MSA ModCon 75 Instruction Manual

Instruction Manual

ModCon®75 Touch Controller
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece of complex equipment, this instrument will perform as designed only if it is used and serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD SUSTAIN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.
The warranties made by Mine Safety Appliances Company with respect to the product are voided if the product is not used and serviced in accordance wit h the instructi ons in this manual. Please protect yourself and others by follow ing them. We encourage our cus­tomers to write or call regarding this equipment prior to use or for any additional infor­mation relative to use or repairs.
For your local MSA contacts please go to our website www.MSAsafety.com
©MSA 2018 - All Rights Reserved
1000 Cranberry Woods Drive Cranberry Township, PA 16066 USA Phone 1-800-MSA-2222 Fax 1-800-967-0398
(L )-Y Rev 0

MSA Permanent Instrument Warranty

1. Warranty- Seller warrants that this product will be free from mechanical defect or faulty workmanship f or a period of eighteen (18) Months from date of shipment or one (1) yea r f rom installation, whichever occurs first, provided it is maintained and used in accordance with Seller's instructions and/ or re commendations. This warranty does not apply to expendable or consumable parts whose normal life expectancy is less than one (1) y ear such as, but not limited to, non-rechargeable batteries, sen sor elements, filter, lamps, fuses etc. The Seller shall be released from all obligations under this warranty in the event repairs or modifications are made by persons other than its own or authorized service personnel or if the warranty claim results from physical abuse or mi suse of the product. No agent, employee or representative of the Seller has any authority to bind the Seller to any affirmation, representation or warranty concerning the goods sold under this cont ract. Seller makes no warranty concerning components or accessories not manufactured by the Seller, but will pass onto the Purchaser all warranties of manufacturers of such compone nt s. THIS
WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.
2. Exclusive Remedy- It is expressly agreed that Purchaser's sole and exclusive remedy for breach of the above warranty, for any tortious conduct of Seller, or for any other cause of act i on, shall be the repair and/ or replacement at Seller's option, of any equipment or parts thereof, which after examination by S el l er is proven to be defective. Replacement equipment and/ or parts will be provided at no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to successfully repair any nonconforming produ ct shall not cause the remedy established hereby to fail of its essential purpose.
3. Exclusion of Consequential Damage- Purchaser specifically understands and agrees that under no circumstanc es will seller be liable to purchaser for economic, special, incidental or consequential damages or losses of any kind whatsoever, including but not limited to, loss of anticipated profits and any other loss caused by reason of non-operation of the goods. Thi s exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller.
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General Warnings

1. The Controller described in this manual must be installed, operated and maintained in strict accordance with it s labels, cautions, warnings, instructions, and within the l im i tations stated.
2. This is a general-purpose (GP) monitor and can be a source of ignition. Install, locate, and operate only in an area where hazardous atmosphere is not presented in accordance with all applicable codes. Locating the Controller in an area where a hazardou s at m osphere is present can result in ignition of the hazardous atmos phere.
3. Use only genuine MSA replacement parts when performing any maintenance procedures provided in this manual. Failure to do so may seriously impair instrument performance. Repair or alteration of the ModCon75 Touch Controller beyond the scope of these maintenance instructions or by anyone other than authorized MSA service personnel, could cause the product to f ail to perform as designed and persons who rely on this product for their safety could sustain serious personal injury or loss of life.
4. If a portion of the system in which the Controller is installed fails, remaining system functions may not operate properly. In this case, do not use the system until proper repairs are made.

FAILURE TO FOLLOW THESE WARNINGS CAN RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.

