akYtec PR200 User guide
akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: +49 (0) 511 16 59 672-0 · www.akytec.de
PR200
Programmable relay
User guide
PR200_2021.01_0309_EN
© All rights reserved
Subject to technical changes and misprints
akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: +49 (0) 511 16 59 672-0 · www.akytec.de
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Contents
Contents ................................................................................................................................................................. 1
Introduction ............................................................................................................................................................ 2
1 Overview ........................................................................................................................................................ 3
1.1 Intended use .............................................................................................................................................. 4
1.2 Ordering key .............................................................................................................................................. 4
2 Specifications ................................................................................................................................................ 5
2.1 Environmental conditions ....................................................................................................................... 7
3 Installation ..................................................................................................................................................... 8
3.1 Mounting .................................................................................................................................................... 8
3.2 Wiring ......................................................................................................................................................... 8
3.2.1 Inputs ................................................................................................................................................ 9
3.2.2 Outputs ........................................................................................................................................... 10
3.2.3 Terminal assignment ..................................................................................................................... 10
3.3 Quick replacement.................................................................................................................................. 11
4 Hardware resources ................................................................................................................................... 12
4.1 Analog inputs AI1…AI4 .......................................................................................................................... 12
4.1.1 Analog mode .................................................................................................................................. 13
4.1.2 Digital mode.................................................................................................................................... 14
4.1.3 Analog input filtering ..................................................................................................................... 14
4.2 Analog outputs AO1, AO2 ..................................................................................................................... 14
4.3 RS485 interface ....................................................................................................................................... 15
4.3.1 Slave mode ..................................................................................................................................... 15
4.3.2 Master mode ................................................................................................................................... 17
4.4 Service modes ........................................................................................................................................ 19
5 Operation ..................................................................................................................................................... 21
5.1 Error mode .............................................................................................................................................. 21
5.2 System menu .......................................................................................................................................... 21
5.2.1 Display navigation ......................................................................................................................... 22
5.2.2 Menu structure ............................................................................................................................... 23
5.3 Display programming ............................................................................................................................. 24
6 Maintenance ................................................................................................................................................ 26
7 Transportation and storage ....................................................................................................................... 27
8 Scope of delivery ........................................................................................................................................ 28
Appendix А. Dimensions .................................................................................................................................. 29
Appendix B. Terminal layouts .......................................................................................................................... 30
Appendix C. Galvanic isolation ........................................................................................................................ 33
Appendix D. Circuit diagrams .......................................................................................................................... 35
Appendix E. Calibration .................................................................................................................................... 36
E.1 General .................................................................................................................................................... 36
E.2 Input ......................................................................................................................................................... 36
E.3 Output 4-20 mA ....................................................................................................................................... 37
E.4 Output 0-10 V .......................................................................................................................................... 37
Appendix F. Battery replacement .................................................................................................................... 39
Appendix G. Interface card installation ........................................................................................................... 41
Introduction
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2
Introduction
This manual describes the functions, configuration, operating instructions, programming and
troubleshooting of the multifunctional programmable relay PR200 (hereinafter referred to as
PR200, device, or relay).
Terms and abbreviations
ALP – programming software akYtec ALP for programming PR series relays, based on
Function Block Diagram (FBD) programming language
ADC – analog-digital converter
DAC – digital-analog converter
Display element – program element used to display information on the device display
Modbus – application layer messaging protocol for client/server communication between
devices connected on different types of buses or networks, originally published by
Modicon (now Schneider Electric), currently supported by an independent organization
Modbus-IDA (www.modbus.org).
Project – user application created in ALP software that also includes the device
configuration
RAM – random access memory, volatile part of the device memory
Retain memory – non-volatile device memory for retain variables
Retain variable – type of variable that keeps its value after device restart (power off/on
cycle)
ROM – read-only memory, non-volatile part of the device memory
Symbols and key words
DANGER
DANGER indicates an imminent dangerous situation that will result in death or serious
injuries if not prevented.
WARNING
WARNING indicates a potentially dangerous situation that could result in death or serious
injuries.
CAUTION
CAUTION indicates a potentially dangerous situation that could result in minor injuries.
NOTICE
NOTICE indicates a potentially dangerous situation that could result in damage to
property.
NOTE
NOTE indicates helpful tips and recommendations, as well as information for efficient and
trouble-free operation.
Overview
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1 Overview
The programmable relay PR200 is a small controller. User program is created as a function
plan with the ALP programming software, which is available for download for free. The ALP
project includes the program as well as the device configuration. Dynamically allocated
memory enables to create complicated programs with many functional blocks, display
elements and advanced display management.
