2500 DIN rail Controller, Installation and operating instructions issue
Contents
1. The shunt option has 5Q reisitors mounted on the PCB The mV option may also be used for mA inputs if fitted with suitable external 5Q burden resistors It permits a 0 20mA input to provide a full scale range of 0 100mvV Dual thermocouple Dual 2 3 4 wire Dual Potentiometer T C platinum Resistance Input Basic 50V _ _ 8 Isolation AI3 mA 4 20mA module powered inputs Al4 Tc mV mA Milli volts A02 V mA 4 20mA self hermocouple powered inputs T C Voltage mA Logic Inputs Contact Inputs Dual Volts V or Milli volt mV Dual milli amps mA High impedance Shunt Option Input Thermometer PRT Al2 ii A1 C1 A2 C2 11 B1 A1C1 A1C1 1 Al PRT insulation PRT OR For 2 wire PRT link A amp C Installation Safety Requirements Various symbols are used on the instrument they have the following meaning Protective earth terminal Caution refer to the L Functional accompanying documents ground earth Installation must only be carried out by qualified personnel Personnel Enclosure of live parts To prevent hands or metal tools touching parts that may be electrically live the controller must be installed in an enclosure Blank Terminal Unit Bases are supplied to hold 2 4 8 or 16 modules In the event that a base is not fully popu2. terminate the Profibus network 2 3 no termination Fit suitable termination ONLY on the last device in the chain On earlier units the use of the termina tion plug is recommended on later units fit either the termination unit or both links in position 1 amp 2 Unit Note Earlier units were fitted with a address gt Ul Uf al i single link On these units this link has no switch a function and the system should be terminated using the termination plug IOC Terminal unit Address Switches Modbus 87654321 P 032168421 wee P E Modbus Address Profibus 87654321 643216 8 4 2 1 kakkaa Profibus Address DeviceNet 8765432 1 position BAUD3216 8 4 2 1 40N PER aia RATE DeviceNet Address P Parity on P Parity off The switch gives 127 Addresses from 0 to 63 can be set O Odd E Even addresses from 1 to 127 SW7 SW8 Communications speed Address 0 is invalid 0 0 125K baud Switch 8 is not normally 0 1 250K baud used 1 0 500K baud If however it is set to ON 1 1 Both speed and node the unit address is settable address controlled over communications software Sixty three Modbus addresses can be set in binary using positions 1 to 6 Parity has three possible states none even odd using SW7 amp 8 as above If the address switch is set to all OFF then the IOC expects to have it address set by the Ethernet Swit
3. 2 upwards as far as they will go towards the top of the screw slots The angled edge of the base retaining clip 2 must locate behind the bottom edge of the DIN rail 6 Tighen the screws 1 DIN Rail Mounting vertical Caution It is acceptable to mount the 2500 base vertically If it is mounted vertically however it is advisable to fit a fan in the cubicle to ensure a free flow of air around the modules Mount the DIN rail vertically using suitable bolts Ensure that the DIN rail makes good electrical contact with the metal base of the enclosure Loosen screws 1 in the base and move them and the associated base retention clips 2 to the bottom of the screw slot In the back of the base is an extruder slot which locates with the DIN rail 3 Fit the top edge of this into the top edge of the DIN rail 3 Slide the screws 1 with the associated clips 2 upwards as far as they will go towards the top of the screw slots The angled edge of the base retaining clip 2 must locate behind the bottom edge of the DIN rail Tighten the screws Direct Panel Mounting 1 Remove the screws 1 and base retention clips 2 2 Hold the base horizontally or vertically on the panel and mark the position of the two holes on the panel 3 Drill two 5 2mm holes in the panel 4 Using M5 bolts supplied secure the base to the metal panel Modbus Communications The Modbus network connection RJ45 sockets and the 2500 syst
4. 2 3 wire or no link for 4 5 wire Fit suitable termination ONLY on the last device in the chain The use of the termination plug is recommended Unit adores PE E E a a T a F S AN caution Do not operate the equipment without a protective earth conductor connected to one of the earth terminals on the base unit The earth cable should have at least the current rating of the largest power cable used to connect to the unit Connect the protective earth with a suitable tinned copper eyelet and use the screw ans washer supplied with the base unit tightened to a torque of 1 2Nm 910 5lbin This connection also provides a ground for EMC purposes For DIN rail mounting use symmetrical DIN rail to EN50022 35 X 7 5 or 35 X 15 mounted horizontally or vertically Connecting the 24Vdc Power Supply Caution Before proceeding with any wiring on this unit please read section on Wiring and Safety and EMC information It is the responsibility of the installer to ensure the safety and EMC compliance of any particular installation The power supply is the 2500P This is a DIN rail mounted unit which may be mounted adjacent to the 2500 base or remotely Alternatively an existing power supply may be used provided it meets the specification below The IOC terminal unit contains a fuse and a reverse biased power diode If the power is wired reverse polarity the fuse will blow a
