Rockwell Automation 1748 Installation Instructions

DataSite Configured Panel

Installation Instructions

1748 DataSite Configured Panel

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

) describes some important differences between solid state equipment and

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

IMPORTANT

ATTENTION

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence

SHOCK HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

Allen-Bradley, DataSite, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication 1748-IN001B-EN-P - May 2009

Preface

Overview

Install and Wire the Panel

Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Common Techniques Used in this Manual. . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

cULus Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Environmental Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Panel Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Receiving, Handling, and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2

Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hazardous Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Panel Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Panel Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Over-current Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Incoming/Outgoing Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20

Install Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Install Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Antenna and Antenna Cable Installation . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 3

Final Checklist Before Energizing

Perform a Pre-energizing Check Procedure . . . . . . . . . . . . . . . . . . . . . 23

Pre-energizing Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 4

Energizing and Commissioning

Energizing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Energizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DataSite Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Radio Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Software Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 5

Maintaining the DataSite Configured Panel

3 Publication 1748-IN001B-EN-P - May 2009

Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance after a Fault Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4 Table of Contents

Troubleshooting

Chapter 6

Field Repairs and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . 33

Troubleshooting the DataSite Configured Panel . . . . . . . . . . . . . . . . . 34

Troubleshooting the Solar Controller of the DataSite Configured

Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Step 1: Check environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Step 2: Check solar panel output. . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Step 3: Check condition of batteries . . . . . . . . . . . . . . . . . . . . . . . . 37

Step 4: Test condition of power transistors in solar controller . . . 38

Step 5: Test condition of blocking diode in solar controller . . . . . 38

Step 6: Test temperature compensation cable . . . . . . . . . . . . . . . . 39

Troubleshooting the Human-machine Interface (HMI) . . . . . . . . . . . 40

Step 1: Test the condition of ’ON’ push button for the HMI. . . . 40

Step 2: Test the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Improper End Connections for Antennas . . . . . . . . . . . . . . . . . . . 41

Moisture Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Renewal Parts

DataSite Configured Panel Battery

Solar Panel

Configuring the ‘ON’ Push Button for the Human-machine Interface

Chapter 7

Renewal Parts Stocking Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Order Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Appendix A

Environmental Effects on Charge Capacity . . . . . . . . . . . . . . . . . . . . . 45

Charging and Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Battery Life Expectancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Temperature Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Rate of Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Deep-cycling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Energy Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Appendix B

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix C

Programming the ‘ON’ Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Preface

Read this preface to familiarize yourself with the rest of the manual. It provides information concerning:

• who should use this manual

• the purpose of this manual

• related documentation

• conventions used in this manual

Who Should Use this

Use this manual if you are responsible for designing, installing, programming, or troubleshooting DataSite configured panels.

Manual

You should have a basic understanding of electrical circuitry and familiarity with relay logic. If you do not, obtain the proper training before using this product.

Purpose of this Manual

Common Techniques Used in this Manual

The following conventions are used throughout this manual:

• Bulleted lists such as this one provide information, not procedural steps.

— An article on wire sizes and types for grounding electrical

A description of important differences between solid-state programmable controller products and hard-wired electromechanical devices.

equipment.

ordering instructions. Also indicates whether the documents are available on CD-ROM or in multi-languages.

A glossary of industrial automation terms and abbreviations.

DataSite configured panel.

Shipped with DataSite configured panel.

• Numbered lists provide sequential steps or hierarchical information.

• Italic type is used for emphasis.

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Overview

Chapter

Introduction

Allen-Bradley industrial control panels consist of a metal or polycarbonate enclosure that house a wide variety of factory-wired industrial control equipment such as motor controllers, switches, relays, auxiliary devices and programmable logic controllers. The panels may also include a disconnecting means and motor branch circuit protective devices.

These enclosures can be wall-mounted or free-standing (pole mounted) to meet varying application requirements. These industrial control panels have been designed to meet the requirements of IP 66/UL Type 4X/NEMA Type 4X (outdoor) when applying proper installation techniques suitable for the environment.

Panel dimensions vary based on the application and equipment being used. Panels can range in size from very small 20.32 x 15.24 x 8.89 cm (8 x 6 x 3.5 in.) operator boxes to large 228.6 x 50.8 x 50.8 cm (90 x 20 x 20 in.) enclosures. Panels are cULus Listed to UL 508A for Industrial Control panels or UL 1604 for Hazardous Locations.

Power can be distributed to the panel via incoming cables provided by the site electrical system. Cables leave the control panel to power motors and other devices and also to send analog and digital control signals.

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8 Overview

Nameplate Data

Each control panel has a nameplate located on the enclosure or enclosure door.

Unit Nameplate

DATASITE CONFIGURED PANEL

CATALOG NO. SERIES

PHASESHZ.LINE [V]A-B SERIAL NO.

ENCL. TYPE.

WIRING DIAGRAM

Allen-Bradley

FULL LOAD [A] LARGEST LOAD [A]

HAZ. LOC TEMP. CODE

MADE IN ____________

The following product information is provided on the panel nameplate.

