Detcon 1600A-N4X User Manual

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Model 1600A-N4X

NEMA 4 Control Panel

Operator’s Installation and Instruction Manual

3200 Research Forest Dr., A-1

The Woodlands, Texas 77381

Ph.281.367.4100 / Fax 281.298.2868

Aug 20, 2009 • Document # 3437 • Revision 0.2

DETCON, Inc.

www.detcon.com

1600A-N4X

Page intentionally blank

1600A-N4X Instruction Manual ii

Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381

Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067

Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 •

www.detcon.com •

1600A-N4X

Table of Contents

Introduction.............................................................................................................................................1

1.0

2.0 System Configuration .............................................................................................................................2

2.1 Hardware Configurations ..................................................................................................................... 2

2.2 Programming Configuration................................................................................................................. 2

2.3 Specifications ....................................................................................................................................... 3

3.0 Installation...............................................................................................................................................4

3.1 1600A Interface Board......................................................................................................................... 6

3.2 Remote Alarm Reset Switch ................................................................................................................ 7

3.3 Installing I/O Modules.......................................................................................................................... 8

3.4 Connecting to the I/O Modules ............................................................................................................ 8

3.5 Initial Power Checks .......................................................................................................................... 12

3.6 Setting Device Identification on the I/O Modules.............................................................................. 12

4.0 Setup.......................................................................................................................................................13

4.1 Program Menu Selections .................................................................................................................. 13

4.1.1 Channel Setup................................................................................................................................................13

4.1.2 DA4 set up.....................................................................................................................................................15

4.1.3 Relay Activation and Configuration..............................................................................................................16

4.1.4 Serial Inputs...................................................................................................................................................17

4.1.5 4-20mA Output Setup....................................................................................................................................19

5.0 System Operation..................................................................................................................................20

5.1 Using the Touch-screen Display ........................................................................................................ 20

5.2 Main Display...................................................................................................................................... 20

5.3 Touch Screen Utilities........................................................................................................................ 21

5.4 Password Protection ........................................................................................................................... 22

5.5 Secondary Modbus™ Port ................................................................................................................. 23

5.6 Firmware Upgrade.............................................................................................................................. 26

5.6.1 Touch Screen Upgrade...................................................................................................................................26

5.6.2 PLC Upgrade .................................................................................................................................................27

6.0 Spare Parts.............................................................................................................................................28

7.0 Warranty................................................................................................................................................28

Appendix A........................................................................................................................................................29

RS-485 System Integration Wiring................................................................................................................ 29

Appendix B ........................................................................................................................................................35

Hexadecimal Table......................................................................................................................................... 35

Appendix C........................................................................................................................................................36

Revision Log .................................................................................................................................................. 36

Appendix D........................................................................................................................................................37

Drawings and Diagrams................................................................................................................................. 37

1600A-N4X Instruction Manual iii

1600A-N4X

Table of Figures

Figure 1 Interface Diagram .................................................................................................................................. 1

Figure 2 System Configurations........................................................................................................................... 2

Figure 3 Unit Mounting and Dimensional............................................................................................................ 4

Figure 4 AC/DC Inputs ........................................................................................................................................ 4

Figure 5 RS-485 wiring Terminals....................................................................................................................... 5

Figure 6 Interface Wiring..................................................................................................................................... 5

Figure 7 Interconnect Wiring Diagram ............................................................................................................... 6

Figure 8 1600A Interface PCA............................................................................................................................ 7

Figure 9 I/O Module Installation........................................................................................................................ 8

Figure 10 Model DA-4 and 4-20mA Gas Sensor Connections............................................................................ 9

Figure 11 Model DA-4 and 4-20mA Gas Sensors ............................................................................................. 9

Figure 12 Modbus™ Gas Sensor Connections................................................................................................... 10

Figure 13 Model RL-4 Relay Module............................................................................................................... 10

Figure 14 Model AO-4 Module.......................................................................................................................... 11

Figure 15 Location of Termination jumper (JP6)............................................................................................... 11

Figure 16 Setting Device Addresses................................................................................................................... 12

Figure 17 Program Menu ................................................................................................................................... 13

Figure 18 Channel Setup.................................................................................................................................... 13

Figure 19 Individual Channel Setup................................................................................................................... 14

Figure 20 Addressing DA Modules.................................................................................................................... 15

Figure 21 DA4 / Analog input Activation.......................................................................................................... 15

Figure 22 Addressing Relay Modules................................................................................................................ 16

Figure 23 Activating Relay Outputs................................................................................................................... 16

Figure 24 Setting up Relay Outputs................................................................................................................... 17

Figure 25 Accessing Serial Setup...................................................................................................................... 18

Figure 26 Serial Setup screen............................................................................................................................. 18

Figure 27 Set-up 4-20mA Outputs..................................................................................................................... 19

Figure 28 Main Display...................................................................................................................................... 20

Figure 29 Screen Utilities................................................................................................................................... 21

Figure 30 Supervisory Modbus Setup................................................................................................................ 22

Figure 31 On-Screen Keyboard................................................................................................... ....................... 23

Figure 32 Password Screen ................................................................................................................................ 23

Figure 33 S7-200 USB/PPI Cable..................................................................................................................... 26

Figure 34 Display Back Panel............................................................................................................................ 27

Figure 35 RS-485 Bus with 4 transceiver chips................................................................................................. 29

Figure 36 Correct and incorrect wiring schemes................................................................................................ 30

Figure 37 Recommended RS-485 communications set-up ................................................................................ 31

Figure 38 Unbalanced Data Bus......................................................................................................................... 32

Figure 39 Data Bus using two repeaters............................................................................................................. 32

Figure 40 Repeater wiring diagram.................................................................................................................... 32

Figure 41 Daisy Chain wiring diagram.............................................................................................................. 33

Figure 42 Unbalanced Data Bus......................................................................................................................... 33

Figure 43 Four repeater Data Bus ...................................................................................................................... 34

Figure 44 wire length vs. data speed.................................................................................................................. 34

1600A-N4X Instruction Manual iv

1600A-N4X

1.0 Introduction

The Detcon Models 1600A-N4X is a “user-configurable” multi-channel alarm controller. The 1600A is configurable for up to 16 channels. Through the use of I/O modules the 1600A can receive analog inputs from either 4-20mA, or can alternatively poll serial sensors via RS-485 Modbus™.

The 1600A-N4X controller uses a modular design approach that allows the user to customize the selection of stand-alone input and output modules. I/O modules are available in four channel sets for 4-20mA inputs, relay outputs, and 4-20mA outputs. Detcon’s I/O Modules are DIN rail mounted and stackable allowing for seamless system expansion. These addressable I/O modules can be located remotely near the gas sensors to simplify wiring.

The status of sensor inputs is displayed on a backlit graphic display that utilizes a touch-screen user interface. Typical sensor status includes channel number, tag name, gas type, concentration, and alarm/fault status. Each input channel can be assigned up to three alarm levels and fault. A standard RS-485 or optional RS 232 serial output is provided for communication with PLC’s, PC’s, and monitoring devices.

The controller can be powered by 110/220VAC, 20-30VDC, or both. The enclosure is rated for NEMA 4 locations. Remote mounted gas sensors (purchased separately) can include serial or 4-20mA input devices such as; toxic gas, combustible gas, or oxygen deficiency sensors or contact closure inputs such as liquid level, temperature, pressure, heat, smoke, pull station, etc. Additional features include: one-touch Alarm Inhibit, Alarm Reset, and Alarm Silence (Acknowledge) functions. An Alarm Reset Switch is also mounted on the outside of the enclosure on the left side. The 1600A controller provides for a unique combination of user programming flexibility and customizable expansion capability, in a low-cost and simple-to-operate package.

RS-485/RS-232

to Master Control

System, DCS, PC, etc.

The 1600 will only handle a maximum of 16 channels.

Sensor 1 Sensor 2 Sensor 3

Alarm 1 Alarm 2 Alarm 3

Fault

Model 1600A-N4X

Muiti-Channel Gas Detection Control System

Power Input

Sensor . . .