5. DI4 DI6 AC Logic Input DI8 D04 RLY4 Voltage Source Contact Inputs 115 and 230 Volt AC Voltage Source Contact Externally Powered Inputs Inputs Logic Outputs Relay Output AFI CE Ahm This supply is an external power supply to power plant devices eee LOPO tein place oi 9 090 F ti CET fitedin place of QO 9 TECE or power rating see c Technical Specification external voltage L3 N3 for the module supply 20100 2000 Appendix A V V CC L1 N1 L2 N2 Ve V CC V V CC 0000 Ns te NG Label fitted to the side of the relay module with space to record which snubbers have been removed 1 NS L6 Functional Isolation p gt To additional L_ AY l 4 A Voltage gt Modules 3 Jy To Additional DO MILA u T Supply 1 Modules Q a Basic 50V 7 Al BI A2 B2 A3 B3 B4 A4 C4 3 4 c 1 C2 c Isolation d HH fee lida p ARN c 1 Functional Isolation _ Basic 50V__ _ Fuses ae Isolation The fuses supplied for the relay units are 3 15A T type Coma Inputs 20mm to EN60127 Relays shown in relaxed state e g power off Note Negative logic inputs can be connected if required Reverse the polarity of the input connections Al2 TC DC mA 1 If the Al module is configured as thermocouple input on one channel and mV input on the other then the Thermocouple MUST be connected to channel one 2
6. ch configuration tools For 87 6 5 4 3 2 1 position addresses between 65 and D 03216842 1 ON 255 the address switch must D DHCP enabled poe poe m D DHCP disabled i be set all OFF and the address set in iTools D Modbus Unit ID Addresses from 1 to 63 are set on the rightmost 6 switches The leftmost switch may be used to enable DHCP Ethernet addressing If all switches are off the Modbus address and DHCP enable will be determined by the value seen in the iTools Operator Colour Orange white Orange Green white Blue Blue white Green Brown white Brown CO NY MJB wy rN Profibus 9 pin D Type Connections 2500A TERM PROFIBUS RJ45 4 Moulding Profibus colour Grey 1802 1 1800 1 IE 1300 1 DeviceNet Communications The DeviceNet Communications IOC is identified by the front label and the order code printed on the side label This IOC must be used with the DeviceNet Terminal Unit The DeviceNet Connector is selected to comply with the Devicenet Open Connector specification 5 way 5 08mm pitch Ethernet Communications The Ethernet IOC is defined by the front label and the order code printed on the side label This IOC must be used with the Ethernet Terminal Unit The Ethernet port is a 10baseT port and can be connected to a hub or switch with Cat5 cable via the standard RJ45 connector Alternatively an RJ45 c
7. configuration Connections to this socket are given below Pin connections RJ11 Pin connections on 9 Pin connections on 25 into IOC way D type into PC_ way D type into PC 6 no connection 5 RX 3 TX 2TX 4 TCX 2RX 3RX 3 0V 5 0V 70V 2 no connection 1 24V in Screen Screen 1 Screen Configuration Connections PC used for configuration ry pala 9 way connector ia Nottage 4 E i polarity f 2500A CABLE CONFIG RJ11 9PINDF of socket 6 i 1 Optional Power Supply The plastic cover supplied 24VPower and cable to enable must be fitted over the Push to release Locate the location tab on Terminal unit with the matching slot in the base Supply 10C to be configured remotely RJ11 socket when the connector is not in use T To Fit a Module Modules are locked into position using the retaining lever on the face of the module The module must be fitted and removed with the lever in the open position as shown in this side view Once fitted the lever is closed to securely lock the module in place Profibus DP and DPv1 Communications There are two ProfiBus TU options a standard 9 Way D type and a dual RJ45 unit The latter is similar to the Modbus terminal unit but must not be confused the Modbus unit includes capacitors that could affect high speed data LED Status Indicators Module c
8. em power connections standard bus screw terminals are provided by the Terminal Module Unit connector The network connection to Configuration an operator interface unit Port RS232 a PC running iTools or 3rd party system or to link further slave 2500 controllers or other Modbus equipment in a system The IOC can be configured from the Modbus network if required LED Status Indicators 1 0 Module interconnection Communications Ports RS485 24V 0V Conections to the Network Connectors Colour Orange White Orange Green White Blue Blue White Green Brown White Brown Modbus RJ45 Type Connections WARNING CABLE COLOURS MAY CHANGE Modbus RJ45 Communications Line Terminator The communications line must be terminated using the appropriate load resistors To minimise on site wiring and to provide the correct resistor values Terminator are available from Eurotherm 2500A TERM MODBUS RJ45 4 Moulding Modbus colour Black 81202 5 A 5 The terminator is plugged into the last RJ45 socket in the chain If the operating interface is a PC or PLC this should be terminated in accordance using the appropriate load resistors RS422 RS485 Modbus communications selection Fit both links 1 2 for 2 3 wire Modbus default 2 3 for 4 5 wire Modbus Note Earlier units were fitted with a single link for