The PR200 enables the following basic functions:
output control according to input statuses and program logic
configuration using ALP software or function buttons
comprehensive display programming
2 programmable LEDs
master and / or slave in Modbus network
Real-time clock
expandable with I/O modules
The relay is available in several versions, for DC and AC voltage, equipped with only digital
or a combination of digital and analog inputs and outputs. The analog inputs can be
configured as analog or as digital. The relay can be expanded with additional I/O modules.
Optional are up to two RS485 interfaces for connection to Modbus networks available.
The device is designed in a plastic enclosure for DIN rail mounting. The enclosure has 3-
level stepped form for distributor installation. Plug-in terminal blocks enable quick and easy
replacement of the device.
Front view:
two-line 32-character alphanumeric LCD display
two LEDs: F1 (green) and F2 (red), program-controlled
6 function buttons for system menu and display navigation
Under the interface cover (to the right):
EXT: 10 pole connector for extension modules
PRG: mini-USB socket for PC connection. USB A-plug to micro B-plug connection
cable is in the package included.
Fig. 1.1 Connection to PC (open interface cover)
Overview
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1.1 Intended use
Programmable relays of PR200 series have been designed and built solely for the intended
use described in this manual, and may only be used accordingly. The technical
specifications contained in this manual must be observed. Only by akYtec GmbH
recommended extension modules may be connected to the relay.
The relay may be operated only in properly installed condition.
Improper use
Any other use is considered improper. Especially to note:
– This device should not be used for medical devices which receive, control or
otherwise affect human life or physical health.
– The device should not be used in an explosive environment.
– The device should not be used in an atmosphere with chemically active substance.
1.2 Ordering key
The relay PR200 can be ordered in various designs depending on the required supply
voltage, number and type of inputs, outputs and interfaces:
Supply voltage
230 - 230 (94…264) V AC
24 - 24 (19…30) V DC
I/O
1 - 8 DI, 6 DO
2 - 8 DI, 4 AI, 8 DO, 2 AO (4-20 mA)
4 - 8 DI, 4 AI, 8 DO, 2 AO (0-10 V)
RS485 interfaces
0 - none *
1 - 1 *
2 - 2
* The models .0 and .1 can be upgraded later by installing up to two interface cards (app. G).
Ordering code for the interface card: PR-IC485
Specifications
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2 Specifications
Table 2.1 General specification
Device
230.1.x
230.2.x
230.4.x
24.1.x
24.2.x
24.4.x
Power supply
230 (94…264) V AC;
50 (47…63) Hz
24 (19…30) V DC
Power consumption, max
10 VA
17 VA
10 W
10 W
Galvanic isolation
2830 V
1780 V
Appliance class
II
III
Integrated voltage source
-
24±3 V DC
100 mA
-
-
Galvanic isolation
-
1780 V - -
Inputs
Digital
8
Analog * - 4 - 4
Outputs
Digital (relay)
6 8 6
8
Analog - 2 - 2
Programming
Software
akYtec ALP
Interface
Mini USB 2.0
Program cycle, min
1 ms
Function buttons
6
LEDs
F1 (green), F2 (red), programmable
LCD display
2x 16 digits, backlight adjustable
Language
English
RS485 interface **
2-pole plug-in terminal block
Protocols
Modbus RTU/ASCII (master/slave)
Baud rate
9.6…115.2 kbit/s
Interface card
PR-IC485 (max. 2)
Galvanic isolation
1500 V
Dimensions
123 x 108 x 58 mm (with terminal blocks)
Mounting
DIN rail (35 mm)
Weight
approx. 350 g
IP code
IP20
* Analog inputs AI1…AI4 can also be configured as digital inputs
** For x.x.1 and x.x.2 models only
Table 2.2 Digital inputs
Device
230.1.x
230.2.x
230.4.x
24.1.x
24.2.x
24.4.x
Input signal
Switch contact
Switch contact
PNP with open collector
Digital signals -3…+30 VDC
Input voltage
230 V AC
24 V DC
Input voltage, max
264 V AC
30 V DC
Logical 1
159…264 V (0.75…1.5 mA)
15…30 V (5 mA)
Logical 0
0…40 V (0…0.5 mA)
-3…+5 V (0…1 mA)
Pulse length, min
50 ms
2 ms
Response time, max
100 ms
30 ms
Galvanic isolation
in groups of 4 (1-4, 5-8)
Test voltage between
input groups
1780 V
Specifications
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Device
230.1.x
230.2.x
230.4.x
24.1.x
24.2.x
24.4.x
Test voltage against
other circuits
2830 V
Table 2.3 Analog inputs
Device
x.2.x, x.4.x
Galvanic isolation
none
Analog mode
Input signal
0-10 V, 4-20 mA, 0-4000 ohm
Input voltage *
-36…+36 V
Input resistance (0-10 V)
61 kohm
Input resistance (4-20 mA)
121 ohm
Basic error
±0.5%
Temperature influence
±0.05%/10°C
Resolution
2.7 mV / 6 µA
ADC resolution
12 bit
Sampling time for 4 inputs, max
10 ms
Digital mode
Logic 1 **
0…10 V, adjustable
Logic 0 **
0…10 V, adjustable
Current at input voltage 15…30 V, max
5 mA
* If the voltage at one input is below -0.5 V, the accuracy for all inputs cannot be guaranteed.