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ModCon®75 Touch

Table of Contents

Chapter 1,

Overview ............................................................. 8
Introducing the ModCon75 Touch Controller ..................... 8
The ModCon75 Touch System ........................................... 8
Technical Description ......................................................... 9
Operating Panel .................................................................. 9
I/Os ................................................................................... 10
Communications ............................................................... 10
HMI Application ................................................................ 10

Chapter 2,

Operating Instructions ..................................... 11
Before Installation ............................................................. 11
Safety and Environmental Guideline ................................ 12
......................... 12
Mounting ........................................................................... 12
ModCon75 Touch Controller Panel Cutout ...................... 13
Earth Assembly ................................................................ 13
HMI Panel Mounting ......................................................... 14

Chapter 3,

ModCon75 Touch HMI Panel ........................... 15
Overview ........................................................................... 15
Installation Space Considerations .................................... 16
HMI Panel Mechanical Dimensions .................................. 16
......................... 17
Specifications ................................................................... 17
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Chapter 4,

ModCon75 Touch CPU Module ....................... 20
Overview ........................................................................... 20
CPU Diagram ................................................................... 20
CPU Installation ................................................................ 20
......................... 20
Removing the CPU ........................................................... 22
RS485 ............................................................................... 22
......................... 22
RS485 Wiring ................................................................... 23
RS485 Termination ........................................................... 23
Battery Backup, Installation, and Replacement................ 23
......................... 24
Specifications ................................................................... 25

Chapter 5,

ModCon75 Touch I/O Module .......................... 26
Overview ........................................................................... 26
I/O Module Diagram ......................................................... 26
I/O Bus Connectors .......................................................... 27
......................... 27
I/O Installation ................................................................... 27
Removing the I/O .............................................................. 28
I/O Module Connection Points .......................................... 29
Specifications ................................................................... 29

Chapter 6,

Power Supply Requirements & Wiring ........... 32
Overview ........................................................................... 32
Safety Considerations ...................................................... 32
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......................... 32
Connecting the Power Supply .......................................... 32

Chapter 7,

ModCon75 Touch Wiring ................................. 34
......................... 34
Wiring Procedure .............................................................. 34
Wiring Guidelines ............................................................. 34
I/O Relay Wiring ............................................................... 35
I/O Output’s Power Supply ............................................... 35
......................... 35
Increasing Contact Life Span ........................................... 36

Chapter 8,

Operating Instructions ..................................... 37
Power Up/Main Menu Screen........................................... 37
Touch Screen Buttons ...................................................... 37
Touch Screen Hierarchy ................................................... 38
Add Units Button ............................................................... 38
Password Lock/Unlock ..................................................... 39
......................... 40
View/Edit all X3 Transmitters or Sensors on Network ...... 41
Add/Display Setpoints Button ........................................... 42
......................... 42
Alarm Setup ...................................................................... 43
Latching, Zone Setup ....................................................... 44
Write SP’s ......................................................................... 46
Main Data Screen Button ................................................. 47
Modbus Alarms ................................................................. 48
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Fault Status....................................................................... 49
Remote I/O Editor Button (Optional) ................................ 50
Setting Remote Relay ID and Relay State ....................... 51
Remote I/O Editor Setup .................................................. 51
Remote Relay Power Supply Wiring ................................ 52
......................... 52
Remote Relay Wiring ........................................................ 52
Zone Setpoints Editor Button ............................................ 53
......................... 54
Network Settings Button ................................................... 54
Date & Time Settings ................................................. 54
Active Alarm/Fault Button ................................................. 55
Active/Fault Screen Selection........................................... 55
Password Editor ............................................................... 56

Chapter 9,

Technical Specifications ................................. 58
Specifications ................................................................... 58
Dimensions ....................................................................... 59

Appendix A,

Register Maps ................................................... 61
Critical Memory Bits .......................................................... 61
Memory Integers, MI273 through MI297 .......................... 61
Memory Integers, MI300 through MI449 .......................... 62
Memory Integers, MI450 through MI474 .......................... 66
Memory Integers, MI525 through MI599 .......................... 67
Memory Integers, MI600 through MI624 .......................... 69
Memory Integers, MI650 through MI674 .......................... 70
Table 1 .............................................................................. 71
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Table 2 .............................................................................. 71
Table 3 .............................................................................. 72
Table 4 .............................................................................. 73
Table 5 .............................................................................. 73

