B&B Electronics ISOCON-3 User Manual

ISOCON-3 USERS GUIDE

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d

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ISOCON-3

MAINS POWERED

ISOLATING SIGNAL CONVERTER

!

Whilst every effort has been taken to ensure the accuracy of this document, we

accept no responsibility for damage, injury, loss or expense resulting from errors

or omissions, and reserve the right of amendment without notice.

This document is issued by Industrial Interface Research Ltd and may not be

reproduced in any way without the prior written permission of the company.

CAUTION:

This equipment is designed for connection to
mains voltages and must be used in accordance
with this guide. If it is not, the safety protection

rovided by the equipment may be impaired.

This equipment relies on double / reinforce
insulation for safety and does not require a

rotective earth.

IMO

Industrial Interface

February 2002

IIG-060901 Page 1

ISOCON-3 USERS GUIDE

CONTENTS

1. INTRODUCTION ____________________________________ 3

1.1 Hardware Features _________________________________ 3

1.1.1 Isolation Details __________________________________ 3

2. UNPACKING________________________________________ 3

3. CONNECTIONS _____________________________________ 4

4. CONFIGURING THE ISOCON_________________________ 5

4.1.1 Voltage Input: ___________________________________ 6

4.1.2 Current Input ____________________________________ 7

4.1.3 Millivolt (mV) Input ______________________________ 8

4.1.4 Potentiometer Input _______________________________ 9

4.1.5 Thermocouple Input______________________________ 10

4.1.6 RTD Input _____________________________________ 11

4.1.7 Output Configuration_____________________________ 12

5. CALIBRATING THE ISOCON ________________________ 13

6. INSTALLATION ____________________________________ 14

7. TROUBLESHOOTING_______________________________ 15

7.1 Incorrect Reading _________________________________ 15

7.2 Sensor Failure ____________________________________ 15

8. SPECIFICATIONS ( @ 25°C) _________________________ 16

IMO

IMO Precision Controls Limited

1000 North Circular Road

Staples Corner, London NW2 7JP

Telephone: [phone]

Fax: [phone]

Web: www.imopc.com

Email: [e-mail]

Page 2 IIG-060901

ISOCON-3 USERS GUIDE

1. INTRODUCTION

1.1 Hardware Features

The ISOCON-3 is a universal input Isolating Signal Converter. It can accept
virtually every type of analogue input signal from millivolts to 40Vdc, mA,
thermocouples, RTD’s etc. It also produces 3 types of analogue output; voltage,
mA source, or mA sink. The unit can be powered by any AC voltage between
90 and 264Vac at 50 or 60Hz. For DC voltage the ISOCON-6 is available which
can be powered from any supply from 12 to 36Vdc and 12 to 32Vac.

The instrument is packaged in a very compact 12.5mm wide enclosure which can
be mounted on standard TS35 DIN-rail.

The unit can also be equipped with 1 digital output which can be either a relay or
an open collector output, or a second analogue output (see DUALCON-3). Note,
units with above options are housed in a 17.5mm wide box.

1.1.1 Isolation Details

The ISOCON-3 has full 3 port isolation of 1000V between the Input Stage,
Output Stage and Power Supply. The process input and output are double
insulated internally from the power supply for safety
process input and output are isolated from each other for functional

reasons. Additionally the

reasons.

2. UNPACKING

The instrument should be carefully inspected for signs of damage which may
have occurred in transit. In the unlikely case that damage has been sustained,
DO NOT use the instrument, as the safety insulation may have been
compromised, but please retain all packaging for our inspection and contact your
supplier immediately.

The instrument comes with the following items as standard:
1 Isocon-3 Isolating Signal Converter

1 Isocon-3 User Guide

If the instrument has been factory configured the input and output details will be
listed on the Serial number label on the side of the unit. If this label is blank then
the unit will be set to its default configuration which is 4-20mA input and 4­20mA source output. Please check that the details on the side label are correct,
especially the power supply voltage and frequency.

If re-configuration is required please refer to Section 4 of this manual.

IIG-060901 Page 3

ISOCON-3 USERS GUIDE

3. CONNECTIONS

The ISOCON is housed in a compact DIN rail mounting enclosure, with 8
terminals, arranged in 4 rows of 2 terminals. Two rows are at the top of the front
panel and 2 rows are at the bottom. All the sensor input terminals are on the
bottom rows and the power supply and analogue outputs are on the top
terminals.