** Parameter can be set in ALP Property Box using the option Input mode = digital.
Table 2.4 Digital outputs
Type
relay (NO)
Switching capacity AC
5 A, 250 V (resistive load)
Switching capacity DC
3 A, 30 V
Minimum load current
10 mA (at 5 V DC)
Service life, electrical
3 A, 30 V DC
200,000 switching cycles
5 A, 250 V AC (resistive load)
100,000 switching cycles
Galvanic isolation
in groups of 2 (1-2, 3-4, 5-6, 7-8)
Test voltage between output groups
1780 V
Test voltage against other circuits
2830 V
Table 2.5 Analog outputs
Device
x.2.x
x.4.x
Auxiliary voltage
12…30 V DC
12…30 V DC
Quantity
2
Output signal
4-20 mA
0-10 V
Output load, max
1 kohm
2 kohm
Basic error, max
±0.5%
Temperature influence
±0.05%/10°C
Inductive load, max
50 µH
-
Signal conversion time
100 ms
DAC resolution
10 bit
Galvanic isolation
2830 V, individual
2830 V, in group
Specifications
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Table 2.6 Memory
ROM memory
128 kB
RAM memory
32 kB
Retain memory
1016 Byte
Network variable memory *
128 Byte
* The limitation applies only to the slave mode, in which all network variables are
automatically declared as retain.
Table 2.7 Real-time clock
Accuracy
±3 s/day (25°C)
Correction
-2.75…+5.5 min/month
Backup, min
8 years
Backup battery
CR2032
2.1 Environmental conditions
The device is designed for natural convection cooling. It should be taken into account when
choosing the installation site.
The following environment conditions must be observed:
clean, dry and controlled environment, low dust level
closed non-hazardous areas, free of corrosive or flammable gases
Table 2.8
Conditions
Permissible range
Ambient operating temperature
-20…+55°C
Storage temperature
-25…+55°C
Relative humidity
up to 80% (at +25°C, non-condensing)
Altitude
up to 2000 m above sea level
EMC immunity
conforms to IEC 61000-6-2
EMC emission
conforms to IEC 61000-6-4
Installation
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3 Installation
The relay is designed for DIN rail mounting. The environmental conditions from the section
2.1 must be observed. For the dimension drawing see Appendix. A
3.1 Mounting
Align the upper slide of the DIN rail
mounting groove with the DIN rail and
push it onto the rail.
Wire external connections in
accordance with sec. 3.2 using plug-in
terminal blocks (included).
Removal:
Take off the terminal blocks without
disconnecting the wires.
Insert a screwdriver into the eyelet of
the slide interlock, push it down and
remove the relay from the rail.
Fig. 3.1
3.2 Wiring
WARNING
Electric shock could kill or seriously injure.
All electrical connections must be performed by a fully qualified electrician.
Ensure that the mains voltage matches the voltage marked on the nameplate.
Ensure that the device is provided with its own power supply line and electric fuse.
Do not feed any external devices from the power contacts of the device.
Remove the terminal blocks only after powering off the device and all connected
equipment.
WARNING
The device must be powered off before connecting to peripheral devices, internal
bus or PC. Switch on the power supply only after the wiring of the device has been
completed.
WARNING
The program runs after transferring it to the relay. It is recommended to transfer the
program before wiring the relay.
Otherwise ensure that all peripheral devices are disconnected from relay outputs
before transferring the program.
NOTICE
Supply voltage for 24 VDC models may not exceed 30 V. Higher voltage can damage
the device.
If the supply voltage is lower than 19 V DC, the device cannot operate properly but
will not be damaged.
NOTICE
Signal cables should be routed separately or screened from the supply cables.
Shielded cable should be used for the signal lines to ensure compliance with the
EMC requirements.
NOTE
Before powering on, make sure that the device was stored at the specified ambient
temperature (-20 ... +55 °C) for at least 30 minutes.
─ For terminal assignment, see Tables 3.1, 3.2
─ For I/O electrical connections, see Fig. 3.2…3.7
─ For terminal blocks layouts, see app. B
Installation
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─ Maximum conductor cross-section is 0.75 mm²
3.2.1 Inputs
a b
Fig. 3.2 Connection of switch contacts to digital inputs: a) 24.x.x, b) 230.x.x
NOTICE
230.x.x models
The digital inputs are divided into two groups, each of four inputs. All inputs must
be operated on the same phase. Different phases are not allowed.