Appendix B,

Optional Remote Relay Module ...................... 74
Dimensions ....................................................................... 74
Specifications ................................................................... 75
Jumper Settings ................................................................ 76
I/O Input Jumper Settings ................................................. 77
Communication Port Jumper Settings .............................. 78
RS485 Pin Layout ............................................................. 78
Opening the Remote Relay Module ................................. 79
Closing the Remote Relay Module ................................... 81
Remote Relay Module Mounting ...................................... 81
DIN-rail Mounting .............................................................. 83
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Chapter 1, Overview
Introducing the ModCon75 Touch Controller
The ModCon75 Touch Controller:
is a pre-programmed logic controller with an integral operating panel
self-configuring to Ultima X Gas Monitors with X3 Technology
offers Modbus communications
event logging
operating panels contain a High-Resolution Tou ch S creen:
The Touch screen displays:
o operator instructions o alarms, faults, gas values, and transmitter/sensor tags
o real-time system information.

Figure 1. The ModCon75 Touch Controller

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ModCon®75 Touch
Two types of modules are compatible with M odCon75 Touch Controllers:
o DIN rail I/O Module plugs directly into the back of a ModCon75 Touch Controller for
a self-contained PLC unit with a local I/O config urat ion (integral to ModCon75 Touch Controller).
o Remote Relay Modules can also be easily integrated to greatly extend the
system’s external notification capacity.
These features combine to offer a cost-effective solution for gas detection controller applications requiring:
o operator interface o the ability to control small to medium processes.

Technical Description

ModCon75 Touch Controller

Dimensions :
211.1 x 150.1 x 114.1 mm (8.31 x 5.91 x 4.49")
Mounting:
Panel-mounted via brackets
Power Requirement:
24 VDC controller unit
Real-time Clock (RTC)
Battery Back-up:
Protects real-time clock (RTC) and all data, including variable data.

Operating Panel

Contains a High-Resolution touch screen:
o Touch Screen Displays o 1 Audio-out 3.5mm jack-Not Supported, No Customer Connection o 1 Micro SD slot o 2 type A, USB host ports-Not Supported, No Customer Connection o 1 Mini-B USB device port-Factory use only o 2 Ethernet ports, RJ45, 10/100 Mbps o 1 Power input connector, 24 VDC
Note:
The HMI panel is designed to comply with NEMA 4X, IP66 and IP65 when installed into a NEMA 4X, IP66 and IP65 enclosure. Note however that the Audio Protection Seal must remain plugged in for NEMA 4X, IP66 and IP65, in which case the audio sound level from the internal speaker is significantly reduced.
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I/Os

16 Sink or Source, 24VDC inputs available-Not S upported, No Customer Connection.
9 Zone Relays, Horn, and Fault relay, 24VDC outputs available.
NOTE:
o Inputs are not used in the standard ModCon75 Tou ch Controller.

Communications

RJ45
The controller has two Ethernet ports, which may be used to.
o establish communications with devices to run a remote display o establish Modbus TCP communications
PLC Application
enables the user to perform automation tasks
HMI Application
The HMI application customizes the operato r interface to.
o enable the operator to enter data via the controller touch screen o variables allow the user to display system data on the ModCon75 Touch LCD
screen
o sensor status, tag name and sensor values o I/O status and values
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Chapter 2, Mounting

Before Installation

Check the contents of the Controller Kit.
Kit contains:
o the HMI panel, Figure 6 o the CPU module, Figure 8 o the I/O module, Figure 15 o a three-pin power supply connector o four mounting brackets, each with an inserted sc rew o a rubber seal to be seated in back of the HMI panel

Figure 2. HMI Panel and Mounting Brackets

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ModCon®75 Touch

Safety and Environmental Guideline

This is a general-purpose (GP) monitor and can be a source of ignition. Install, locate, and operate only in an area where hazardous atmosphere is not present and in accordance with all applicable codes.
Do not install in areas with.
o excessive or conductive dust o corrosive or flammable gas o moisture or rain o excessive heat o regular impact shocks or excessive vibration.
Do not place in water or allow water to leak onto the controll er.
Do not allow debris to fall inside the unit during instal lation.
Do not touch live wires.
Double-check all the wiring before turning ON the power supply.
Stay as far as possible from high-voltage cables and power equipment.
Allow a minimum of 0.4” of space for ventilati on between the top and bottom edges of
the controller and the enclosure walls Read and follow all instructions, warnings, and cauti ons pertaining to this controller.
FAILURE TO FOLLOW THESE WARNINGS CAN RESULT INSERIOUS PERSONAL INJURY OR LOSS OF LIFE.
.

