Red Lion CSSG User Manual
Bulletin No. CSSG1-E
1
7
13
1.24
(126.5)
4.17 (105.9)
4.98
(31.5)
C
US LISTED
Drawing No. LP0626
Released 01/12
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL CSSG1 – MODULAR CONTROLLER SERIES STRAIN GAGE MODULE
STRAIN GAGE MODULE FOR THE MODULAR CONTROLLER SERIES
HOT-SWAPPABLE REPLACEMENT REDUCES DOWNTIME
AUTO ADDRESSING MINIMIZES CONFIGURATION TIME
PID CONTROL WITH REDUCED OVERSHOOT
LOAD CELL, PRESSURE AND TORQUE BRIDGE INPUTS
SOFTWARE SELECTABLE LOW LEVEL INPUTS
(20 mV, 33 mV or 200 mV FULL SCALE)
SOFTWARE SELECTABLE 5 VDC or 10 VDC BRIDGE EXCITATION
DIGITAL TARE (re-zero), BATCH TOTALIZER, AND PEAK/VALLEY
(max/min) RECORDING
ON DEMAND AUTO-TUNING OF PID SETTINGS
DC ANALOG OUTPUT
U
R
C
L
US LISTED
IND. CONT. EQ.
34AD
WINDOWS
®
CONFIGURATION SOFTWARE
GENERAL DESCRIPTION
The Model CSSG is a full featured single loop PID controller designed for
use with the Modular Controller Series. The module accepts low level signals
from a variety of bridge-type transducers, such as load cells, pressure
transducers, torque transducers, etc. An optional second signal input is available,
providing math capabilities between the two input channels (average, differential,
etc.). Each input channel provides a software selectable 5 V or 10 V stable
bridge excitation voltage, capable of driving up to four 350 bridges (combined
total per module). The inputs are software selectable for ±20 mV, ±33 mV, or
±200 mV full scale. With solid state or relay outputs, plus an analog output, the
CSSG module can perform virtually any combination of time-proportioning or
linear control. The discrete outputs may also be assigned to one of seven internal
soft alarms; and the linear output can be assigned to transmit virtually any
internal variable. In addition, digital tare (re-zero), batch totalizer, and peak/
valley (max/min) are provided.
The modules connect and communicate via a backplane connection to the
CSMSTR Master module. The Master, equipped with serial ports as well as an
Ethernet port, allows the system to share data with PCs, PLCs, and SCADA
systems. The Master supports up to 16 CS Series modules (when using CSSG
modules, refer to “Power” specifications).
The CSSG modules are available with relays, or open drain MOSFET
outputs. For applications requiring large loads to be controlled, several DIN rail
mount relays are available.
The modules can operate in On/Off, P, PI, or PID control mode, and use an
on-demand Auto-Tune that establishes the tuning constants. The PID constants
may be fine-tuned through the serial or Ethernet interface. The modules employ
a unique overshoot suppression feature, which allows the quickest response
without excessive overshoot. The modules can also be operated in manual mode,
providing the operator with direct control of the output.
Internal power management circuits allow the modules to be replaced while
power is applied, which reduces downtime in the event of a relay failure. All
configuration information is stored locally within each module, as well as in the
Master, so replacement modules do not need to be configured.
The Modular Controller Series’ high density packaging and DIN rail
mounting saves time and panel space. The backplane connection provides power
and communication to the module and snaps easily onto standard top hat (T)
profile DIN rail.
SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Do not use the controller to directly command motors, valves, or other
actuators not equipped with safeguards. To do so can be potentially harmful to
persons or equipment in the event of a fault to the controller.
CAUTION: Risk of Danger.
Read complete instructions prior to
installationand operation of the unit.
CAUTION: Risk of electric shock.
DIMENSIONS In inches (mm)
CONFIGURATION
The Modular Controller Series is configured with Windows® compatible
Crimson® software. The software is an easy to use, graphical interface which
provides a means of configuration and commissioning of new systems, as well
as routine module re-calibration.
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SPECIFICATIONS
1. POWER: Derived from system backplane. 250 mA max. load on power input
of MASTER. Module may be hot-swapped (replaced while powered up).
Modules per Master: A single Master can support up to 11 CSSG1 modules
combined with any 5 other module types. For applications that require
more than 11 CSSG1 modules, please contact technical support.
2. LEDs*:
STS - Status LED shows module condition.
OP1, OP2, OP3 - Indicate status of outputs 1, 2, and 3
ALM - Alarm LED is lit during an internal alarm condition.
* Default configuration.
3. MEMORY: Non-volatile memory retains all programmable parameters. The
MASTER also stores the parameters in order to reprogram any modules that
are replaced.
4. INPUTS:
SOFTWARE
SELECTABLE
INPUT RANGE
±20.000 mVDC
±33.000 mVDC 0.02% of reading +5 μV 0.07% of reading +7 μV
±200.00 mVDC 0.02% of reading +30 μV 0.07% of reading +40 μV
* After 20 minute warm-up. Accuracy over the 0 to 50°C range includes
the temperature coefficient.