Sensor 14

Sensor 15 Sensor 16

Figure 1 Interface Diagram

1600A-N4X Instruction Manual Rev. 0.2 Page 1 of 38

1600A-N4X

2.0 System Configuration

2.1 Hardware Configurations

The Model 1600A-N4X is a “user configurable” alarm controller platform. The basic 1600A-N4X Controller includes the NEMA 4 panel enclosure with Controller Module (including display), Power Supply, two AC and one DC breakers, and a DC over-voltage protection module.

NOTE: I/O modules are normally factory installed unless specifically instructed otherwise. A maximum of 12 I/O modules will fit inside the standard N4X enclosure. I/O Modules are purchased separately.

The available Detcon I/O modules include: Model DA-4 – Four channel analog 4-20mA input module Model RL-4 – Four channel relay output module Model AO-4 – Four channel analog 4-20mA output module

Detcon I/O modules are individually addressable and operate on 11.5-30 VDC. Each module communicates with the controller via the RS-485 Modbus™ RTU protocol. A maximum of 12 I/O modules can be mounted in the N4X enclosure. Other modules need to be mounted in separate enclosures.

Figure 2 System Configurations

2.2 Programming Configuration

The 1600A controllers are normally configured at Detcon based on application specific information provided by the customer on the Configuration Form. It must be verified that the correct quantity and type of I/O modules have been purchased to support the customer’s configuration requirements. On the Configuration Form, the customer should supply all site-specific information pertaining to:

1) Number of gas channels

2) Range, units, and gas type for each channel

3) Alarm level(s) for each gas channel

4) Tag Name for each channel

5) Assignment and set-up information for each relay contact

1600A-N4X Instruction Manual Rev. 0.2 Page 2 of 38

1600A-N4X

NOTE: The set-up configuration is fully field-programmable and can easily be executed by the user in the field, refer to Section 4.0. Modifications to the set-up configuration are expected to take place at the customer’s site due to requirement changes and/or system expansions.

2.3 Specifications

Capacity

User Configurable Up to 16 analog or serial inputs (Model 1600A)

Inputs

Analog 4-20mA (using DA-4 Modules) RS-485 Modbus™ RTU

Outputs

User Configurable: Form C Relay Contacts (using RL-4 Modules) 4-20mA outputs (using AO-4 Modules) Standard: RS-485

Accuracy/Repeatability

Display: < 1% F.S. DA-4: < 1% F.S. AO-4: < 1% F.S.

Power Input

110-230VAC 20-30VDC

Power Consumption

Base 1600A Controller: 20 Watts at 24VDC Total Power is dependent on number of I/O modules, number of gas sensors, and type of gas sensors Total power of unit with I/O modules and gas sensors not to exceed 120 Watts

Display

5 inch diagonal Graphic Backlit LCD with Touch screen

Electrical Classification

NEMA 4 Panel Mount

Dimensions

16''W x 17.85''H x 8.75''D

Operating Temperature Range

0°C to +50°C

Warranty

One year

1600A-N4X Instruction Manual Rev. 0.2 Page 3 of 38

1600A-N4X

3.0 Installation

1. Securely mount the Model 1600A-N4X enclosure.

ALARM RESET

8.75"

17.85"

16.75"

Model 1600A-N4X

Muiti-Channel Gas Detection Control System

12" 16"

Figure 3 Unit Mounting and Dimensional

2. Connect 110/220VAC input wiring to the terminals labeled “ACV (L1)”, “Neutral (L2)”, and “Ground”

(Figure 4). The Power Supply is capable of handling AC inputs from 100-240VAC 50-60Hz without degradation.

WMS1C03

240V-

I ON

10000

I ON

PLUGTRUB

GROUND

24VDC

VAC (L1)

NEU (L2)

Figure 4 AC/DC Inputs

3. If applicable, connect 24 VDC to the terminals labeled “24VDC” and “DC Comm”. This input can be

used for primary power or back-up power in the event of AC power failure. The 24VDC Input voltage should be capable of delivering at least 5Amps of current to the load (120Watt @ 24VDC).

1600A-N4X Instruction Manual Rev. 0.2 Page 4 of 38

1600A-N4X

4. Connect the RS-485 wiring from remotely located I/O devices to the terminals located on the Back Panel.

These terminals are labeled RS-485 “A” (+), “B” (–), and “Shld” (shield) for primary RS-485 communication (Figure 5). RS-485 wiring should consist of a two conductor, shielded twisted pair (Belden cable P/N 9841 is recommended). Also available are two output terminal blocks to provide 24VDC to external RS-485 devices. This power should be used only to power remotely located I/O modules and/or sensors, and should not exceed a total of 3 Amps accumulative for all I/O modules and sensors attached to the controller. (I.E. if there are two modules mounted in the enclosure that have an accumulative current draw of 0.5Amps, the sensors and/or I/O modules connected to the output 24VDC should not exceed 2.5Amps.) Refer to each module and sensor manual for maximum expected current draw from each device.

Part of

TB1

RS-485 VDC Primary Out

Figure 5 RS-485 wiring Terminals

WARNING: Do not attach more devices to the controller power supply than the power supply has the capacity for, as damage may occur to the controller and will void the warranty. Modules and sensors attached to the unit that exceed this 3Amp power rating should be powered by an external power supply capable of handling the extended load.

5. The secondary serial RS-485 port from the controller is connected to a set of Terminal Blocks on the DIN

Rail (Figure 6). The Terminal Blocks are labeled Secondary “A, B & Shld” and can be connected to a PLC, PC/HMI, DCS, or other Modbus™ master polling serial communications device, refer to Secondary Modbus™ Port Section 5.5.

Part

TB1

Figure 6 Interface Wiring

RS-485

RESET

Second

1600A-N4X Instruction Manual Rev. 0.2 Page 5 of 38

1600A-N4X

3.1 1600A Interface Board

The 1600A Interface Board Figure 8 is connected to a set of Terminal Blocks on the DIN Rail (Figure 6 and Figure 7.) The Terminal Blocks are labeled “NO COMM” “C”, “NO” and “NC”. The Interface PCA, mounted on the back of the Display Panel, will de-energize the No Comm/Fault relay in the event there is a Communication Fault with any activated device. A ‘No Communication Fault’ condition will create a ‘short’ between the ‘Common’ and ‘Normally Closed’ contacts, and create an open between the ‘Normally Open’ and ‘Common’ relay contacts. This is required for fail-safe operation. There is a two-minute delay before any active device will trigger a no communication condition.

GROUND

nd Stud)

TB1

Green/Yellow

16AWG Grounds

Green/Yellow

White

Green/Yellow

WMS1C03 240V-

10000

I ON

WMS1C03 240V-

I ON

White

Black

10000

COMMUNICATIONS

MODULE

Blue

White

Black

Red

PLUGTRUB

2.6

2.7ML+

7 8 9

L+

White

Green/Yellow

Black

+V -V

ABS

Blue

White

Shield

Gray

Orange

Blue

Yellow

ALM

DC ON V.ADJ

+V -V

Gray

2221201918 252423

Orange

Blue

Yellow

Gray

Red

Black

Alarm Reset

SW1

Blue

White

Shield

L+ M

0.0

0.1

0.2

0.3

1L+

PLC

MODULE

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

1.0

Blue

Red

BlueBlue

WhiteWhite

Red

RedRed

10 13

Red

Black

Red

Black

Red Black White

Blue

Blue White Shield

Black Red

0.4

0.5

0.6

0.7

1.0

2L+

1.1

1.2

1.3

1.42M1.5

1.6

Black

RedRed

1514121198

1.1

1.2

1.3

1.4

1.5

1.6

1.7

2.0

2.1

2.2

2.3

2.4

2.5

Black

Ground

VAC (L1)

24VDC

12345

TB2

Red

Blue

White

Red 16 AWG

1 2 3 4 5

RS-485 VDC Primary Out

Red Black

White Blue

Black 16AWG

Red

Black

Red 16AWG

Black 16 AWG

White

Blue

TB2-J1

Red

TB2-J2

SBA-+

RS-485

RESET

Second

Figure 7 Interconnect Wiring Diagram

1600A-N4X Instruction Manual Rev. 0.2 Page 6 of 38

1600A-N4X

GR G

10 11 12

PWR

XPSN

GND SCRN

PWR SCRN

GND PLC

PWR PLC

GND NO

COM FLT

RST

A B

Shld

RST

FAULT

XPSN

RS 4 8 5

NO COMM

ABSHLD

POWER INFAULT / NO COMRESET

NCNOC

Figure 8 1600A Interface PCA

1600A Interface PCA (located on back of Display Panel)

LEDS: RST —This LED is normally off. It glows red when the external reset switch is pressed

FAULT —This LED is normally red. NO COMM —This LED is normally green. It will glow red when a sensor or I/O module is not

communicating. A sensor fault will also cause this LED to glow red.