Mounting

NOTE:
o The mounting panel cannot be more than 0.2” thick.
To max i m ize system performance, avoid electromagnetic interference by.
o mounting the controller on a metal panel o earthing the ModCon75 Touch Controller according to Figure 4.
Make a panel cutout for your ModCon75 Touch Controller.
o See Figure 3 for cutout dimensions.
If you are mounting the controller on a metal panel, earth the power supply.
o Bore a hole (Figure 4). o Scrape the panel paint away from the contact area to ensure a conductive
connection.
o Ensure proper ingress protection per applicable codes and standards. o Drive the screw into the hole.
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Figure 3. ModCon75 Touch Controller Panel Cut-out—Front View

o On the screw’s shank, place the following hardware in t hi s order:
washer, ring terminal, second washer, spring, and nut as shown in Figure 4.

Figure 4. Earth Assembly

Slide the HMI panel into the cutout, ensuring that the rubber seal is in place as shown in Figure 5.
Push the four mounting brackets into their slots on the sides of the HMI panel as shown in Figure 5.
Tighten the bracket screws against the HMI panel. Hold t he brackets securely against the unit while tightening the screws.
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Figure 5. HMI Panel Mounting

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Chapter 3,

Panel.
serves the HMI panel’s embedded speaker.
must be kept in place for IP65, IP66 and NEMA 4X complian ce.
end of the power cable.
ports
10/100Mbps.

ModCon75 Touch HMI Panel

The platform comprises the CPU controller, HMI panel and I/O module that snap together to form the ModCon75 Touch Controller.

HMI Panel
High-resolution touch screen provides the operator interf ace for the system.
The DIN-rail structure on the panel’s back is design ed to physically support the CPU
controller and the I/O module.
HMI Panel Diagram

Figure 6. HMI Panel Front and Rear View

Screen Protection
2 Audio Outlet Seal Prevents dust accumulation in the small outlet that
A plastic sheet attached to the HMI Panel screen for protection. Remove it during installation on the HMI
Caution: Keep the seal in place when the embedded speaker is not used. The seal
3 DIN-rail structure Physical support for the CPU and I/O m odules. 4 24VDC power input Connection point for the HMI Panel’s power source.
Connect the Terminal Block supplied with the kit t o the
5 2 Ethernet (RJ45)
6 USB Device Not Supported, No Customer Connection. 7 2 USB Host ports Not Supported, No Customer Connection.
Support high-speed Ethernet communications,
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8 Micro SD slot Supports standard micro SD cards.
(AUX)
9 Audio-out jack Not Supported, No Customer Connection.
10 Auxiliary connector
Provides the electrical connection for the CPU.

Installation Space Considerations

Allocate space for:
o The HMI Panel including the CPU and I/O modules that will be installed on it. o Opening the doors of the CPU and I/O modules.

HMI Panel Mechanical Dimensions

Figure 7. HMI Panel Mechanical Dimensions

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ModCon®75 Touch
Power Supply
consumption
Display
(brightness)
50% of its original level.
Height x Width (mm)

HMI Panel Interface Connections

Ethernet CAT-5e shielded cable with RJ45 connector
Micro SD Standard micro SD
Disconnect system power before connecting or disconnecting any modules or device s.
Components in this system are electrostat i c discharge sensitive (ESDS). Use proper
personal grounding procedures when removing, handling or adjusting the electronic modules.
FAILURE TO FOLLOW THESE WARNINGS CAN RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.

