 wire RS485 is selected See above On the 9 way connector pins 2 3 amp 5 are used Connect the RX of the computer to the TX of the unit and the TX of the computer to the RX of the unit Connect pin 5 to the COM terminal Analogue ranges Range Code Range Code 20 000V 032 Type K 042 10 000V 033 Type J 043 5 0000V 034 Type S 044 2 0000V 035 Type R 045 1 0000V 036 Type T 046 200 00mV 037 PRT 047 100 00mV 038 Output continuous 002 50 000mV 039 Output one shot 003 20 000mV 040 Unused 000 Y Page 12 of 15 Vg 07 01 2008 625Manuallss1 doc 4 4 3 Digital configurations Configuration Code PWM continuous mode 0 1s units 004 1 0s units 005 PWM _ one shot mode 0 1s units 006 1 0s units 007 Timer 0 1s units 008 1 0s units 009 Counter 016 Status input and output 000 Y Page 13 of 15 Vg 07 01 2008 625Manuallss1 d
18. verter with a 330 Ohm resistor to eliminate reflections This is done at the unit furthest from the converter Check the communications protocol for correct parity setting Check that the correct tristate control is enabled AUN O 6 4 Measurement errors 1 Ensure that the correct input type has been configured in the unit 2 Ensure that the correct input has been specified at the computer 3 Check that no inadvertent offsets or scaling have been added to the channel Thermocouples 1 A hard full scale reading indicates that the Thermocouple is open circuit check connection polarity and security 2 An error of about 20 to 30 C implies a cold junction compensation error Ensure that the correct compensating cable is used and that any joins maintain the correct polarity 3 Noisy readings can be caused by excessive common mode voltage on the signal by the use of type R or S thermocouples in very noisy environments or loose thermocouples or other sensors Anville Instruments instrumentation is designed for use in industrial environments and is designed for very high noise rejection If noise is a problem please contact the company for further advice 4 If inter channel compliance is not good enough use the offset facility to correct for temperature gradients across the unit Platinum Resistance Thermometers 1 If consistent errors are present check that all input connections are correct since a common return is used a
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