POWER IN —This LED will glow green when the system is powered on.

Terminal Block Inputs: XPSN PWR +24VDC connection for PLC expansion module

XPSN GND Ground connection for PLC expansion module SCRN PWR +24VDC connection for touch screen SCRN GND Ground connection for touch screen NO COM PLC output that is set to +24VDC when a NO COMM or senor fault condition occurs FLT Not used RST Input from external reset switch A Primary Modbus ‘A’ connection B Primary Modbus ‘B’ connection SHLD Primary Modbus shield connection. Not used.

3.2 Remote Alarm Reset Switch

The unit includes connections for an optional Remote Alarm Reset Switch. A set of Terminal Blocks is supplied for the connection of a Remote Alarm Reset Switch that can be mounted anywhere outside the unit. The Remote Alarm Reset incorporates a set of normally closed contacts that cause the unit to reset the Alarms when contact is broken. To install a Remote Reset Switch the jumper between terminal blocks 8 and 9 (labeled “Remote Reset”) must be removed and the switch wired to these terminals. Connect only a normally

1600A-N4X Instruction Manual Rev. 0.2 Page 7 of 38

1600A-N4X

closed switch to these terminal blocks. If more than one switch is to be connected, the switches must be connected in series.

NOTE: The Remote Alarm Reset switch should be a ‘Normally Closed’ Switch and should be wired as such. Failure to wire the switch correctly will cause the Enclosure Alarm Reset and all subsequently connected Remote Alarm Reset Switches to be non operational.

3.3 Installing I/O Modules

A maximum of 12 I/O modules may be installed in the 1600A NEMA 4 enclosure. Additional modules should be mounted in a separate enclosure.

I/O modules are mounted on industry-standard 37.5 x 7.5 mm din-rail. Install the first I/O module on the left side of the din-rail. Plug the Female Connector (TB2-J1) from the RS-485 Output Terminal Blocks onto the Left Most Module. Slide it all the way to the left side stop. Add additional modules to the right. When installing additional I/O modules, make sure there is about 0.5 inch clearance on either side of the module and snap the module onto the din rail (the 0.5” spacing is to allow for connector clearance). Once the I/O module is snapped onto the din-rail, slide it to the left and assure that it firmly plugs into the next module. The unit will accommodate up to 12 I/O Modules. Additional modules should be mounted in a separate enclosure. Connect the RS-485 and Power Connector to the last module installed on the right side of the Din Rail. Secure End-Stop.

COMM

M S D

L S D

RELAY

Add Additional Modules as needed. Maximum of 12 Modules.

COMM

M S D

L S D

4-20mA

INPUT

COMM

M S D

L S D

4-20mA

INPUT

SBA-+

RS-485 and Power CableRS-485

TB2-J1 TB2-J2

COMM

RELAY

Cable to Output Terminal Blocks.

RELAY

Figure 9 I/O Module Installation

NOTE: The TB2-J1 Connector must be plugged into to the I/O Module on the left hand side of the Din

Rail. If this connector is not properly installed, communication with other RS-485 devices will not be possible. Refer to Secondary Modbus™ Port Section 5.5

NOTE: If no I/O Modules are installed in the unit TB1-J1 and TB1-J2 must be plugged into each other for the RS-485 to communicate.

For addressable I/O modules or Modbus™ sensors that are being located remotely from the Model 1600AN4X controller use Belden 1502P cable for serial and power connections. For serial only connections use Belden 9841 cable.

3.4 Connecting to the I/O Modules

4-20mA Gas Sensors

Connect 4-20mA type gas sensors to the Model DA4 4-20mA input modules. There are four 4-20mA inputs in each Model DA4 module.

1600A-N4X Instruction Manual Rev. 0.2 Page 8 of 38

1600A-N4X

Figure 10 Model DA-4 and 4-20mA Gas Sensor Connections

Sensor 4

S D

L S D

4-20mA

INPUT

COMM

Sensor 3

Typical Sensors

Sensor 2

Sensor 1

Figure 11 Model DA-4 and 4-20mA Gas Sensors

RS-485 Modbus™ Gas Sensors

Connect the five wires from the Modbus™ gas sensors (Detcon Model 600 and Model 700 Series types) to the din rail mounted terminals labeled RS-485 “A”, “B”, and “Shld” and VDC “+” and “-”. Note: the controller power supply is only capable of handling 3Amps accumulative. If the external sensors plus the controller’s internal modules exceeds this rating, only three wires (RS-485 “A”, “B”, and “Shld”) should be used and a remote DC power source should be utilized to provide DC power for the remote mounted gas sensors.

NOTE: A 120: end of line resistor should be installed on the last gas sensor in the serial loop to enhance communications reliability.

1600A-N4X Instruction Manual Rev. 0.2 Page 9 of 38

1600A-N4X

Figure 12 Modbus™ Gas Sensor Connections

Relay Output Contact Modules

There are four ‘Form C’ 5 Amp relay contacts in each Model RL4 module. These can be used to control annunciating devices or as signal inputs to other control devices. Connections to the relay contacts of the Model RL4 module are shown in Figure 13. Note that the 5Amp rating of the relay contact should not be exceeded.

Figure 13 Model RL-4 Relay Module

4-20mA Output Modules

There are four 4-20mA outputs in each Model AO-4 module. These can be used as signal inputs to other control devices. Connect to the AO-4 modules as shown in Figure 14:

1600A-N4X Instruction Manual Rev. 0.2 Page 10 of 38

1600A-N4X

Figure 14 Model AO-4 Module

General Wiring Notes:

 When I/O Modules are located at a remote distance from the controller, an end-of-line terminating resistor

is required to enhance communications reliability. Identify the last I/O Module in the loop, and open the module casing using the clip release points. Locate and install the jumper on JP6 (TERM) Figure 15. This adds a 120: resistor to the end of the line. If applicable, add a 120: resistor to the last Modbus™ gas sensor.

 Follow generally accepted guidelines for RS-485 serial networks. Do not wire I/O Modules and/or

Modbus™ gas sensors in long-distance ‘T-Tap’ configurations. Stay with direct serial configurations. See Appendix A for serial communications configuration guidelines.

 Use Detcon Recommended cabling whenever possible.

x Belden P/N 1502P cable is recommended for a single cable providing serial communications and

power.

x Belden 9841 cable is recommended for a single cable providing serial communications only.

 Ground the cable shielding at the Model 1600A-N4X Controller only. Other points of grounding may

cause a ground loop, and induce unwanted noise on the RS-485 line, which in turn may disrupt communications.

Jumper located

on component

side of PCB

Figure 15 Location of Termination jumper (JP6)

1600A-N4X Instruction Manual Rev. 0.2 Page 11 of 38

1600A-N4X

3.5 Initial Power Checks

Before applying power, make sure that all I/O Modules are correctly installed and that all wiring connections between I/O modules and external devices are made correctly.

NOTE: Applying power with devices hooked up incorrectly may cause damage.

Turn the applicable AC and DC Breaker Switches to the ON positions. Verify that the main touch-screen LCD comes on displaying gas readings. After 5 seconds, verify that all the I/O modules are being polled by observing a sequence of blinking LED’s on the I/O Modules representing successful serial communication.

NOTE: The polling of the input devices takes place more frequently than the communications to the relay output devices. The sequence of polling communication will follow the order of the I/O device switch addresses.

3.6 Setting Device Identification on the I/O Modules

NOTE: If the Model 1600A controller has been configured at Detcon, it may be possible to skip to the

Operator Interface (Section 4.0) for further review of system operation.