Specifications

Table 1. Specifications for ModCon75 HMI Panel

Input voltage 24VDC Permissible range 20.4VDC to 28.8VDC Maximum current
LCD type TFT Backlight type White LED Luminous intensity
Backlight longevity 50k hours Note: Panel’s longevity is the typical operating t i m e after which the brightness drops to
Resolution (pixels) 800 x 480 (WVGA) Size 7” Viewing area
0.75A @ 24VDC
Typically, 400 nits (cd/m2), at 25°C
152.4 x 91.44
Color support 65,536 (16bit)
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ModCon®75 Touch
Surface treatment Anti-glare
System
1GB user memory
Data speed: up to 200Mbps
Audio
IP66 or NEMA 4X.
Communication
Ethernet port
USB device – Not Supported, No Customer Connection
USB host - Not Supported, No Customer Connection
Environmental
Rear side: IP20, NEMA 1
IP66 or NEMA 4X.
Touch screen Resistive Analog Actuation force (min) >80 g (0.176 lb.)
Processor 32bit, 800Mhz RISC Processor, with Graphic A cc el erator Internal memory RAM: 512MB
ROM: 3GB system memory
External memory Micro SD or Micro SDHC card
Size: up to 32GB
Note: The audio outlet seal must be inserted in the outl et in order to comply with IP65,
Number of ports 2 Port type 10/100 Base-T (RJ45) Auto crossover Yes Auto negotiation Yes Isolation voltage 500VAC for 1 minute Cable Shielded CAT5e cable, up to 100m (328 ft.)
Protection Front face: IP65/66, NEMA 4X
Note: The audio outlet seal must be inserted in the out l et in order to comply with IP65,
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Operating temperature -20°C to 55°C (-4°F to 131°F)
8.4Hz to 150Hz, 1G acceleration
Storage temperature -30°C to 70°C (-22°F to 158°F) Relative Humidity (RH) 5% to 95% (non-condensing) Operating Altitude 2,000m (6,562 ft.) Shock IEC 60068-2-27, 15G, 11ms duration Vibration IEC 60068-2-6, 5Hz to 8.4Hz, 3.5mm constant ampl itude,
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ModCon®75 Touch
Chapter 4, ModCon75 Touch CPU Module
The CPU cannot operate independently. It m ust be pl ugged into the back of an HMI panel. The HMI panel provides the CPU’s power source.

Features:

