Pepperl+Fuchs 2/209 User Manual
ISO9001
MANUAL
Trip Amplifier
2/209
PROCESS AUTOMATION
Trip Amplifier 2/209
EN
Table of contents
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Safety applications/certificates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Front view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9 Device layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.11 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 Front control elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Cabinet design and heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6 Changing current inputs/voltage inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Service instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Numerical parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 System parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Programming example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6 Installation of the PC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of contents
5 Handling without a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Handling with a PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.1 Action 1 – Preparing the hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2 Action 2 – Preparing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Action 3 – Preparing a back-up copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Action 4 – How to edit standard programs . . . . . . . . . . . . . . . . . . . . . . . . . . .41
6.5 Action 5 – How to save and send programs. . . . . . . . . . . . . . . . . . . . . . . . . 41
6.6 Action 6 – How to check edited programs . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.7 Action 7 - How to edit a program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.8 Action 8 - Ending a job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Test programs using the EMULATOR . . . . . . . . . . . . . . . 43
9 Safety concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.1 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Safety related parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
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Attention
Attention
Safety information
1Safety information
Target group: experiences skilled electricians.
The trip amplifier must not be converted or altered in any way.
Device must be mounted outside hazardous areas.
When working on the trip amplifier always comply with national safety and accident
prevention regulations and the safety information contained in this manual. Safety
information is printed in italics like this paragraph and marked accordingly.
Screened cables are recommended for all wiring which leaves the building.
According to IEC 801-5 application class 0 analog inputs must not be subjected to high
energy pulses. In all other respects the unit fulfils IEC 801 to the more stringent
applications class 3.
Redundant analog inputs A and B should be fed from separate sources. The signals
must not differ by more than 5 % since the sister channels are continuously compared
with each other.
In safety applications front push buttons should not be incorporated in those parts of the
program which are relevant to safety. Trip settings should not be changed during
operation. Front push buttons can be locked by placing the jumper KEY in the LOCK
position. The push buttons will then only be used to read values sequentially rather than
alter them (protection against unauthorized changes).
Programs for safety applications should try and avoid conditional branches because this
would simplify the final approval test considerably. This could then be restricted to a
functional test concentrating on the reaction of outputs to input changes.
For safety applications relay outputs must be configured to be normally energized. After
a power down the device will restart automatically. For safety applications it is therefore
necessary to establish suitable external means to resume production in an orderly
fashion.
The serial data link is not a safety related part of the circuitry.
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Technical data
2 Technical data
2.1 Features
• 4-channel isolated barrier
• Input 0/4 mA ... 20 mA
• 4 relay contact outputs
•Programmable
• Simple operation via front buttons
• Lead monitoring
• Galvanic isolation between input, power supply and contact output
• With computational function SIL3
•LCD display
• Self-monitoring
2.2 Technical data
General specifications
Signal type analog input
Supply
Connection z2+, z4-, z6 (PE)
Rated voltage 18 ... 30 V DC, 18 ... 26.4 V AC 48 ... 62 Hz
Power consumption 2 W/2.5 VA
Input
Connection Input A I: d32+, z32-
Input resistance 50 (mA)
Current range 0/4 ... 20 mA (0/1 ... 5 V)
Input A II: d30+, z30Input A III: d28+, z28Input A IV: d26+, z26Input B I: b32+, z32Input B II:b30+, z30Input B III: b28+, z28Input B IV: b26+, z26-
10 k (V)
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Technical data
Output
Connection Output I: z10, d12, d10
Output II: d14, z14, z12
Output III: z16, d18, d16
Output IV: d20, z20, z18
Relay
Switching voltage 50 V
Switching current 2 A AC/DC
Switch power 500 VA/60 W
Mechanical life 50 mio. cycles
Electrical lifetime 0.5 mio. cycles
Response time > 20 ms (variable)
Transfer characteristics
Temperature influence < 0.1 %/10 K
Indicators/settings
Display elements LED 1: trip value 1
LED 2: trip value 2
LED 3: trip value 3
LED 4: trip value 4
LED green: Power on
Configuration via RS 485 interface at the front side
Directive conformity
Electromagnetic compatibility
Directive 2004/108/EC EN 61326-1:2006
Conformity
Protection degree IEC 60529
Ambient conditions
Ambient temperature -10 ... 60 °C (14 ... 140 °F)
Storage temperature -25 ... 80 °C (-13 ... 176 °F)
Relative humidity < 75 % (annual mean)
Mechanical specifications
Protection degree IP20
Mass 300 g
Dimensions 22 x 143 x 193 mm (0.9 x 5.6 x 7.6 in)
Construction type Eurocard 100 x 160 mm (3.9 x 6.3 in) acc. to
< 95 % (30 d/year), no moisture condensation
DIN 41494, front panel 4TE, mountable in 19" rack
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Attention
Attention
Technical data
2.3 Mounting
Devices must be mounted outside hazardous areas.
Fits 19" racks or DIN rail enclosures.
2.4 Options
Additional functions basic functions like mathematics and logical
operations are freely configurable.