44743

Information Fields on Panel Nameplate

Field Description

CATALOG NO. Catalog number SERIES Series letter of product A-B SERIAL NO. Product serial number LINE [V] Line voltage (V) HZ Frequency (Hz) PHASES Number of phases ENCL. TYPE. UL enclosure type FULL LOAD [A] Maximum panel amperage LARGEST LOAD [A] Largest component current load WIRING DIAGRAM Schematic number HAZ. LOC Hazardous (Classified) location code TEMP. CODE Operating temperature code

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Overview 9

cULus Marking

Environmental Ratings

Each industrial control panel, where applicable, will bear a cULus Listing Mark. Panels that do not meet cULus Listing will not bear a label.

ATTENTION

The panel is rated for IP 66/UL Type 4X/NEMA Type 4X applications; enclosures constructed for either indoor or outdoor use that provide a degree of protection to personnel against incidental contact with the enclosed equipment. They provide a degree of protection against falling dirt, rain, sleet, snow, windblown dust, splashing water, and hose-directed water, will be undamaged by the external formation of ice on the enclosure and will provide corrosion protection.

The unit is rated to function within a temperature range of -30 °C to 50 °C (-22 °F to 122 °F) and 0 °C to 50 °C (32 °F to 122 °F) with the human-machine interface (HMI).

Suitable for use in Class I Division 2, Groups A, B, C, and D Hazardous Locations, or Nonhazardous Locations only.

Battery life is reduced at lower temperatures. For battery derating information, see Appendix A

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10 Overview

Components

This table provides a list of the main components in the DataSite configured panel and their descriptions. The numbers in the Number column refer to the components as shown on page 11

DataSite Configured Panel Components (All Options Shown)

Number Component Description

1 DataSite controller Low power logic device used for calculation and storing of field attached measuring devices. 2 Radio Wireless communication device designed for sending data output from the DataSite configured

panel back to a central location.

3 Solar charge controller This device is designed to regulate the charging of the backup batteries of the DataSite

configured panel by using a solar panel as an external power source.

4 Backup batteries These batteries serve as a backup in the event that there is no output from the solar panel or

when there is no solar power available.

5 DC-DC converter

(optional)

6 Surge suppressor This device is designed to help protect the solar charge controller from high transient voltages

7 On/Off switch Primary power disconnect for the panel. May be locked in the ‘On’ or ‘Off’ position. 8 Human-machine

interface (optional)

9 ‘ON’ push button for the

HMI (optional)

This device outputs 24V DC for use with components requiring higher input than the 12V DC supplied from the solar panel and backup batteries.

caused by lightning strikes to the connected solar panel.

The human-machine interface (HMI) allows the user to see different parameters that are programmed into the DataSite controller. The HMI and the DataSite controller do not come programmed from the factory. In order for them to work together properly, they must be programmed. For more information, refer to the IDEC and DataSite user manuals.

This push button will turn on the HMI for a configurable amount of time. The push button serves as a power saving component by turning on the HMI only when necessary.

10 Fuse blocks Fuse holder for FU1, FU2 and FU3 fuses. 11 Lightning suppressor

(optional) 12 Terminal blocks (optional) Provided for ease of wiring to the DataSite controller. 13 Enclosure vents These provide pressure equalization and cooling of the DataSite configured panel enclosure.

This device helps protect the radio in the event of a lightning strike.

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DataSite Configured Panel Components

Front view (with door closed) Side view (with door closed)

Allen-Bradley

WARNING

CAUTION

Overview 11

Allen-Bradley

Mounting Holes

44746

Inside view

12 11

Note:

(3) is located beneath (8) and is not visible in this drawing.

44747

Mounting Holes

44748

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12 Overview

Panel Layout

This figure shows a typical layout of the DataSite configured panel.

Typical DataSite Configured Panel Layout

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Overview 13

Receiving, Handling, and Storage

Catalog Number Explanation

1-4 5 6 7-8 9 10 11 12-13 14 15-18 19 20-21 22 23 24-25

1748 - F DC - P - 14 - PS9E - 10 Y - TB

Bulletin Number

1748 DataSite Enclosure in

UL Type 4X polycarbonate

Code Product Type

F Enclosed with Flow Measurements (AGA) R Enclosed, RTU only

Code Analog Inputs

DC 0…10V DC MA 4…20 mA

Code Mounting Type

W Wall mounting kit P Pipe mounting kit

For a complete list of receiving, handling and storage instructions, please refer to "Receiving, Handling, and Storage Industrial Control Panels Instructions", publication 1000-IN001

The following chart describes the parts that make up the catalog number for a DataSite configured panel.

Antenna Cable Length

Code Battery

14 14 Ah 28 28 Ah 56 56 Ah

Radio

Code Brand Frequency Comm.