9. lated a blank terminal unit part number 026373 will be supplied with the system It is important that this is fitted into the position immediately to the right of the last module in order to maintain IP20 rating Caution Live sensors The controller is designed to operate with the temperature sensor connected directly to an electrical heating element However you must ensure that service personnel do not touch connections to these inputs while they are live With a live sensor all cables connectors and switches for connecting the sensor must be mains rated Wiring It is important to connect the controller in accordance with the wiring data given in this instruction sheet Take particular care not to connect AC supplies to the low voltage sensor input or other low level inputs and outputs Only use copper conductors for connections except thermocouple inputs and ensure that the wiring of installations comply with all local wiring regulations For example in the UK use the latest version of the IEE wiring regulations BS7671 In the USA use NEC Class 1 wiring methods Power Isolation The installation must include a power isolating switch or circuit breaker This device should be in close proximity 1 meter to the controller within easy reach of the operator and marked as the disconnecting device for the instrument Earth Leakage Current Due to RFI Filtering there may be an earth leakage current of up to 3 5mA This may affect the design of an in
10. lter requirements will depend on the type of load For typical applications we recommend Schaffner FN321 or FN612 Reinforced E S Taaa a E EAEI IE P A T a oN OEE r ear AR Legh Zirconia Probe ale Al2 ii Al2 ii SQ 5Q A1 C1 A2 C2 Q 000 AICI A2 C2 Q 000 PI P2 P3 C1 C2 C3 n i2 13 against electric shock Reinforced insulation against electric shock Functional insulation This is defined as Insulation between conductive parts that is necessary only for the proper functioning of the equipment This does not necessarily provide protection JAI 0000 0000 0000 0000 1 i 3 Hi BT H2 B Hi BT H2 6B Hi BT H2 B HIB B Q O00 000 oe o000 ii n D112 D 1 D112 D D n D D This is defined as Insulation between conductive parts which provides protection Invensys EUROTHERM Declaration of Conformity Merieurer ye Menaiaurer i kki Frrhri iar Mctebr Safety pini eC onion eect LHT units pein sm Aes Erria Limited Pornday Cee Wri Wari Some BHI JPL Undid Eirgis BEI Modular Control Syin AL AD AH AD DH Cie DE baei ai Err iit DH i ad RLYT4 Cai as EE phra EMAL AN dT Ba Ene EEEL p emol a bes mwih ke Lore Tee Te Cee Be ol Trema Mare 2 j 4 I Voltage mode The input impedance Rv of the device connected to the analog
11. nd protect the complete 2500 base from damage The fuse is not user replacable The unit should be returned to the factory for replacement Power supply specification Power supply voltage 18 0Vdc min to 28 8Vdc max Supply ripple 2Vp p max Power consumption 90W max per base Note The current taken by each module is 100mA on average 18V is the absolute lower limit The use of an 18V power supply with any appreciable voltage drop may cause unpredictable or out of specification operation Assembling I O Modules amp Terminal Units To Fit Terminal Unit Push to lock into place The Configuration Port An RS232 configuration port is provided on the front of the IOC via a RJ11 socket When the IOC is powerd up with a PC connected to the RJ11 configuration port it will start in configuration mode Alternatively the IOC is put into configuration mode by setting a command from the configuration software Note Existing configuration mode must be done using iTools or through communications The IOC will not control the process if 1 It is in configuration mode or standby mode 2 A network watchdog time out occurs if configured 3 It is removed from the system Under these conditions all modules will enter a safe state Generally this defaults as digital output modules will go to an OFF state and analogue output modules will go to a minimum output state generally OV or 4mA Unless set otherwise in the
12. onnector Configuration Port RS232 Baud rate Baud rate is set by the Profibus Master which is able to detect the fastest Baud at which all slaves can operate The Profibus IOC is capable of operating at 12Mbaud 9 way D Type Communications Connector 24V power supply terminals eS 24V 0V Connections to the Network Connectors The 9 pin D Type connector is intended for installations using standard Profibus cables 5 z Signal Name Meaning Shield Shield ground Not used RxD TxD P Not used DGND Data ground VP Voltage Plus Not used RxD TxD N Not used Receive Transmit Data P Receive Transmit Data N Wl OND JB wr Profibus 9 pin D Type Connections ProfiBus 9 Pin connectors communications line terminators For 9 pin D connectors standard ProfiBus cables should be used These cables have special headers on the 9 pin D male connector which allow one or two cables to be connected into them and have a small termination load built in with an ON OFF switch which is set to ON at the two ends of the link The ProfiBus standard states that two types of cable Line A and Line B may be used The termination details for these two types of cable are shown below 5 8 3 6 5 8 3 6 3902 2209 3909 150Q 3909 Profibus Line A Profibus Line B Profibus RJ45 type built in communictions line terminators l Fit both links 1 2 to