Configuration via RS 232 serial data link via commercial PCs or
PC-like units such as SIEMENS PG 685, PG 730,
PG770, PG 790 or MS-DOS PC.
Handling Menu support to SAA standard.
Storage Non volatile EEPROM storage.
Function disable via jumpers.
2.5 Safety applications/certificates
SIL classification SIL3, TÜV Rheinland, 968/EL 292-03/08
acc. to IEC 61508
6
Device must be mounted outside hazardous areas.
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2/209
ESC
STEP
4
3
2
1
SET
5
P
R
O
G
R
A
M
Front view
LED green:
Power supply
LED red:
Limit value
LC display
Technical data
2.6 Front view
2.7 Dimensions
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17.5 175.5
160
100
143
22
7
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z 10
d 12
d 10
d 26+
z 26-
d 28+
z 28-
d 30+
z 30-
d 32+
z 32-
b 26+
z 26-
b 28+
z 28-
b 30+
z 30-
b 32+
z 32-
z 2+
z 4z 6
24 V
IV
III
II
I
IV
A
B
III
II
I
IV
III
II
I
d 14
z 14
z 12
z 16
d 18
d 16
d 20
z 20
z 18
45312
62718
A B
(A) and (B)
input modules with
jumper J
5 V, 10 V,
20 mA
RS 232 C
K1
K2
K3
display
Test X2
X5 - KEY, MODE
jumpers
X2 - TEST
jumpers
line fuse
mP socket space for label processors A + B
push buttons
jumper J
20 mA
5 V
10 V
jumper J
20 mA
5 V
10 V
Technical data
2.8 Connection
2.9 Device layout
8
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Technical data
2.10 Block diagram
2.11 Connection diagram
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Technical data
2.12 Front control elements
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Attention
Hardware description
3 Hardware description
3.1 Mounting instructions
Devices must be mounted outside hazardous areas.
The devices are manufactured as narrow plug-in units for 19" racks. The exact
dimensions can be taken from the section "Technical data".
The racks should be mounted in easily accessible positions on walls, in panels, in
cabinets or protective enclosures so that the front panels of the devices take on a vertical
position. The mounting position should be dry and dust-free. Heavy vibrations,
mechanical stress, and strong heat sources are unacceptable. Maximum ambient
conditions must be observed.
The units are EMC-RFI tested to IEC 801.2-5 plus NAMUR AK EMV. Despite their
excellent RFI immunity, the mounting position should not be in the immediate vicinity of
strong electromagnetic fields and be low on RFI. To avoid radio frequency interference
shielded racks and screened cables are recommended. Please observe installation
code of practice. For advice on EMC - RFI see application notes EAN 1610. For best
EMC performance make sure to earth the assigned connector pin.
The units are pushed into the racks fitted with guide rails and female connectors until the
front panels are flush with the front frame of the rack. The units are then connected to the
external wiring via the female connectors. Screw or snap-in fasteners secure the units
against unintentional removal from the rack.
The following mounting recommendations should be observed. A maximum of
21 devices can be fitted in a rack. Power dissipation can be taken form the section
"Technical data". In order to disperse the heat sufficiently the racks should be mounted
in such a way as to ensure best ventilation. The following advice may be useful:
1. It is recommended in particular that permanent overvoltages should be avoided.
2. In particularly adverse operating conditions check the ambient temperature in the
vicinity of the devices (approx. 1 cm away from the front panels). The temperature
should not exceed 60 °C under worst case conditions.
3. Normally natural convection is sufficient for 19" racks in open frames. It has to be
noted however that the topmost rack should not be covered over unless by a cover
plate with sufficient air vents to avoid heat build-up.
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V
Z = –––
G
Z = number of devices per cabinet
V = permissible power dissipation
G = power per device
Attention
Hardware description
3.2 Cabinet design and heat dissipation
Electronic devices will dissipate some of the energy applied to them in the form of heat.
The resulting cabinet temperature must not impair the device function. Therefore the
cabinets should be designed not to exceed the maximum permissible ambient
temperatures as given in the section "Technical data". The following table is based on
an over-temperature of 25 K.
The devices have been designed for 60 °C ambient. Further assuming that the control
room temperature does not exceed 40 °C, the permissible power dissipation in the
cabinet can be given as follows:
1. unforced draught convection 400 W
2. draught convection using vents and filters 800 W
3. draught convection using vents without filters 1600 W
4. unforced natural convection 160 W
5. forced convection ventilators per rack 320 W
6. forced convection using heat exchangers plus forced convection inside and out
1500 W
The number of devices per cabinet can then be computed as follows:
For mixed installations the individual power dissipation of devices can be used to
compute the total power loss to compare with the permissible values.
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3.3 Connections
For all device types the rules and regulations for the installation of electrical equipment
and wiring (e. g. VDE 0100) of the user country must be observed.
Power and measuring cables have to be kept separate.
Devices are electrically connected using a male and female connector to DIN 41612,
type F. Connections see section "Technical data". The male connector is mounted on
the printed circuit board while the female connector is fitted at the back of the rack.