Connection Type:
4-wire bridge (differential)
2-wire (single-ended)
Sample Time: 67 msec (15 readings per second)
Common Mode Range (with respect to input common): 0 to +5 VDC
Common Mode Rejection: > 100 dB, DC to 120 Hz
Temperature Coefficient (ratio metric): 20 ppm/°C max.
Step Response Time: 200 msec max. to within 99% of final process value
Input Impedance: 100 M
Max Continuous Overload: 30 V
PV Range: -30,000 to 30,000
Effective Resolution: 16-bit
5. BRIDGE EXCITATIONS:
Software selectable:
5 VDC, ±2%, 65 mA max.
10 VDC, ±2%, 125 mA max. combined (excitation 1 plus excitation 2).
Temperature coefficient (ratio metric): 20 ppm/°C max.
Max. four 350 bridges per module.
6. ISOLATION LEVEL: 500 Vrms @ 50/60 Hz for 1 minute between the
following:
OP1 * OP2 * OP3
Linear Output
Signal Inputs (the 2 input channels are not isolated from each other)
CS Master Power Supply Input
* Outputs OP1 and OP2 of SSR model are not isolated from each other
7. COMMUNICATIONS: Provided by the CS Master.
8. DISCRETE OUTPUTS:
Outputs 1 and 2 are available as Solid State NFET, or Form A relay. Output
3 is a Form C relay.
Solid State Output:
Type: Switched DC, N Channel open drain MOSFET
Current Rating: 1 A max
VDS ON: 0.3 V @ 1 A
VDS MAX: 30 VDC
Offstate Leakage Current: 0.5 mA max
Form A Relay Output:
Type: N.O.
Current Rating: 3 Amps @ 125 VAC
1/10 HP @ 125 VAC
Life Expectancy: 200,000 cycles at maximum load rating. (Decreasing
load, increasing cycle time, and use of surge suppression such as RC
snubbers increases life expectancy.)
Form C Relay Output:
Type: SPDT
Current Rating: 5 Amps @ 125 VAC or 28 VDC (resistive load)
1/8 HP @ 125 VAC
Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing
load, increasing cycle time, and use of surge suppression such as RC
snubbers increases life expectancy.)
9. CONTROL MODES:
Control: On/Off, P, PI, or PID
Output: Time proportioning or linear
ACCURACY *
18 TO 28°C
10 TO 75% RH
0.02% of reading +3 μV
ACCURACY *
0 TO 50°C
0 TO 85% RH
0.07% of reading +4 μV
Cycle Time: Programmable from 0.0 to 60.0 sec
Auto-Tune: When selected, sets proportional band, integral time, derivative
time values, and output dampening time
Input Fault Response: Upscale
10. ALARMS:
Modes: Manual
Absolute High Acting Absolute Low Acting
Deviation High Acting Deviation Low Acting
Inside Band Acting Outside Band Acting
Reset Action: Programmable; automatic or latched
Standby Mode: Programmable; enable or disable
Hysteresis: Programmable
Input Fault Response: Upscale
11. ANALOG DC OUTPUT:
Jumper Selectable/programmable for 0-10 VDC, 0-20 mA, or 4-20 mA
Resolution:
Voltage: 500 μV
Current: 1 μA
Accuracy:
0.1% of full scale (18 to 28°C)
0.2% of full scale (0 to 50°C)
Update Time: 0.0 to 60.0 sec
Compliance (for current output only): 500 max.
Minimum load (voltage output only): 10 K min.
Output is independently jumper selectable for either 10 V or 20 mA. The
output range may be field calibrated to yield approximate 10% overrange
and a small underrange (negative) signal.
12. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to +50°C
Storage Temperature Range: -40 to +85°C
Operating and Storage Humidity: 85% max relative humidity, non-condensing,
from 0 to +50°C
Vibration According to IEC 68-2-6: 10 to 150 Hz, 0.075 mm amplitude in X,
Y, Z direction 1 g.
Shock According to IEC 68-2-27: Operational 25 g (10 g relay), 11 msec in
3 directions.
Altitude: Up to 2000 meters
13. CERTIFICA TIONS AND COMPLIANCES:
SAFETY
UL Listed, File # E302106, UL508, CSA C22.2 No. 14-M05
LISTED by Und. Lab. Inc. to U.S. and Canadian safety standards
IEC 61010-1, EN 61010-1: Safety requirements for electrical equipment for
measurement, control, and laboratory use, Part 1.
ELECTROMAGNETIC COMPATIBILITY
Emissions and Immunity to EN 61326: 2006: Electrical Equipment for
Measurement, Control and Laboratory use.
Immunity to Industrial Locations:
Electrostatic discharge EN 61000-4-2 Criterion B
4 kV contact discharge
Electromagnetic RF fields EN 61000-4-3 Criterion B
8 kV air discharge
3
10 V/m (80 MHz to 1 GHz)
3 V/m (1.4 GHz to 2 GHz)
1 V/m (2 GHz to 2.7 GHz)
Fast transients (burst) EN 61000-4-4 Criterion B
power 2 kV
I/O signal 1 kV
I/O signal connected to power 2 kV
Surge EN 61000-4-5 Criterion B
power 1 kV L to L, 2 kV L to G
signal 1 kV
RF conducted interference EN 61000-4-6 Criterion A
3 Vrms
Emissions:
Emissions EN 55011 Class A
Notes:
1. Criterion A: Normal operation within specified limits.
2. Criterion B: Temporary loss of performance from which unit self-recovers.
3. The module’s analog input and/or output signals may deviate during
disturbance but self-recover when disturbance is removed.