The diagram below shows how to connect all the different input, output and
power supply types.

2

L

1

PSU

90 – 264VAC

N

2 1

OUTPUT

12 10

INPUT

5 4

INPUT

+ve

12

- ve

10

5

+ve

4

- ve

3

24V Tx Supply

6

0-10V 0(4)-20mA

Current Source Voltage Source

Input: mA, Volts, mV, T/C

2 Wire
Transmitter

4-20mA Sink

24V Supply

4-20mA Sink

Current Sink

2 Wire RTD

125R to 1K
2 Wire Pot

1K to 100K

4 Wire RTD 3 Wire RTD

3 Wire Pot

3 6

Page 4 IIG-060901

ISOCON-3 USERS GUIDE

4. CONFIGURING THE ISOCON

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
POWER SUPPLY, INPUT OR OUTPUT CONNECTED

The ISOCON is an extremely versatile device which can support many different
types of input. The unit is configured by turning the power off, selecting the
internal switch settings required and turning the power back on.

To open the ISOCON, 2 catches just below the outer terminal blocks must be
pushed in gently, one at a time. The front of the case can then be pulled and the
unit will come out of the box.

! WARNING !

Press here gently

There are 3 switch banks, S1, S2, and S3, located inside the ISOCON as shown
below:

Switch S3

12 1

12 1110

Switch S2

Switch S1

1

12

1

12

Switch 10 is OFF
Switch 11 is ON
Switch 12 is OFF

ON = 1

OFF = 0

Switch S1 and S2 configure the input type and range, and switch S3 configures
the output type, range and a few additional functions. The switch settings are
explained in the next few pages. The diagrams refer to switch positions 0 and 1,
with 0 being OFF and 1 being ON. This is illustrated in the picture above.

IIG-060901 Page 5

ISOCON-3 USERS GUIDE

V

3456789

V

V

V

V

V

A

4.1.1 Voltage Input:

Select the range from the table below and set Switch S1 to the required values.

oltage

Switch S1

Range

0-1

12
000001001100

10 11 12

0-2V 0 0 0 1 0
0-4V 0 0 1 0 0

0-5

0100 0

0-7.5V 1 0 0 0 0

0-8V 0 0 1 1 0

0-10

0101 0

0-15V 1 0 0 1 0
0-20V 0 1 1 0 0
0-30V 1 0 1 0 0
0-40V 0 1 1 1 0

1-5

0100 1

-5 to +5V 1 1 0 0

-10 to +10

110101001100

Then select the required setting from the table below for switch S2

Switch S2

! WARNING !

Vo!ltage Rang

e

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH

123456789101112

POWER SUPPLY, INPUT OR OUTPUT CONNECTED

1

0-30V & 0-40V

Ranges 001100110000

ll other Ranges

Listed Above

001010100000

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

Page 6 IIG-060901

ISOCON-3 USERS GUIDE

A

A

A

4.1.2 Current Input

Select the range from the table below and set Switch S1 to the required values.

Switch S1

mA Range

123456789101112

0-1m

0-2mA 0 0 0 1 0
0-4mA 0 0 1 0 0
0-5mA 0 1 0 0 0

0-8mA 0 0 1 1 0
0-10mA 0101 0
0-15mA 1001 0

0-20m

0-30mA 1010 0

4-20m

4-40mA 0111 1
4-30mA 1010 1

-5 to +5mA 1 1 0 0 1

-10 to +10mA 110100001110

000000001110

0110 0

0110 1

Then select the required setting from the table below for switch S2

Switch S2

mA Range

123456789101112

Using Internal 24V

Tx Supply for

4 to 20mA

Unipolar Ranges

(e.g. 0-20mA,

4-20mA)

Bipolar Ranges

(e.g.

-10 to +10mA)

!

110100110010

110000110000

110010100000

! WARNING !
DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
POWER SUPPLY, INPUT OR OUTPUT CONNECTED

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

IIG060901 Page 7

ISOCON-3 USERS GUIDE

V

V

V

4.1.3 Millivolt (mV) Input

Select the range from the table below and set Switch S1 to the required values.