Fig. 3.3 Connection of 3-wire sensors with PNP transistor outputs to digital inputs (24.x.x
only)
For 24.x.x models, it is permissible to connect sensors with switch contacts and transistor
outputs to digital inputs within the same input group.
If the galvanic isolation between inputs groups is not required, a common power supply,
including the integrated 24 VDC voltage source, can be used for both groups.
a b c
Fig. 3.4 Analog inputs: a) 4-20 mA, b) 0-10 V, c) 0-4000 ohm
Different sensors can be connected within a group. For example, AI1 can be configured as
digital and AI2 as analog 4-20 mA.
Installation
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3.2.2 Outputs
Fig. 3.5 Relay outputs
Fig. 3.6 Analog outputs 4-20 mA (x.2.x)
Fig. 3.7 Analog outputs 0-10 V (x.4.x)
NOTICE
The output voltage of an external voltage source may not exceed 30 V. Higher
voltage can damage the device.
For voltage supply of analog outputs 4-20 mA or 0-10 V, the integrated voltage source can
be used.
3.2.3 Terminal assignment
For terminal layouts see App. B.
Table 3.1 Terminal assignment
No.
Marking
Description
1
AC230V L / DC24V-
AC / DC power supply *
2
AC230V N / DC24V+
AC / DC power supply *
3
COM1
DI1...DI4 common contact
4
DI1
DI1 digital input
5
DI2
DI2 digital input
6
DI3
DI3 digital input
7
DI4
DI4 digital input
8
COM2
DI5...DI8 common contact
9
DI5
DI5 digital input
10
DI6
DI6 digital input
11
DI7
DI7 digital input
12
DI8
DI8 digital input
13
OUT 24V+
24 VDC integrated voltage source **
14
OUT 24V-
24 VDC integrated voltage source **
15
DO1
DO1 digital output
16
-
DO1...DO2 common contact
17
DO2
DO2 digital output
Installation
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No.
Marking
Description
18
DO3
DO3 digital output
19
-
DO3...DO4 common contact
20
DO4
DO4 digital output
21
DO5
DO5 digital output
22
-
DO5...DO6 common contact
23
DO6
DO6 digital output
24
DO7
DO7 digital output
25
-
DO7...DO8 common contact
26
DO8
DO8 digital output
27
AI1
AI1 analog input
28
COM3
AI1...AI2 common contact
29
AI2
AI2 analog input
30
AI3
AI3 analog input
31
COM4
AI3...AI4 common contact
32
AI4
Analog input AI4
33
RS-485 D-
RS485 Interface 1-
34
RS-485 D+
RS485 Interface 1+
35
RS-485 D-
RS485 Interface 2-
36
RS-485 D+
RS485 Interface 2+
37…40
see Table 3.2
* Depending on device model (230.x.x or 24.x.x)
** 230.x.x model only
Table 3.2 Terminals 37-40
No.
Marking
Description
x.2.2
37
АО1-
AO1 analog output (4-20 mA)
38
АО1+
39
АО2-
AO2 analog output (4-20 mA)
40
АО2+
x.4.2
37
V-
-24 VDC external voltage supply
38
V+
+24 VDC external voltage supply
39
АО1
AO1 analog output (0-10 V)
40
АО2
AO2 analog output (0-10 V)
3.3 Quick replacement
PR200 is equipped with plug-in terminal blocks which enable
quick replacement of the device without disconnecting the
existing wiring (Fig. 3.8).
To replace the device:
power off all connected lines including power supply
remove the terminal blocks
replace the device
connect the terminal blocks with existing wiring to the
device
Fig. 3.8 Quick replacement
Hardware resources
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4 Hardware resources
To use all hardware resources in a program, the device must be configured. The
configuration is carried out in ALP and is transferred as a part of user project to the device
memory. The configuration parameters are stored in non-volatile memory of the device and
are safe when the device is powered off.
The device can also be configured with the function buttons via the system menu without
being connected to ALP (sect. 5.2). If some parameter has been changed this way, it has to
be taken from the device memory into the ALP project in order to keep the project
syncronized. Use Read button in the corresponding mask in the configuration window.
The following hardware can be configured:
Display
Clock
Interfaces (sect. 4.3)
Extension modules
Inputs (sect. 4.1)
Outputs (sect.4 2)
See ALP Help for detailed information about configuration.
4.1 Analog inputs AI1…AI4
To configure analog inputs use the ALP menu item Device > Configuration. Open the node
Inputs > Analog in the open window Device configuration (Fig. 4.1) and select an analog
input.
Fig. 4.1 Analog input configuration
For quick access select an input in the circuit program and use Property Box (see Fig. 4.2) to
set the parameters. The parameter Input mode has to be set first.
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