4. Power supplied from backplane via Master Module.
14. CONSTRUCTION: Case body is burgundy high impact plastic. For indoor
use only. Installation Category II, Pollution Degree 2.
15. CONNECTIONS: Removable wire clamp screw terminal blocks.
Wire Gage: 28-16 AWG terminal gage wire
Torque: 1.96-2.23 inch/lbs (0.22-0.25 N-m)
16. MOUNTING: Snaps on to standard DIN style top hat (T) profile mounting
rails according to EN50022 -35 x 7.5 and -35 x 15.
17. WEIGHT: 7 oz (198.4 g)
2
24VDC
PORT 1
PROGRAMMING
A
COMMUNICATIONS
PORT 2
POWER
SUPPLY
+
-
ISOLATED
PORT 3
ETHERNET
CSMSTR - MASTER
INPUT2
ISOLATED
CSSG1 - STRAIN GAGE MODULE
SUPPLY
POWER
A
B
C
A
D
OUTPUTS
RELAY
ISOLATED
OP3-RELAY
OP2-RELAY
OP1-RELAY
INPUT1
+EXC
+SIG
COM
-SIG
ISOLATED
SSR
OUTPUTS
E
OP1-SSR1
OP2-SSR2
ISOLATED
LINEAR
OUTPUT
0-20mA
0-10V
F
+EXC
-SIG
+SIG
COM
BLOCK DIAGRAM
EMC INSTALLATION GUIDELINES
Although Red Lion Controls Products are designed with a high degree of
immunity to Electromagnetic Interference (EMI), proper installation and wiring
methods must be followed to ensure compatibility in each application. The type
of the electrical noise, source or coupling method into a unit may be different
for various installations. Cable length, routing, and shield termination are very
important and can mean the difference between a successful or troublesome
installation. Listed are some EMI guidelines for a successful installation in an
industrial environment.
1. A unit should be mounted in a metal enclosure, which is properly connected
to protective earth.
a. The mounting clip that connects to the DIN rail should have the DIN rail
connected to protective earth.
2. Use shielded (screened) cables for all Signal and Control inputs. The shield
(screen) pigtail connection should be made as short as possible. The
connection point for the shield depends somewhat upon the application.
Listed below are the recommended methods of connecting the shield, in
order of their effectiveness.
a. Connect the shield to earth ground (protective earth) at one end where the
unit is mounted.
b. Connect the shield to earth ground at both ends of the cable, usually when
the noise source frequency is over 1 MHz.
c. Connect the shield to common of the module and leave the other end of the
shield unconnected and insulated from earth ground.
3. Never run Signal or Control cables in the same conduit or raceway with AC
power lines, conductors feeding motors, solenoids, SCR controls, and
heaters, etc. The cables should be run through metal conduit that is properly
grounded. This is especially useful in applications where cable runs are long
and portable two-way radios are used in close proximity or if the installation
is near a commercial radio transmitter. Also, Signal or Control cables within
an enclosure should be routed as far away as possible from contactors,
control relays, transformers, and other noisy components.
4. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
5. In extremely high EMI environments, the use of external EMI suppression
devices such as Ferrite Suppression Cores for signal and control cables is
effective. The following EMI suppression devices (or equivalent) are
recommended:
Fair-Rite part number 0443167251 (RLC part number FCOR0000)
TDK part number ZCAT3035-1330A
Steward part number 28B2029-0A0
6. To protect relay contacts that control inductive loads and to minimize radiated
and conducted noise (EMI), some type of contact protection network is
normally installed across the load, the contacts or both. The most effective
location is across the load.
a. Using a snubber, which is a resistor-capacitor (RC) network or metal oxide
varistor (MOV) across an AC inductive load is very effective at reducing
EMI and increasing relay contact life.
b. If a DC inductive load (such as a DC relay coil) is controlled by a transistor
switch, care must be taken not to exceed the breakdown voltage of the
transistor when the load is switched. One of the most effective ways is to
place a diode across the inductive load. Most RLC products with solid
state outputs have internal zener diode protection. However external diode
protection at the load is always a good design practice to limit EMI.
Although the use of a snubber or varistor could be used.
RLC part numbers: Snubber SNUB0000
Varistor ILS11500 or ILS23000
Note: Reference manufacturer’s instructions when installing any EMI
suppression device.
7. Also care should be taken when connecting input and output devices to the
instrument. When a separate input and output common is provided, they
should not be mixed. Therefore a sensor common should NOT be connected
to an output common. This would cause EMI on the sensitive input common,
which could effect the instruments, operation.
Visit RLC’s web site at www.redlion.net for more information on EMI
guidelines, Safety and CE issues as they relate to Red Lion Controls products.
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