Switch S1

mV Range

123456789101112

0-25mV 000000011100
0-50mV 0001

0-100m

0-125mV 0100
0-150mV 1000

0-200m

0-250mV 0101
0-300mV 1001

0-500m

0-600mV 1010
0-1000mV 0111
0-1200mV 1011

-125 to +125mV1100

-125 to +1000mV111100011100

0010

0011

0110

And then select the required setting from the table below for switch S2

Switch S2

mV Range

123456789101112

All Unipolar

Ranges (e.g.

0-500mV)

Bipolar Ranges

(e.g.

-125 to +125mV)

010000110000

010010100000

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
POWER SUPPLY, INPUT OR OUTPUT CONNECTED

! WARNING !

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

Page 8 IIG-060901

ISOCON-3 USERS GUIDE

4.1.4 Potentiometer Input

Select the range from the table below and set Switch S1 to the required values.

Potentiometer

Input

123456789101112

2 Wire 0-125R 0 0 0 0 0 0 0 1 1 1 0 1
2 Wire 0-250R 0 0 0 1

2 Wire 0-500R 0 0 1 0

2 Wire 0-625R 0 1 0 0
2 Wire 0-750R 1 0 0 0

2 Wire 0-1K 0 0 1 1

3 Wire from

0-1K to 0-100K000001011110

Switch S1

00011101

Then select the required setting from the table below for switch S2

Potentiometer

Input

2 Wire

Potentiometer

3 Wire

Potentiometer

123456789101112

010010010001

001100110010

Switch S2

!

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
POWER SUPPLY, INPUT OR OUTPUT CONNECTED

! WARNING !

IIG060901 Page 9

ISOCON-3 USERS GUIDE

4.1.5 Thermocouple Input

Select the range from the table below and set Switch S1 to the required values.

Switch S1 for Thermocouple Input

Temperature Range in °C

K J R S N E B T 123456789101112

0 to 100 400 to 500 0 to 50 0000 00 0
0 to 200 400 to 600 0 to 100 0001
0 to 400 400 to 800 0 to 200 0010
0 to 800 400 to 12000 to 400 0011
0 to 125 400 to 525-50 to 50 0100 000
0 to 250 400 to 650-50 to 1000101 001
0 to 500 400 to 900-50 to 2000110 010

0 to 1000400 to 1400-50 to 4000111 011

0 to 150 400 to 550-100 to 501000 100
0 to 300 400 to 700-100 to 1001001 101
0 to 600 400 to 1000-100 to 2001010 110

0 to 1200*400 to 1600-100 to 4001011 111

0 to 175 400 to 575-200 to 501100
0 to 350 400 to 750-200 to 1001101
0 to 700 400 to 1100-200 to 2001110

0 to 1400**400 to 1800-200 to 4001111 00 0

Switch

T/C

Type

K

J
R
S
N
E
B
T

Linearisation ON 0

Linearisation off 1

* n/a for types N and E CJC ON 0
** n/a for types K, J, N and E CJC off 1

Then set switch S2 to the setting shown in the table below.

Switch S2

Thermocouple

123456789101112

All Ranges

010011100000

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH

POWER SUPPLY, INPUT OR OUTPUT CONNECTED

! WARNING !

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

Page 10 IIG-060901

ISOCON-3 USERS GUIDE

4.1.6 RTD Input

Select the range from the table below and set Switch S1 to the required values.

Range in °C

123456789101112

0 to 100 0 0 0 0 0 0 1 0 0
0 to 200 0 0 0 1
0 to 400 0 0 1 0
0 to 800 0 0 1 1

-50 to 50 0 1 0 0

-50 to 150 0 1 0 1

-50 to 250 0 1 1 0

-50 to 350 0 1 1 1

-100 to 50 1 0 0 0

-100 to 100 1 0 0 1

-100 to 200 1 0 1 0

-100 to 400 1 0 1 1

-200 to 200 1 1 0 0

-200 to 400 1 1 0 1

-200 to 600 1 1 1 0

-200 to 800 1 1 1 1 0 0 1 0 0

Switch S1

RTD linearisation ON 0 PT100 0

RTD linearisation off 1 PT1000 1

RTD 2 or 4 wire 0

RTD 3 wire 1

And then select the required setting from the table below for switch S2

RTD

123456789101112

2 Wire RTD 010010010001
3 Wire RTD 010000001001
4 Wire RTD 010000010100

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH

!