I/O modules must be serially addressed to establish correct communications. All I/O Modules are addressed in Hexadecimal. The I/O module’s address is established by setting the two rotary switches to the correspondingly correct position. The top rotary switch sets the Most Significant Bit (MSB). The bottom rotary switch sets the Least Significant Bit (LSB). For an address of 01, set the top switch (MSB) to 0 and the bottom switch (LSB) to 1. See Appendix B for Decimal to Hexadecimal conversion.

NOTE: All addresses must be unique. There can be no duplication of addresses or a failure to communicate will occur.

COMM

M S D

L S D

RELAY

COMM

M S D

L S D

RELAY

COMM

M S D

L S D

RELAY

M S D

L S D

RELAY

M S B

M S D

L S D

4-20mA

INPUT

M S D

L S D

4-20mA

INPUT

M S D

L S D

4-20mA

INPUT

COMM

L S

4-20mA

INPUT

Figure 16 Setting Device Addresses

1600A-N4X Instruction Manual Rev. 0.2 Page 12 of 38

1600A-N4X

4.0 Setup

4.1 Program Menu Selections

To enter the Program Menu touch Program Menu and see Passwords in Section 5.4.

NOTE: If any configuration changes are made to the system, the Modbus™ must be reset to ensure the system operates normally. See section 5.3 for more information.

Figure 17 Program Menu

4.1.1 Channel Setup

The individual Channel set up screen is used to activate/disable each channel for which the 1600A is currently programmed. The 1600A has a maximum of 16 active input channels (Channel Setup, Figure 18). This number must be consistent with the number of sensors and I/O modules connected to the system. Activating more channels than are attached to the Modbus™ will cause a “Communication Fault”, and should not be attempted. It is possible, however, to activate fewer channels than are attached to the Modbus™.

Figure 18 Channel Setup

The ‘Individual Channel Setup’ screen (Figure 19) is used Activate, Label/Tag, set Alarm 1, Alarm 2, Alarm 3, and Relays for Alarms, and set the Range, Units, and Gas type. Press ‘ENTER’ after the appropriate

1600A-N4X Instruction Manual Rev. 0.2 Page 13 of 38

1600A-N4X

selections have been made for the current active gas channel. The Channel Information is displayed for the current channel being set-up. To exit the channel touch MAIN, Channel Setup, PREV or NEXT. To exit Channel Setup touch Program Menu or Main.

Figure 19 Individual Channel Setup

Channel Activation: If the channel is active, touch the ACTIVE button to disable it; touch the ENTER button

to save change. If the channel is disabled, touch the DISABLED button to activate it; touch the ENTER button to save change. The main display will show “DISABLED” if a channel is selected as disabled.

Tags/Labels: The Main, Zone 2 and individual channel screens displays the current tag names assigned to each active gas channel. To add or change a Tag Name, enter Channel Setup, press channel you wish to change, press the current tag/label, type the new tag on the screen, press “ ” (enter key on on-screen keyboard). When each entry in the channel setup screen is complete, press the ‘ENTER’ key to save the entry.

Alarm 1, 2, 3: Set point, direction, and relay assignments are all handled in the 3 alarm blocks. The Set points are changed by touching the value window below each alarm designation. The example shown in figure 17 is 10 for ALARM 1, 20 for ALARM 2, 50 for ALARM 3. Touch the current value window, enter the new value on the screen touch pad, touch ENTER to save change. Touching the Ascend and Descend window will toggle between Ascend and Descend. Each Alarm has up to two relays assigned to it. To change a relay assignment touch the relay window, enter the new relay on the screen touch pad, touch “ “, touch ENTER to save change.

NOTE: Relay output assignments can be set as discrete or common and a relay can be used as many times as desired. However, relay outputs can only be set up one way (relative to latching, energized, silence able) and will be applied in that way for every function they are assigned.

NOTE: The relay state configuration for latching/unlatching, energized/non-energized, and silenceable / non-silenceable is set in the RELAY OUTPUT on the PROGRAM MENU. See section 4.1.3.

Range: To change the range of a channel touch the MIN or MAX window, enter the new value on the screen touch pad, touch “”, touch ENTER to save change.

Units: To change the units of a channel touch the UNIT window, select the new unit (% or PPM) on the screen touch pad, touch “”, touch ENTER to save change.

Gas Type: To change the Gas Type touch the GAS window, Select Gas Type from the selection on the screen touch pad, touch “”, touch ENTER to save change.

1600A-N4X Instruction Manual Rev. 0.2 Page 14 of 38

1600A-N4X

Press the ‘ENTER’ key after the completed set-up selections for each gas channel are made

4.1.2 DA4 set up

Touch the Analog Input/DA4 button. This function enables up to 4 DA4 modules. They are identified as CH 1-4, CH 5-8, CH 9-12, and CH13-16. There are four sensor inputs for each DA4 module, labeled 1 – 4. The address for each module is:

CH 1-4 01 Hex CH 5-8 05 Hex CH 9-12 09 Hex CH 13-16 0D Hex

The DA4 menu is entered by pressing the Analog Input from the Program Menu. Channels 1 thru 4 are in Module 1-4. Channels 5 thru 8 are in Module 5-8 and so on. Simply press the Module button for each module you wish to enable. When done press the Program Menu button.

S D

L S D

4-20mA

INPUT

COMM

Sensor 3

Typical Sensors

Sensor 2

Figure 20 Addressing DA Modules

Sensor 4

Sensor 1

Figure 21 DA4 / Analog input Activation

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Example: The 1600A is to be set up for two Model DA4 input modules. Make sure that the switch setting for

the first Model DA4 module is set to 01, representing the first gas input and is wired to terminal connection #1, for position 1 on the module’s wiring connector. The first Model DA4 module would look like this:

CH # DA4 Address 01 thru 04 01 Hex

The second Model DA4 module with identification switches set to 05 and handling sensor inputs 5 – 8, would appear as follows:

CH # DA4 Address 05 thru 08 05 Hex

4.1.3 Relay Activation and Configuration.

The relay output setup is similar to the gas channel setup. The default setting for the relays as shown in Figure 1 is for all relays to be in “Off” status. Press the “CH1-4 OFF” key for the CH1-4 box to use the first RL4 module. Note the block now shows as “CH1-4 ON”. The second part of Relay Setup requires the decision of how the individual relay contacts will be configured. Press the block labeled “CONFIGURE CH 1-4”, and a relay setup screen will appear. Each relay must be selected as latching or non-latching, energized or nonenergized, and silenceable or non-silenceable. These selections are shown in three small blocks to the right of the Relay # input. Make selections by pressing the buttons on screen (Figure 1). Entries are saved automatically when exiting the screen by pressing MAIN or Device Setup. Continue this sequence for all other relays

Figure 22 Addressing Relay Modules

Figure 23 Activating Relay Outputs

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Figure 24 Setting up Relay Outputs

NOTE: This selection controls the output state for that relay regardless of how many alarm/fault

conditions for which the relay output may be used. A single relay output can only be set up in one configuration.

The set-up for the first Model RL4 module would look like this:

Relay # RL4 Address

01 thru 04 41 Hex

The second Model RL4 module set to 69 (45Hex) and handling relays 5 – 8, would appear as follows:

Relay # RL4 Address

05 thru 08 45 Hex

4.1.4 Serial Inputs

Activating Serial Inputs

The 1600A can handle 16 serial inputs from either a model 600 or model 700 series sensor. To activate the serial inputs enter Program Mode. Touch the Serial Sensors button to read “Serial Sensors 700 Series” or toggle to “Serial Sensors 600 Series”. This is a global command and as such all sensors must be either 600 or 700 series. See Figure 25, touch the Serial button, and select each channel that is to be enabled or disabled, Figure 26.

WARNING: If the wrong 600/700 selection is made while sensors are connected, The Modbus may need to be reset to re-initialize Modbus communications. Refer to the “Modbus Reset” function in the SCREEN UTILITIES menu to re-start Modbus™ polling (Section 5.3).