IO/COM Bus connector for interfacing I/O module s
Isolated RS485.
Backup battery.
CPU Diagram
Figure 8. CPU Front and Rear View
1. DIN-rail clips
2. Battery pull-tab (remove during installation)
3. Battery compartment cover
4. IO/COM Bus connector, Shipped covered. Leave c overed when not in use.
5. RS485 connector
6. RS485 termination selection DIP switch
7. CANbus connector-Not Supported, No Customer Connection
8. CPU door
9. CPU connector to HMI panel
Installation
Disconnect system power before connecting or disconnecting any modules.
Components in this system are electrostat i c discharge sensitive (ESDS). Use proper
personal grounding procedures when removing, handling or adjusting the electronic modules.
FAILURE TO FOLLOW THE THESE WARNINGS CAN RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.
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The AUX connector on the back of the HMI panel prov ides t he connection point for the CPU, including power. The DIN-rail type structure on the back of the panel provides the physical support.
1. Remove the AUX connector cover from the panel.
2. Remove the IO/COM bus connector cover.
3. Plug the CPU into the HMI panel AUX connector as sh own in Figure 9. The guide tunnel on the CPU will be used to install the I/O module as shown in Figure 12.
4. Verify that the DIN-rail clips located on the top and bottom of the CPU have been locked onto the DIN-rail structure on the back of t he HMI panel as shown in Figure 10.
Figure 9. CPU Assembly
Figure 10. Locked Figure 11. Unlocked
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Figure 12. Guide Tunnel
Removing the CPU
1. Power off the HMI panel before removing the CPU.
2. Disconnect the RS485 connector.
3. Disconnect the I/O module connected to the CPU (by pushing the Bus Connector lock to the right).
4. On the CPU, pull the top DIN-rail clip up and the bott om clip down to the unlocked position as shown in Figure 11.
5. Pull the CPU out of its place.
About the CPU I/O Bus Connector
The IO/COM Bus connector on the right side of the CPU provides the electrical connection point for the I/O module. The connect or is shipped covered by a protective cover, protecting the connector from debris, damage and ESD.
RS485
Disconnect power before making any communications connections.
FAILURE TO FOLLOW THIS WA RNING CAN RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.
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ModCon®75 Touch
The CPU is shipped with a 4-pin RS485 terminal block. This connector is marked with a pin assignment that is identical to the corresponding marking on the CPU as shown in Figure
13.
Figure 13. RS485 Terminal Block
D+ Tx/Rx+ (Ultima X3 A) D- Tx/Rx- (Ultima X3 B) SG Signal Ground Functional Ground
Note:
RS485 Wiring
Use shielded twisted-pair cable, incompliance with EIA RS 485 specifications.
When wiring each node, connect the cable shield to the functional ground point of the
RS485 terminal block.
In order to avoid ground loops, do not connect the R S 485 f unct i onal ground terminal to the earth of the system, as it is internally connected t o the HMI panel’s functional ground point.
RS485 Termination
Use the DIPswitches shown in figure 9 to set the RS485 termination accordi ng to the table as shown in Table 2.
The device is shipped with both its DIP switches set to ON; change the settings if the device is not at one of the ends of the RS485 network.
Table 2. DIP Switch Settings
Battery: Back-up, Installation and Replacement Backup
In order to preserve back-up values for the Real Time Clock (RTC) and system data in the event of power off, the battery must be conne cted.
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ModCon®75 Touch
Battery Installation
The CPU is shipped with the battery installed, but wit h a pl ast ic battery pull-tab inserted in the battery compartment. Pull out the Battery pull-tab during installation in order to connect the battery.
Battery Replacement
Components in this system are electrostat i c discharge sensitive (ESDS). Use proper personal grounding procedures while servicing the battery.
FAILURE TO FOLLOW THIS WARNING CAN RESULT IN SERIOUS PERSONAL INJURY OR LOSS OF LIFE.
Caution
To preserve back-up values for RTC and system dat a during battery replacement, the CPU must be powered from the HMI panel.
1. Open the CPU door and remove the battery cover.
2. Remove the used battery and insert the new one, ensuring that the polarity is aligned with polarity as shown in Figure 14.
3. Replace the battery cover.
4. Dispose of the used battery according to local and nat i onal st andards and regulations.
Figure 14. Battery Polarity
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Specifications
General
Horn and Fault relay
the HMI panel and via System Tag).
Customer Connection
Communication
RS485
RS485
Environmental
8.4Hz to 150Hz, 1G acceleration
Table 3. Specifications for ModCon75 Touch CPU
I/O Support Zone relay module includes 9 Zone Alarm,
Ladder Memory 1MB Bit Operation Battery Model: CR2032 Lithium battery
Connectors IO/COM Bus connector
Voltage limits -7 to +12 VDC maximum, Common+Differential Baud rate range 1,200 – 115,200 bps Nodes Up to 32 Isolation voltage 500VA C f or 1 minute Cable type Shielded twisted pair in compliance with EIA
0.13 μs
Battery Lifetime: 4 years typical at 25°C
Battery Low detection and indication (via
CANbus connector – Not Supported, No
.
Cable Length Maximum 1,200 m (3,937 ft.) Termination Set using DIP Switches
Protection IP20, NEMA1 Operating temperature Storage temperature Relative Humidity (RH) 5% to 95% (non-condensing) Operating Altitude 2,000m (6,562 ft.) Shock IEC 60068-2-27, 15G, 11ms duration Vibration IEC 60068-2-6, 5Hz to 8.4Hz, 3.5mm constant ampl itude,
-20°C to 55°C (-4°F to 131°F)
-30°C to 70°C (-22°F to 140°F)
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