POWER SUPPLY, INPUT OR OUTPUT CONNECTED

Switch S2

! WARNING !

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

IIG060901 Page 11

ISOCON-3 USERS GUIDE

A

A

/

4.1.7 Output Configuration

Select the range from the table below and set Switch S3 to the required values.

Switch S3 - Output Configuration

1 23456 78 910 1112

01010
10100mA Sink 1Inverted o/p
01011Voltage

0 Buttons Disabled

1 Buttons Enabled

Output value if fault on input signal

Front panel buttons can be disabled to allow 2-10mA / 1-5V 1 1
tamper-proof operation of the unit

mA Source 0 Normal 0

Normal 0

High Burnout 0

Low Burnout 1

Square Root 1

4-20m
0-20m

0-10mA / 0-5V 1 0

/ 2-10V 0 0

0-10V

Examples:

Switch S3 Examples

123456789101112

4-20mA Source 101010000000
0-20mA Source 101010000001
0-10V 101011000001
4-20mA Sink 110100000000

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
POWER SUPPLY, INPUT OR OUTPUT CONNECTED

! WARNING !

Please note that PC Software is available to provide information on

switch settings for your input and output requirements.

01

Page 12 IIG-060901

ISOCON-3 USERS GUIDE

5. CALIBRATING THE ISOCON

When the unit is shipped the ISOCON will be calibrated for the input and output
types and ranges noted on the side label. If this label is blank then the unit will be
calibrated for 4-20mA input and 4-20mA source output.

If the unit is re-ranged by the user it is necessary to re-calibrate the unit to obtain
the maximum accuracy. The calibration is achieved by using both switches on the
front panel to select the zero or span input and then using the switches as
raise/lower buttons to adjust the output to the value required.

The mode the unit is in is indicated by the colour of the LED:
Green - Normal Operation
Red - Span Adjust
Yellow - Zero Adjust

Setting of the zero and span points is non-interactive, so each point need only be
set once. A typical calibration sequence would be as follows:

LED Colour Mode Action

Apply full scale input.

Green Normal

Press and release both buttons together to enter
span mode
Press raise / lower buttons to adjust output value

RED Span Adjust

Press and release both buttons together to return
to normal mode
Apply zero scale input

Green Normal

Press and release both buttons together to enter
zero mode
Press raise / lower buttons to adjust output value

YELLOW Zero Adjust

Press and release both buttons together to return
to normal mode

Green Normal Use product

The unit is now calibrated and ready for use.

Note: The unit will

retain the new settings on power down.

IIG060901 Page 13

ISOCON-3 USERS GUIDE

When the unit is used to convert a thermocouple input it is important when
calibrating to ensure that the thermocouple simulator employed is switched to
automatic cold junction compensation and is at the same ambient temperature as
the ISOCON. Note that this is not always easy to achieve, especially if the
ISOCON is mounted in a warm cabinet. An altenative method is to use an ice­point reference and a mV source.

6. INSTALLATION

The ISOCON’s input and output circuits are classed as Separated Extra Low
Voltage (SELV). This means that they must not be externally connected to
voltages exceeding 30V ac or 60V dc, nor do they generate voltages above these
limits internally. Where a higher voltage input is required a specially designed
DIVIDER unit can be used to condition the input signal prior to connection to the
process input terminals.

The ISOCON unit clips directly onto ‘Top Hat’ (TS35) symmetrical DIN rail.
Ideally, mounting orientation should be vertical, with the power supply situated
on the top face to minimise temperature rise. Good airflow around the unit will
maximise reliability of the instrument.

The use of bootlace ferrules is recommended on wiring terminations.

Do not exceed terminal torque rating of 0.4 Nm – use an appropriate screwdriver.
The unit can be removed from the DIN rail by sliding a small screwdriver into the
slot at the rear of the enclosure on the lower face and gently levering the metal
clip, whilst lifting the unit from the rail.