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Figure 25 Accessing Serial Setup

Figure 26 Serial Setup screen

Addressing Serial Sensors

When connecting to a Detcon Model 600 or Model 700 Series sensor, the addressing procedure is different. First, note how the gas sensors are addressed. Each sensor must be set to a different address. The addresses start from 01 and count up to 16 (hex 10). An example is shown below to explain the procedure. To address the gas sensors, set the following:

CH # Sensor Address CH # Sensor Address 01 01 Hex 09 09 Hex 02 02 Hex 10 0A Hex 03 03 Hex 11 0B Hex 04 04 Hex 12 0C Hex 05 05Hex 13 0D Hex 06 06 Hex 14 0E Hex 07 07 Hex 15 0F Hex 08 08 Hex 16 10 Hex

NOTE: the CH# is the gas channel number displayed on the Main Display. The sensor address is the serial ID address (in Hexadecimal) set at the 600 or 700 Series sensor.

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NOTE: The 1600A Device # is in decimal format, and the serial address switch setting for the 600 or 700

Series Sensor is in hexadecimal format. This means that device number 10 decimal on the 1600A corresponds to the 600 or 700 Series Sensor at address 0A hexadecimal.

4.1.5 4-20mA Output Setup

This menu entry is used to address Detcon AO-4 modules 4-20mA output.

NOTE: If there are no AO-4 modules being used, do not enter any device and address information on this screen. Misinformation entered here will cause the controller to generate a ‘No Communication Fault’.

Figure 27 Set-up 4-20mA Outputs

Make sure to set each AO-4 module to a unique module address using the front panel switches. The values should be as follows:

CH# AO4 Address

01 thru 04 81 Hex 05 thru 08 85 Hex 09 thru 12 89 Hex 13 thru 16 8D Hex

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5.0 System Operation

5.1 Using the Touch-screen Display

The Operator Interface is conducted through a graphic touch-screen backlit display. A suitable small blunt device such as the Detcon stylus wand should be used to conduct touch-screen interaction.

NOTE: Sharp objects such as pens, pencils, screwdrivers, etc, are not permissible as they may permanently damage the display and will void the warranty. The use of fingertips to activate keys is permissible, but is difficult due to the small press key areas in some cases. A pencil’s eraser tip is a suitable alternative.

In general, displayed items that are outlined with a box represent Press Keys. Press Keys should be firmly pressed down for about 0.5 seconds to engage properly. The outline of the key will change momentarily when activated properly.

The graphic display is back lit. The contrast can be adjusted using the ‘Screen Utilities’ function described in section 5.3.

5.2 Main Display

The main display shows the status of the active gas channels. They are labeled by channel number, reading, units, and gas type. Example: CH1 - 0ppm - H2S – User Tag – (F, NC, C). When there is an active alarm or fault condition, the channel in alarm will be shown in reverse video. A channel number in flashing reverse video represents a channel that is actively in alarm/fault/No Comm or has cleared alarm but was set to latching mode in the relay output. A Fault will also be represented by the letter “F” flashing after the user tag. A No Comm condition will also be represented by the letters “NC” flashing after the user tag. An in-cal condition will be represented by the letter “C” flashing after the user tag.

Figure 28 Main Display

Channels are displayed in groups of eight per screen, called ‘Zones’. The ‘Zones’ are represented by a key at the bottom of the main display as Main or Zone 2 for the 1600A. To view a particular ‘Zone’, press the appropriate key on the screen. During normal operation, the display will rotate between zones at 10-second intervals, displaying each zone for 10 seconds and moving on to the next zone.

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The controller may be configured to have less than eight channels per ‘Zone’. Only those ‘Zones’ with active channels will be displayed. Channels that have been disabled will show “DISABLED” in lieu of sensor information. When any channel in a ‘Zone’ has an alarm or fault condition the controller will automatically display the channels in that ‘Zone’. When there are alarms or faults in multiple ‘Zones’, the controller will display each zone for 10 seconds and rotate to the next ‘Zone’. The display will continue to rotate through each ‘Zone’ until a ‘Zone’ key is selected by the user.

The main function keys reside across the bottom of the Main Display area. They are: Main or Zone 2, Program Menu, Alarm Reset, Alarm Silence, and Cal Mode.

Program Menu requires a username and password to logon (see Passwords in Section 5.4) and takes the operator to the functions for configuration and set-up.

Alarm Reset is used to reset all relay output contacts that have been set up as “latching” outputs, only after the condition has cleared. If the alarm condition has not cleared, then the Alarm Reset will not reset the relay output. If no alarms have been set-up as “latching” then the Alarm Reset has no function.

NOTE: Alarm Reset can also be accomplished using an externally mounted Alarm Reset switch.

Alarm Silence is used to reset all relay output contacts that are in an active alarm state. Alarms that have been

silenced will remain silenced until they clear or another alarm is triggered. Once cleared, the alarms will fire again if the alarm condition repeats.

Cal Mode is used to disable all relay outputs so that the user can go off-line and calibrate the gas sensors without activating any alarm devices. After pressing Cal Mode, the button converts to an alternating display of “IN CAL” and “60-minute” countdown cycle, and the gas channels switch to reporting “IN CAL” to let the user know the system has been temporarily taken out of service. At the conclusion of the 60-minute cycle, the unit will automatically return to normal operating mode and all relay outputs will become activated again. Any time during the 60-minute countdown the user can return to normal operating mode by pressing the Cal Mode button again.

5.3 Touch Screen Utilities

This menu item is provided for field adjustment of the LCD screen contrast and provides the means to readjust calibration of the graphic touch screen should this become necessary. The Touch Screen Utilities key is located at the bottom center of the Program Menu Screen (Figure 17) and is accessed by pressing the touch key. Adjust the screen contrast using the up and down arrows.

Figure 29 Screen Utilities

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Transfer Mode

To place the 1600A in transfer mode, press the “TRANSFER” key. The system will begin shutting down and automatically go into transfer mode. Transfer mode allows the user to load critical updates from Detcon, Inc to the touch screen.

Clean Screen

The touch screen can be cleaned while the 1600A-N4X is operational. To do this, the user must press the “CLEAN SCREEN” key. Once the cleaning screen is activated, touch screen operation is locked for 30 seconds. During this time period the user may clean the screen as needed. The time remaining for the lockout is indicated by a progress bar.

Reset Modbus

In the event of a Modbus™ communication error, press the “RESET MODBUS” key to restart Modbus polling.

Modbus Diagnostics

To view the status of slave devices, relay modules, and analog output modules, press the “MODBUS DIAGNOSTICS” key. Modbus diagnostics will generate a two page list, displaying real-time status, of 16 slave devices, 4 relays modules, and 4 analog output modules.

Supervisory Modbus

When using the 1600A as a Modbus slave, press the “SUPERVISORY MODBUS” key to adjust Modbus slave settings. See section 5.5 for Modbus slave settings.

Figure 30 Supervisory Modbus Setup

5.4 Password Protection

A simple form of Program Menu protection is provided to the end-user. This will allow the user to functionally operate the unit, but will not allow the user the capability to change any important configuration parameters.

When switching between the unprotected mode and the Program Menu protected mode, the user must touch Program Menu, the User window(Figure 31Error! Reference source not found.), type ABCD, press “”, touch the Password window, type ABCD, press “” (Figure 32 Error! Reference source not found.), touch

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Figure 31 On-Screen Keyboard

Figure 32 Password Screen

5.5 Secondary Modbus™ Port

Model 1600A controllers feature Modbus™ compatible communications protocols and are addressable by a PLC, PC/HMI, DCS, or other Modbus™ RTU master device. Communication is accomplished by two wire half duplex RS-485, 9600 or 19,200 baud, 8 data bits, 1 stop bit, no parity, with the 1600A Controller secondary port setup as a slave device. Wiring should be brought directly to the back of the controller (See section 3.0 and). A Modbus™ RTU master device up to 4000 feet away can theoretically poll up to 64 different controllers. This number may not be realistic in harsh environments where noise and/or wiring conditions would make it impractical to place so many devices on the same pair of wires. If a multi-point system is being utilized, each controller must be set to a different device address.

Modbus™ Register Detail: Read Holding Registers is the only code supported by the 1600A controllers. The 1600A contains 21 holding registers that reflect the status its 16 channels. The register data is shown below.