NR None None None Space for radio included. PS9E Prosoft 900 MHz Ethernet PS9S Prosoft 900 MHz Serial PS24E Prosoft 2.4 GHz Ethernet PS24S Prosoft 2.4 GHz Serial DL9E Datalinc 900 MHz Ethernet DL9S Datalinc 900 MHz Serial DL24E Datalinc 2.4 GHz Ethernet DL24S Datalinc 2.4 GHz Serial FW9E FreeWave 900 MHz Ethernet FW9S FreeWave 900 Mhz Serial FW24E FreeWave 2.4 GHz Ethernet FW24S FreeWave 2.4 GHz Serial

Code Feet Meters

NC None None 10 10 3.1 25 25 7.6 50 50 15.2 100 100 30.5

Cable length between panel and antenna must not be longer than 30.5m (100 ft).

Code Antenna Brand

Y Yagi OOmni NA No antenna

Code Enclosed Options

Blank No options AL Aluminum NEMA 4X enclosure, 60.96 x 50.8 x 25.4 cm (24 x 20 x 10 in.).

See note 6. TB RTU wired to control terminals. If not selected, no terminals provided. HMI IDEC display unit HG1X-222. See note 5. 24V 24V system voltage. This means 24V is available for field devices, but the

DataSite panel, radio and batteries remain at 12V DC. See note 8.

Notes:

1. Unit is UL Class I Division 2 certified only when FreeWave 900 MHz radios are selected (options FW9E and FW9S).

2. Solar panels are available from local RA authorized distributors. Please see DataSite Configured Panel Application Techniques, publication 1748-AT001A-EN-P for proper sizing and selection. Solar panels must meet UL Class I Division 2 if required.

3. Standard system voltage is 12V DC.

4. Radio surge suppressor included when a radio is specified.

5. Human-machine interface (HMI) option includes: 2-line, 16-character or 4-line, 20 character backlit LCD HG1X-222 is 24V DC and supports RS232 or RS485 communications. A 12V/24V voltage converter is included.

6. Replaces NEMA 4X polycarbonate enclosure.

7. DC-DC converter included for voltage conversion from 12…24 V DC.

8. If a radio is not selected, antennas and cables cannot be selected.

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14 Overview

Notes:

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Chapter

Install and Wire the Panel

This chapter provides you with an overview of the installation and wiring of the DataSite configured panel.

Environment and Enclosure

Hazardous Location Considerations

Most applications require installation in an industrial enclosure to reduce the effects of electrical interference and environmental exposure. Locate your controller as far as possible from power lines, load lines, and other sources of electrical noise such as hard-contact switches, relays, and AC motor drives. For more information on proper grounding guidelines, see the Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

ATTENTION

The DataSite configured panel is UL Listed for use in hazardous locations Class I Division 2, groups A, B, C, and D, or non-hazardous locations only.

Proper installation must be considered for the panel to be used in these locations. Installation of the panel should be done only after ensuring the location is free of any hazardous gases or substances. For proper installation refer to articles 500, 504 and 505 of the National Electric Code, NFPA 70,

2005.

Be careful of metal chips when drilling mounting holes for your controller or other equipment within the enclosure or panel. Drilled fragments that fall into the controller could cause damage. Do not drill holes above a mounted controller if the protective debris strips have been removed.

The following WARNING statement applies to use in hazardous locations.

WARNING

15 Publication 1748-IN001B-EN-P - May 2009

Explosion Hazard

• Substitution of any component may impair suitability for Class I

Division 2.

• Do not disconnect equipment while the circuit is live or unless

the area is known to be free of ignitable concentrations.

•

Batteries must only be changed in an area known to be non-hazardous.

16 Install and Wire the Panel

Panel Dimensions

Front view (with door closed) Side view (with door closed)

Allen-Bradley

Depending on the options chosen, the dimensions for the DataSite configured panel are 59.69 x 41.28 x 26.67 cm (23.5 x 16.25 x 10.5 in.) or

59.69 x 41.28 x 20.96 cm (23.5 x 16.25 x 8.25 in.).

WARNING

CAUTION

45.72 cm (18.00 in.)

57.98 cm

(22.83 in.)

Allen-Bradley

44751

Inside view

44752

Note: Depending on options chosen, the panel depth is 26.67 cm (10.50 in.) or 20.96 cm (8.25 in.).

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37.99 cm (14.96 in.)

44753

Install and Wire the Panel 17

Panel Weights

Mounting

The weight of the DataSite configured panel depends on the battery included. The following are the approximate weights of the panel for each battery option:

• With a 14 Ah battery: 9.07 kg (20 lb)

• With a 28 Ah battery: 13.61 kg (30 lb)

• With a 56 Ah battery: 20.41 kg (45 lb)

When planning the location for your DataSite configured panel, be sure to consider the following:

• Conduits

• Installation type and requirements for mounting

• Connection to other equipment

• Future needs

• Ambient considerations: The environment must be compatible with the

enclosure rating of the equipment.

When your panel was purchased, an option was available to purchase a pole or wall-mounting kit. In addition to properly mounting your control panel, other items such as radios, solar panels, auxiliary devices, sensors and incoming/outgoing cables will have to be installed to complete the installation of your DataSite configured panel.

The pole or wall mounting kit provided with the DataSite configured panel includes instructions on how to use those kits to properly mount the panel. Refer to those instructions for clear directions on how to mount the panel.

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