13. ross over cable may be used to connect direct to a pc 10baseT network Interface Card Module connector Address Switch 5 way DeviceNet Communications Connector Module connector Address Switch m 24V power supply terminals 24V 0V The mating DeviceNet connector female Open Connector is supplied to facilitate screwing user wiring The pin functions are marked on the TU RJ45 Socket 24V power supply terminals Connections to the RJ45 Socket The RJ45 socket is connected according to the Ethernet standard Pin Number Function Colour Signal RJ45 pin 1 Orange white TX Orange TX Green white RX Blue DeviceNet Terminators Blue white The DeviceNet specification states that Green the bus terminators should not be Brown white included as any part of a master or Brown slave They are not supplied as part of the 2500 DeviceNet termination eves daa MAY assembly
14. stallation of multiple controllers protected by Residual Current Device RCD or Ground Fault Detector GFD type circuit breakers Overcurrent Protection It is recommended that the DC power supply to the system is fused appropriately to protect the cabling to the units The 2500 provides a fuse on the IOC Terminal Unit to protect the supply from a fault within the 2500 Voltage Rating The maximum continuous voltage applied between any of the following terminals must not exceed 264Vac DI6 input or RLY4 relay output to logic dc or sensor connections any connection to ground The controller should not be wired to a three phase supply with an unearthed star connection Under fault conditions such a supply could rise above 264Vac with respect to ground and the product would not be safe Conductive Pollution Electrically conductive pollution must be excluded from the cabinet in which the controller is mounted To secure a suitable atmosphere in conditions of conductive pollution fit an air filter to the air intake of the cabinet Where condensation is likely include a thermostatically controller heater in the cabinet Installation requirements for EMC To ensure compliance with the European EMC directive certain installation precautions are necessary as follows For general guidance refer to Eurotherm Controls EMC Installation Guide HA025464 When using relay outputs it may be necessary to fit a filter suitable for suppressing the emissions The fi
15. t Three communications versions are available for Modbus Profibus or DeviceNet The system requires 24Vdc at less than 100mA module A suitable power supply is 2500P available in 2 5 5 or 10 amp versions Part No HA027773 Issue 3 2 Jan 04 The Base To mount the base This unit is intended to be mounted within an enclosure or in an environment suitable for IP20 rated equipment It can be DIN rail or bulkhead mounted le A gt DINrail Side cover Retention clip Support for terminal 0 EMC earthing ___ protective earth Dimensions mm Weights Kgms B C No models S02 87 180 S04 137 180 S08 239 180 S10 289 180 S12 340 180 S16 442 180 DIN Rail Mounting horizontal Mount the DIN rail horizontally using suitable bolts Ensure that the DIN rail makes good electrical contact with the metal base of the enclosure Loosen screws 1 in the base and allow them and the associated base retention clips 2 to drop to the bottom of he screw slot In the back of the base is an extruded slot which locates with the DIN rail 3 Fit the top edges of this into the top edge of the DIN rail 3 Slide the screws 1 with the associated clips
16. ue output module must be gt 2KQ for 10V range Current mode The input impedance or loop impedance Ri of the device connected to the analogue output module must be lt 6009 Invensys EUROTHERM MODEL 2500 DIN RAIL CONTROLLER INSTALLATION AND WIRING INSTRUCTIONS WHAT IS THE 2500 The 2500 is a modular system which can provide multi loop PID control analogue and digital I O signal conditioning and computational blocks with a variety of plug in modules I O Control Moduel IOC Always mounted in the left hand position 2500M Plug in I O Modules Can be mounted in any order am as add ma Bel E gE _s i a ae fae FPS fe eee ae rs Pee Ss inne fee ee Eben hee abe svi fw fh Ea S F ELDE ra Communications 2500B Base port RS485 422 Plant and Process Connections The base unit 2500B can be provided in different sizes with up to 16 I O modules The base can be mounted on DIN rail 35mm top hat or just bolted to a wall Terminal units 2500T clip into the base providing customer cconnections to and from the plant devices and interconnections between modules and the Input Output Control module IOC Terminal units are specific to particular modules I O Modules 2500M clip into the Terminal Units These modules are dedicated to specifc functions analogue or digital input or output The IOC module 2500E or 2500C contains the configuration for the system and communications suppor
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