40000 Channel 1 Reading 40001 Channel 2 Reading

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40002 Channel 3 Reading 40003 Channel 4 Reading 40004 Channel 5 Reading 40005 Channel 6 Reading 40006 Channel 7 Reading 40007 Channel 8 Reading 40008 Channel 9 Reading 40009 Channel 10 Reading 40010 Channel 11 Reading 40011 Channel 12 Reading 40012 Channel 13 Reading 40013 Channel 14 Reading 40014 Channel 15 Reading 40015 Channel 16 Reading

40016 Fault Status Bits

High Byte Bit 7 1 = Channel 16 Fault 0 = Channel 16 no Fault Bit 6 1 = Channel 15 Fault 0 = Channel 15 no Fault Bit 5 1 = Channel 14 Fault 0 = Channel 14 no Fault Bit 4 1 = Channel 13 Fault 0 = Channel 13 no Fault Bit 3 1 = Channel 12 Fault 0 = Channel 12 no Fault Bit 2 1 = Channel 11 Fault 0 = Channel 11 no Fault Bit 1 1 = Channel 10 Fault 0 = Channel 10 no Fault Bit 0 1 = Channel 9 Fault 0 = Channel 9 no Fault Low Byte Bit 7 1 = Channel 8 Fault 0 = Channel 8 no Fault Bit 6 1 = Channel 7 Fault 0 = Channel 7 no Fault Bit 5 1 = Channel 6 Fault 0 = Channel 6 no Fault Bit 4 1 = Channel 5 Fault 0 = Channel 5 no Fault Bit 3 1 = Channel 4 Fault 0 = Channel 4 no Fault Bit 2 1 = Channel 3 Fault 0 = Channel 3 no Fault Bit 1 1 = Channel 2 Fault 0 = Channel 2 no Fault Bit 0 1 = Channel 1 Fault 0 = Channel 1 no Fault

40017 Alarm 1 Status Bits

High Byte Bit 7 1 = Channel 16 Alarm 1 0 = Channel 16 no Alarm 1 Bit 6 1 = Channel 15 Alarm 1 0 = Channel 15 no Alarm 1 Bit 5 1 = Channel 14 Alarm 1 0 = Channel 14 no Alarm 1 Bit 4 1 = Channel 13 Alarm 1 0 = Channel 13 no Alarm 1 Bit 3 1 = Channel 12 Alarm 1 0 = Channel 12 no Alarm 1 Bit 2 1 = Channel 11 Alarm 1 0 = Channel 11 no Alarm 1 Bit 1 1 = Channel 10 Alarm 1 0 = Channel 10 no Alarm 1 Bit 0 1 = Channel 9 Alarm 1 0 = Channel 9 no Alarm 1 Low Byte Bit 7 1 = Channel 8 Alarm 1 0 = Channel 8 no Alarm 1 Bit 6 1 = Channel 7 Alarm 1 0 = Channel 7 no Alarm 1 Bit 5 1 = Channel 6 Alarm 1 0 = Channel 6 no Alarm 1 Bit 4 1 = Channel 5 Alarm 1 0 = Channel 5 no Alarm 1 Bit 3 1 = Channel 4 Alarm 1 0 = Channel 4 no Alarm 1 Bit 2 1 = Channel 3 Alarm 1 0 = Channel 3 no Alarm 1 Bit 1 1 = Channel 2 Alarm 1 0 = Channel 2 no Alarm 1

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Bit 0 1 = Channel 1 Alarm 1 0 = Channel 1 no Alarm 1

40018 Alarm 2 Status Bits

High Byte Bit 7 1 = Channel 16 Alarm 2 0 = Channel 16 no Alarm 2 Bit 6 1 = Channel 15 Alarm 2 0 = Channel 15 no Alarm 2 Bit 5 1 = Channel 14 Alarm 2 0 = Channel 14 no Alarm 2 Bit 4 1 = Channel 13 Alarm 2 0 = Channel 13 no Alarm 2 Bit 3 1 = Channel 12 Alarm 2 0 = Channel 12 no Alarm 2 Bit 2 1 = Channel 11 Alarm 2 0 = Channel 11 no Alarm 2 Bit 1 1 = Channel 10 Alarm 2 0 = Channel 10 no Alarm 2 Bit 0 1 = Channel 9 Alarm 2 0 = Channel 9 no Alarm 2 Low Byte Bit 7 1 = Channel 8 Alarm 2 0 = Channel 8 no Alarm 2 Bit 6 1 = Channel 7 Alarm 2 0 = Channel 7 no Alarm 2 Bit 5 1 = Channel 6 Alarm 2 0 = Channel 6 no Alarm 2 Bit 4 1 = Channel 5 Alarm 2 0 = Channel 5 no Alarm 2 Bit 3 1 = Channel 4 Alarm 2 0 = Channel 4 no Alarm 2 Bit 2 1 = Channel 3 Alarm 2 0 = Channel 3 no Alarm 2 Bit 1 1 = Channel 2 Alarm 2 0 = Channel 2 no Alarm 2 Bit 0 1 = Channel 1 Alarm 2 0 = Channel 1 no Alarm 2

40019 Alarm 3 Status Bits

High Byte Bit 7 1 = Channel 16 Alarm 3 0 = Channel 16 no Alarm 3 Bit 6 1 = Channel 15 Alarm 3 0 = Channel 15 no Alarm 3 Bit 5 1 = Channel 14 Alarm 3 0 = Channel 14 no Alarm 3 Bit 4 1 = Channel 13 Alarm 3 0 = Channel 13 no Alarm 3 Bit 3 1 = Channel 12 Alarm 3 0 = Channel 12 no Alarm 3 Bit 2 1 = Channel 11 Alarm 3 0 = Channel 11 no Alarm 3 Bit 1 1 = Channel 10 Alarm 3 0 = Channel 10 no Alarm 3 Bit 0 1 = Channel 9 Alarm 3 0 = Channel 9 no Alarm 3 Low Byte Bit 7 1 = Channel 8 Alarm 3 0 = Channel 8 no Alarm 3 Bit 6 1 = Channel 7 Alarm 3 0 = Channel 7 no Alarm 3 Bit 5 1 = Channel 6 Alarm 3 0 = Channel 6 no Alarm 3 Bit 4 1 = Channel 5 Alarm 3 0 = Channel 5 no Alarm 3 Bit 3 1 = Channel 4 Alarm 3 0 = Channel 4 no Alarm 3 Bit 2 1 = Channel 3 Alarm 3 0 = Channel 3 no Alarm 3 Bit 1 1 = Channel 2 Alarm 3 0 = Channel 2 no Alarm 3 Bit 0 1 = Channel 1 Alarm 3 0 = Channel 1 no Alarm 3

40020 Cal Status Bits

High Byte Bit 7 1 = Channel 16 Cal 0 = Channel 16 no Cal Bit 6 1 = Channel 15 Cal 0 = Channel 15 no Cal Bit 5 1 = Channel 14 Cal 0 = Channel 14 no Cal Bit 4 1 = Channel 13 Cal 0 = Channel 13 no Cal Bit 3 1 = Channel 12 Cal 0 = Channel 12 no Cal Bit 2 1 = Channel 11 Cal 0 = Channel 11 no Cal Bit 1 1 = Channel 10 Cal 0 = Channel 10 no Cal Bit 0 1 = Channel 9 Cal 0 = Channel 9 no Cal Low Byte

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Bit 7 1 = Channel 8 Cal 0 = Channel 8 no Cal Bit 6 1 = Channel 7 Cal 0 = Channel 7 no Cal Bit 5 1 = Channel 6 Cal 0 = Channel 6 no Cal Bit 4 1 = Channel 5 Cal 0 = Channel 5 no Cal Bit 3 1 = Channel 4 Cal 0 = Channel 4 no Cal Bit 2 1 = Channel 3 Cal 0 = Channel 3 no Cal Bit 1 1 = Channel 2 Cal 0 = Channel 2 no Cal Bit 0 1 = Channel 1 Cal 0 = Channel 1 no Cal

5.6 Firmware Upgrade

The 1600A-N4X is capable of firmware upgrades for both the PLC and touch screen device. Upgrades will be performed by the user. The following components are needed to perform firmware upgrades:

o ProSave Software (Download free from http://www.siemens.com o S7-200 USB PPI cable o S7-200 Memory cartridge o DB9 Gender Changer

)

Figure 33 S7-200 USB/PPI Cable

5.6.1 Touch Screen Upgrade

1. Disconnect blue DB9 cable from PLC Communications Module (Figure 34).

2. Using a Gender Changer, connect the USB/PPI cable to the DB9 Cable disconnected from the PLC

Communications Module, and connect the USB end of the USB/PPI cable to a PC or laptop.