Although the unit is protected by a non-resettable internal fuse, it is essential that
the following provisions are made in the installation:

An anti-surge fuse with a voltage rating of 250V ac and a breaking capacity of
35A at 250V ac shall be wired in series with the supply live conductor (terminal

2). For 230V supplies T32mA should be used and for 115V supplies T63mA
should be used. An appropriately marked or labelled switch or circuit breaker
meeting the requirements of IEC947-1 and IEC947-3 shall be included in the
supply installation in close proximity to the equipment, within easy reach of the
operator. The supply neutral (terminal 1) should be connected to the mains
supply neutral.

Page 14 IIG-060901

ISOCON-3 USERS GUIDE

7. TROUBLESHOOTING

The ISOCON has some built in self diagnostic functions. If the LED on the front
panel is flashing then the fault mode can be found by counting the number of
flashes between gaps and using the table below to locate the problem.
NOTE: Even if the LED is not lit, mains voltages
ALWAYS isolate the mains supply before removing or examining the unit.

could still be present –

No of

Nature of Fault Corrective Action

Flashes

0 (Green

On)

2,3,4,5,6,8,9,

10,11,12

Green

Unit Working – no suspected
fault
Hardware Error, extreme
noise, poor supply

Check Wiring and switch
settings
Switch off unit, check switch
settings, and wiring, and retry.
If still faulty please contact
supplier

7 Green RTD / Thermocouple

Repair RTD, T/C or wiring

burnout

3 or 4 Red Span point is too close to

zero point

3 or 4

Yellow

Zero point is too close to
span point

Change input span value and
retry
Change input zero value and
retry

No LED Power Failure Check supply lines and voltage

7.1 Incorrect Reading

• Check that Unit is configured for the correct Sensor

• Check that Input Scaling is as required.

• Check that Linearisation has not been set incorrectly.

• Check that Thermocouples have correct compensation cables, and polarity.

• Check that RTD is set for correct option 2, 3 or 4 Wire.

• Check that RTD leads are connected to appropriate terminal pins.

7.2 Sensor Failure

• Check that sensor wiring is correct.

• Check Thermocouple polarity.

• Check that all RTD leads are connected to correct terminals.

• Check that the ISOCON is configured for correct sensor.

• Check that applied voltage is not out of range.

• Check that applied current is not out of range.

• Check that applied millivoltage is not out of range.

IIG060901 Page 15

ISOCON-3 USERS GUIDE

8. SPECIFICATIONS ( @ 25°C)

Operating Temperature 0 to 55 °C (Storage: –40 to +100°C)
Operating Altitude Sea Level to 2000m
Humidity 0-90% RH
Power Requirements AC Supply 90 to 264Vac 50 or 60Hz
VA Rating 1.6VA ±10% typ (20mA in & out)

2.8VA ±10% (maximum load, tx supply)
Transmitter Power Supply 21V to 28V @ up to 24mA

Dependant on supply voltage and load

Calibration accuracy ±0.05% full scale
Linearity ±0.05% full scale
Temperature Stability 50ppm / °C
Input Impedance:

Current Input 15 ohms
Voltage Input 1 Mohm

Millivolt Input Greater Than 10 Mohm
Thermocouple Burn Out Current: 500nA Nominal
Cold junction compensation accuracy ±0.5°C over operating range
Maximum Voltage Output 11.5 V into a minimum of 7Kohm
Maximum Current Output 23.0 mA into a maximum of
1Kohm
Time Response (90% of step change): 50ms ± 10ms

Unit has full 3 port Isolation to 1kV between Power Supply, Input and Output.
The unit can also withstand transients of 2.5kV for 50 µsecs.

Dimensions 114.5 mm x 99mm x 12.5mm (HxDxW)
Mounting DIN Rail TS35
Connections Screw Clamp with pressure plate
Conductor Size 0.5 to 4.0 mm
Insulation Stripping 12 mm
Maximum Terminal Torque 0.4 Nm
Weight Approx. 95g
EMC Emissions EN50081-2:1993
EMC Immunity EN61000-6-2:1999
EMC, Voltage Fluctuations EN61000-3-2:1995 CLASS A
EN61000-3-3:1995
LVD Standards EN61010-1:1993
Installation Category (IEC 664) II
Pollution Degree (EN61010-1:1993) 2
Equipment Class (IEC 536) II

Page 16 IIG-060901