External connections are normally soldered to the connectors. The solder points are
covered by a heat shrunk sheath e. g. Drakavita Ray Quality H, manufacturer: Deutsche
Schrumpfschlauch Gesellschaft. Other wiring techniques are also acceptable (wirewrap, termipoint, crimp snap-in etc.).
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4 digits plus sign, status line with one alpha
character plus 2 numerals
nn
T
Hardware description
3.4 Commissioning
The following checks are recommended prior to start-up.
1. Output relay: observe the voltage and current ratings of the relay or electronic
output.
2. Input
– Ensure that the measuring circuit is not subjected to overvoltages.
– Check the input connections and the corresponding jumper setting if the factory
setting is not required.
– For multiple analog inputs check that galvanic isolation is used where
appropriate (e. g. if several signals are also transmitted to another multiple input
device).
3. Power supply: check the supply voltage (see section "Technical data")
Most device settings will be carried out in Software. Check the setting using the
parameter list. This can be addressed via the PC menu
Example
PC menu (details see disk)
Place jumper X5 in position 4–5 for programming.
Connect the device to COM1 or COM2 RS 232 seria l dat a lin ks on your PC. Set your PC
MENU to COM1 or COM2 accordingly via <ALT><C>.
Use the command <ALT><U> to read all data from the device and then printing it
(1 A4 page)
1. LOAD DATA from the device (<ALT><L>).
2. Check constants (<F4> ... <ESC>).
3. Check the program (<F5> ... <ESC>).
Before attempting any changes the old parameters should be stored on disk using
<ALT><W> (see PC HELP TEXT). After effecting the changes these must be stored in
the device using <ALT><S>. Again a back-up copy on disk or WINCHESTER under a
suitable file name is recommended.
After these checks the unit can be plugged into its rack position. Devices are calibrated
ex works. Recalibration is therefore not normally required (see section "Calibration").
A simple functional test can be carried out as for conventional trip amplifiers by
connecting input signal sources to check the relays trip at the setpoint.
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X5
X2
453
12
627
1
8
Hardware description
3.5 Functional test
3.5.1 General
The device will be calibrated ex works following the specifications given with orders. The
unit is operational and approximately 0.2 % accurate as soon as the power is turned on.
It has to be noted however that best performance is only achieved once temperature
balance is reached between the device and its ambient conditions. A device taken from
stock inserted in a warm rack may therefore take 1 ... 2 hours before it reaches its full
accuracy given that the ambient temperature is stable and within the boundaries
mentioned in the section "Technical data".
Factory calibration is carried out at 20 °C ... 25 °C after a 72 hour soak test. Due to the
excellent long term stability of the device no regular maintenance is needed. An annual
check of zero and span is regarded as being sufficient. The PCB carries a row of
jumpers:
Standard setting for row of jumpers X2, X5:
•MODE: X5
–jumper 4–5 PROGRAM
programming mode (program execution stops)
–jumper 3–6 RUN
run mode (device cannot be programmed)
•KEY: X5
– jumper 2–7 KEY LOCK
disable front push button changes
– jumper 1–8 KEY UNLOCK
enable front push button changes
•TEST: X2
–jumper 1–2 TEST
if this jumper is set during the programming mode X5 4–5 testing is enabled.
Device calibration is only possible in this mode of operation.
MODE jumper 4–5 is required for testing. The unit goes offline.
MODE jumper 3–6 for normal operation.
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Hardware description
3.5.2 Testing analog inputs
Analog inputs are tested via the LCD-Display in the front of the device. Download a
program into the device which enables tests of analog inputs (e. g. program TESTE.EDT
in the DEMO directory). The program TESTE.EDT will allow you to display analog inputs
E01 ... E04 in percentage values in the display. Use the push button marked "STEP" to
advance the display to the next input.
The device connections are explained in the data sheet. Inputs A and B have to have the
same input signals applied to them because the program carries out a continuous cross
check between the two for safety reasons.
Use precision signal sources to apply to the inputs. Display readings will be in
engineering units or percentage values depending on the device software.
Use also PC MENUE "TERMINAL EMULATORS". There are the following parameter:
• P711 = input 1
• P712 = input 2
• P713 = input 3
• P714 = input 4
3.5.3 Testing push buttons
Front push buttons are used to set alarm points and to step the display to show
measured values, trip points or computed values. In safety applications changes via
push buttons are sometimes not permitted. Values may then only be read via push
button access.
Download a program into the device which allows several values to be displayed under
push button control (e. g. program TESTE.EDT in the DEMO directory). The program
TESTE.EDT will allow you to display analog inputs E01 ... E04 in percentage values in
the display. Use the push button marked "STEP" to advance the display to the next input.
Setpoints can be altered after placing jumper "KEY" in position 1–8. Press the upper and
lower push buttons "SET" simultaneously. The display will start to flash. Adjust trip points
by using the UP ">" and DOWN "<" push buttons. Store the setting by using the "STEP"
button. Return to normal operation by pressing the two lower push buttons "<" and ">"
simultaneously (ESC). The flashing stops. All three push buttons have now been tested.
Download your operating program and replace the jumpers as shown in
section "Functional test – Generals".
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