3. From the touch screen display, switch to transfer mode by selecting:

Program Menu Ź Screen Utilities Ź Transfer

4. Open ProSave software on PC or laptop:

Start Ź All Programs Ź Simatic Ź ProSave Ź ProSave

5. Click on the “General” tab.

6. Under "Device Type", select TP 177A 6”.

7. Under "Connection", select Serial (via USB-PPI cable) for connection.

8. Click on the “Restore” tab.

9. Select the firmware file named “Detcon_1600AN1P_HMI_vXX.psb”.

XX represent current version.

10. Ensure that “Booting” check box is unchecked.

11. Press “Star Restore” to start the firmware upgrade.

NOTE: This operation may take some time, depending on the type of connection selected.

NOTE: Before entering Program Menu, an appropriate username and password may be required.

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12. “Downloading successful” will display on the ProSave software once firmware upgrade has

completed.

13. Remove USB/PPI cable from touch screen.

14. Cycle the power on the Model 1600A.

15. Verify the proper touch screen firmware version has been loaded.

Touch screen version can be found in the top right corner of the “Screen Utilizes” menu. Program Menu Ź Screen Utilities: HMI v.XX

5.6.2 PLC Upgrade

1. Install memory cartridge with new firmware (refer to Figure 34 for memory cartridge location).

2. Cycle the power on the Model 1600A.

Firmware and CPU configuration are copied to the system once the system power cycles. This operation takes approximately 15 seconds.

3. Once the 1600A power has been cycled and the unit has returned to normal operation, remove memory cartridge.

NOTE: Powering on a PLC with a blank memory cartridge, or a memory cartridge that was programmed in a different model of PLC will cause an error.

4. Verify the proper PLC firmware version has been loaded.

PLC version can be found in the top right corner of the “Screen Utilizes” menu.

Program Menu Ź Screen Utilities: PLC v.XX

J1J2J3

NCNOC

FLT/COMMRESET POWER

ABSHLD

RS-485

XPSN

PWR

XPSN

GND

1345678

SCRN

PWR

SCRN

GND

PLC

PWR

PLC

GNDNOCOM

FLT

RST

101211

USB/PPI cable to

Touch Screen

9-Pin Male

connector

Memory cartridge

Figure 34 Display Back Panel

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6.0 Spare Parts

Recommended spare parts list:

Detcon Part # Description

975-041400-000 RL-4 Relay Module (As applicable) 976-041400-000 DA-4 4-20mA Input Module (As applicable) 975-041401-000 AO-4 4-20mA Output Module (As applicable) 320-283934-700 VAC (230VAC) Over Voltage Module 320-283931-800 VDC (24VAC) Over Voltage Module 360-SWS150-024 24VDC Power Supply

7.0 Warranty

Detcon, Inc., as manufacturer, warrants under intended normal use each new Model 1600A-N4X controller to be free from defects in material and workmanship for a period of one year from the date of shipment to the original purchaser. Should the controller fail to perform in accordance with published specifications within the warranty period, return to Detcon, Inc., for necessary repairs or replacement. All warranties and service policies are FOB the Detcon facility located in The Woodlands, Texas.

The over-voltage protection modules are designed to fail preferentially based on lightening strikes and other abnormal power fluctuations. These are not covered under the warranty policy.

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Appendix A

RS-485 System Integration Wiring

RS-485 is a generic electrical specification only. It does not specify connector types, protocols, or cable type. It is the responsibility of the installer to provide a correct physical installation for the RS-485 network to function properly.

RS-485 is very inexpensive and inherently rugged, allowing multiple devices to communicate over a single twisted pair of wires. Detcon has chosen to implement the Modbus™ protocol using the RS-485 electrical specification.

RS-485 is a two way half-duplex data bus made up of a transceiver (transmitter and receiver). In its simplest form, one transceiver is located on each end of a twisted pair cable of up to 4,000 feet maximum. Data can be sent in either direction, but can only be sent in one direction at a time.

The specification allows for the connection of up to 40 unit loads (UL’s) to the twisted pair. An older transceiver chip would have represented 1 UL. Connection of more than 40 UL’s to the bus will limit the drivers and cause attenuation of the signal, thus preventing the system from operating properly.

Since RS-485 allows multiple devices to be connected to the bus, wiring is not as straightforward as it is in a bus with only 2 devices. The best wiring scheme is the daisy-chain connection from device 1 to device 2 to device 3 to device n. All devices that tap into the bus should not be at the end of long stubs, branches, or ttaps. A true daisy-chain has direct wiring between devices with no minor branches.

Detcon equipment contains four wiring terminals for RS-485 connections: Two for A (+) and two for B (-). All connections should be made directly to these. Figure 3.1 shows an electrical representation of a simple RS-485 bus with 4 transceiver chips.

Figure 35 RS-485 Bus with 4 transceiver chips

The use of a daisy-chain connection will perform the best in all applications given the bus is properly terminated. The RS-485 standard specifies the transceiver characteristics only, not the interconnection of the transceivers themselves. Depending on the environment, distance and other factors it is possible to connect transceivers using flat cable, twisted pair cable, even PCB traces. However, for the most reliable data transfer in industrial environments, shielded twisted pair is required. Wiring of 24 AWG is highly recommended, but 18 to 28AWG can be used.

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The characteristic impedance of the cable must be between 100 to 120 ohms. Twisted pair is used because if the cable does run near a noise source both conductors will pick up the same amount of noise; therefore, effectively canceling it out.

Incorrect Wiring Schemes

Among the biggest problems with an RS-485 bus is the use of incorrect wiring schemes mixed with improper or no line termination.

Most existing installations do not have wire runs in a daisy-chain like fashion; instead, wire runs typically originate from a central point and run to different devices in a star-like pattern. This is a very undesirable way to wire an RS-485 bus. The chances of problem free operation over the life of the equipment decreases dramatically the further you stray from a straight daisy-chain wiring scheme. The bus needs to be terminated at each end of the cable run to operate ideally. Other wiring schemes introduce multiple “cable ends” making it impossible to balance the lines. Wiring as in Figure 36 (A, B & C) would provide reliable data flow. Figures D, E & F could possibly work, but would require many repeaters and an experience worker with RS485 communications and networks knowledge to achieve implementation.

Figure 36 Correct and incorrect wiring schemes

Figure 37 shows a typical RS-485 communication setup using 2-wire digital communication. Each RS-485 loop should have (1) beginning and (1) end, with a 120-ohm resistor at the end of each loop.

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Figure 37 Recommended RS-485 communications set-up

Grounding

Another problem that can occur with RS-485 is incorrect grounding. Neither one of the two conductors in the cable is ground. Both of the conductors are supplying a current to maintain a voltage level relative to an external reference. A third conductor must be supplied to establish a reference through earth ground.

RS-485 is specified be able to work normally with a ±7V ground potential difference and survive ±25V surges. In most applications, the equipment is powered from its own DC power supplies. This is good as long as the supplies are located in the same physical location, and the DC commons are tied together and tied to earth ground.

Problems occur when part of the data bus is powered by one supply and the second part of the bus is powered by a power supply located elsewhere. In this case, earth ground is being relied upon to be the reference between the two sections of the bus. If noise is induced onto the earth ground of one power supply and not the other, data errors may occur. This is even more likely to occur when the distance between ground references is large. A solution to this problem is to install an isolated repeater into the data bus to isolate the grounds from each other, thus enabling the bus to use only one of the two references.

Isolated Repeaters

Repeaters can play many rolls in the implementation of an RS-485 data bus. Repeaters can: 1) Extend the distance if needed to go further than 4000 feet. 2) Allow for the addition of more devices to the bus. 3) Increase signal strength and integrity. 4) Solve grounding problems and solve some of the problems that occur when an incorrect wiring scheme is implemented.

A repeater consists of two transceivers working together. One transceiver is connected to the main data bus and the other transceiver connects to the remainder of the devices as it creates a new and separate data bus. Figure 38 depicts a data bus that implements an undesirable branched wiring scheme. Depending on the length of the taps of slave 1 and slave 2, they may or may not communicate properly back to the master. Long lengths of cable to slaves 1 and 2 create four ends to the cable instead of two, which cannot be balanced with the two terminating resistors on the extreme ends. Without a balanced bus, the long taps of slave 1 & 2 will introduce reflections to the signal that can lead to problematic operation in the field. These problems can be very hard to diagnose, isolate, and fix.

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Figure 38 Unbalanced Data Bus

The addition of 2 repeaters (Figure 39) can solve this problem. The repeaters look like short stubs to the main bus, and at the same time they create 2 new buses that have all the same characteristics as the main bus. Each leg must have termination resistors to balance the new data bus.

Figure 39 Data Bus using two repeaters

Be sure to check the equipment being installed. Some manufacturers include a built-in terminating resistor that can be selected by a jumper or dipswitch. Detcon Model 880 has such a jumper located on the FA-Isonet card. The jumper is labeled “120 ohm Term.”

Detcon 600 series gas sensors and DA1 modules do not include this resistor, and therefore, if one of these devices is the last on the RS-485 bus, a discrete 120 ohm resistor should be placed across the “A” and “B” terminals on the connector board. Figure 40 illustrates the wiring scheme of a repeater when used in a wiring bus with DA-1 devices.

Figure 40 Repeater wiring diagram

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Device Hook-Up

Installation should begin by deciding where devices will be located and how the connections between devices and the master will be established. The ideal scenario would look like Figure 41. The example shows the 880 Controller connected to 11 slave devices using a daisy-chain wiring scheme. This would require 2 different twisted pair cables, one pair for power, and the other for the RS-485 data bus.

Connections would be point-to-point starting at the master and running to the last slave. The RS-485 data cable should come into the sensor enclosure and be connected to the A & B terminals. The next segment of cable should also connect to the A & B terminals and leave the enclosure headed for the next device. The shields must be tied together inside the enclosure and not allowed to short to any other wires or surfaces. The shield should be connected only inside the Model 880 cabinets to the shield terminal. The Rt label in the drawing shows where the termination resistors would be installed.

 

%QPVTQN4QQO



C





D

 





Figure 41 Daisy Chain wiring diagram

Daisy Chain Wiring is ideal, although wiring may already exist or the wiring cannot be run this way for some reason. Figure 42 shows a more realistic wiring situation that may occur.

 



%QPVTQN4QQO



C D









Figure 42 Unbalanced Data Bus

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1600A-N4X

In this case it is impossible to balance the data bus because there is no distinct beginning or end to the cable run. The best way to make this type of installation successful is to install repeaters in a few key areas as shown in Figure 43. Repeaters are used to eliminate the t-taps or stubs, which can cause communication problems. The location and number of stubs will dictate where repeaters need to be installed. Four repeaters are installed to eliminate the stubs.



D

TGRGCVGT





 





TGRGCVGT

TGRGCVGT

%QPVTQN4QQO

C

TGRGCVGT

 

Figure 43 Four repeater Data Bus

Notice there are 5 different data buses that make up the communications network. The first one consists of the master located in the control room, device 09, repeater #1, device 01, device 02, repeater #2, device 03, and device 05. Notice the termination resistors at the beginning and end of this bus section. The second bus starts at repeater #2. It consists of the repeater and device 04. Since this is a new bus, it has terminating resistors at each end. The third bus starts at repeater #1. It includes device 08, repeater #3, device 07, repeater #4, and device 06. It also has its own resistors. The fourth bus starts at repeater #3 and consists of the repeater, device 0A, and the terminating resistors. The fifth bus starts at repeater #4 and consists of the repeater, device 0B, and termination resistors. This configuration isolates all of the t-tap stubs. This configuration should function properly as long as the wire type and proper distances are observed.

The following chart shows an approximation of wire length vs. data speed. Detcon operates its equipment at 19,200bps (baud) and lower.

ODRU

ODRU

ODRU

MDRU

MDRU

MDRU

HV

HV

HV

HV

HV

HV

Figure 44 wire length vs. data speed

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1600A-N4X

Appendix B

Hexadecimal Table

ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2

none

1 0 1 44 2 C 87 5 7 130 8 2 173 A D 216 D 8 2 0 2 45 2 D 88 5 8 131 8 3 174 A E 217 D 9 3 0 3 46 2 E 89 5 9 132 8 4 175 A F 218 D A 4 0 4 47 2 F 90 5 A 133 8 5 176 B 0 219 D B 5 0 5 48 3 0 91 5 B 134 8 6 177 B 1 220 D C 6 0 6 49 3 1 92 5 C 135 8 7 178 B 2 221 D D 7 0 7 50 3 2 93 5 D 136 8 8 179 B 3 222 D E 8 0 8 51 3 3 94 5 E 137 8 9 180 B 4 223 E F

9 0 9 52 3 4 95 5 F 138 8 A 181 B 5 224 E 0 10 0 A 53 3 5 96 6 0 139 8 B 182 B 6 225 E 1 11 0 B 54 3 6 97 6 1 140 8 C 183 B 7 226 E 2 12 0 C 55 3 7 98 6 2 141 8 D 184 B 8 227 E 3 13 0 D 56 3 8 99 6 3 142 8 E 185 B 9 228 E 4 14 0 E 57 3 9 100 6 4 143 8 F 186 B A 229 E 5 15 0 F 58 3 A 101 6 5 144 9 0 187 B B 230 E 6 16 1 0 59 3 B 102 6 6 145 9 1 188 B C 231 E 7 17 1 1 60 3 C 103 6 7 146 9 2 189 B D 232 E 8 18 1 2 61 3 D 104 6 8 147 9 3 190 B E 233 E 9 19 1 3 62 3 E 105 6 9 148 9 4 191 B F 234 E A 20 1 4 63 3 F 106 6 A 149 9 5 192 C 0 235 E B 21 1 5 64 4 0 107 6 B 150 9 6 193 C 1 236 E C 22 1 6 65 4 1 108 6 C 151 9 7 194 C 2 237 E D 23 1 7 66 4 2 109 6 D 152 9 8 195 C 3 238 E E 24 1 8 67 4 3 110 6 E 153 9 9 196 C 4 239 F F 25 1 9 68 4 4 111 6 F 154 9 A 197 C 5 240 F 0 26 1 A 69 4 5 112 7 0 155 9 B 198 C 6 241 F 1 27 1 B 70 4 6 113 7 1 156 9 C 199 C 7 242 F 2 28 1 C 71 4 7 114 7 2 157 9 D 200 C 8 243 F 3 29 1 D 72 4 8 115 7 3 158 9 E 201 C 9 244 F 4 30 1 E 73 4 9 116 7 4 159 9 F 202 C A 245 F 5 31 1 F 74 4 A 117 7 5 160 A 0 203 C B 246 F 6 32 2 0 75 4 B 118 7 6 161 A 1 204 C C 247 F 7 33 2 1 76 4 C 119 7 7 162 A 2 205 C D 248 F 8 34 2 2 77 4 D 120 7 8 163 A 3 206 C E 249 F 9 35 2 3 78 4 E 121 7 9 164 A 4 207 C F 250 F A 36 2 4 79 4 F 122 7 A 165 A 5 208 D 0 251 F B 37 2 5 80 5 0 123 7 B 166 A 6 209 D 1 252 F C 38 2 6 81 5 1 124 7 C 167 A 7 210 D 2 253 F D 39 2 7 82 5 2 125 7 D 168 A 8 211 D 3 254 F E 40 2 8 83 5 3 126 7 E 169 A 9 212 D 4 255 F F 41 2 9 84 5 4 127 7 F 170 A A 213 D 5 42 2 A 85 5 5 128 8 0 171 A B 214 D 6

0 0 43 2 B 86 5 6 129 8 1 172 A C 215 D 7

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1600A-N4X

Appendix C

Revision Log

Revision Date Changes made

0.1 04/1/2009 Unit wiring and firmware changed.

0.2 08/20/2009 Images: revised screen shots and wiring diagram. Added image of 1600A interface board. Text: removed references to DI module, Spare parts no longer in assembly

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