SCADA 3000
Universal Input Module
UNIVERSAL INPUT MODULE
UIM-1
SCADA 3000 User’s Manual
Every effort has been made to ensure that the information in this document is complete, accurate and up-to-date. Phonetics, Inc. assumes no responsibility for the results of errors beyond its
control. Phonetics, Inc. also cannot guarantee that changes in equipment made by other manufacturers, and referred to in this manual, will not affect the applicability of the information in
this manual.
Copyright 1999 by Phonetics, Inc.
First Edition, version 1.0, June, 1999.
Written and produced by Phonetics, Inc.
Please address comments on this publication to:
Phonetics Inc.
901 Tryens Road
Aston, PA 19014
Sensaphone is a registered trademark of Phonetics, Inc.
For information on updates to this manual, check our website at
www.sensaphone.com
UIM-2
Universal Input Module
IMPORTANT SAFETY INSTRUCTIONS
Your UNIVERSAL INPUT MODULE has been carefully designed to give you years of safe,
reliable performance. As with all electrical equipment, however, there are a few basic precautions
you should take to avoid hurting yourself or damaging the unit:
•Read the installation and operating instructions in this manual carefully. Be sure to
save it for future reference.
•Read and follow all warning and instruction labels on the product itself.
•To protect the Universal Input Module from overheating, make sure all openings on
the unit are not blocked. Do not place on or near a heat source, such as a radiator or
heat register.
•Do not use your Universal Input Module near water, or spill liquid of any kind into
it.
•Be certain that your power source matches the rating listed in the specification
section of this manual. If you’re not sure of the type of power supply to your facility,
consult your dealer or local power company.
•Do not allow anything to rest on the power cord. Do not locate this product where
the cord will be abused by persons walking on it.
•Do not overload wall outlets and extension cords, as this can result in the risk of fire
or electric shock.
•Never push objects of any kind into this product through ventilation holes as they
may touch dangerous voltage points or short out parts that could result in a risk of
fire or electric shock.
•To reduce the risk of electric shock, do not disassemble this product, but return it to
Phonetics’ Customer Service, or another approved repair facility, when any service or
repair work is required. Opening or removing covers may expose you to dangerous
voltages or other risks. Incorrect reassembly can cause electric shock when the unit is
subsequently used.
•If anything happens that indicates that your Universal Input Module is not working
properly or has been damaged, disconnect it immediately and follow the procedures
in the manual for having it serviced. Return the unit for servicing under the following conditions:
1. Liquid has been spilled into the product or it has been exposed to water.
2. The unit has been dropped, or the enclosure is damaged.
3. The unit doesn’t function normally when you’re following the operating
instructions.
FCC Requirements
Part 15: This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy
and, if not installed and used in accordance with the instructions, may cause harmful interference
to radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the interference at his
own expense.
UIM-3
SCADA 3000 User’s Manual
Universal Input Module Supplement
Contents
IMPORTANT SAFETY INSTRUCTIONS.................................................................................. 3
FCC Requirements .............................................................................................................................. 3
INTRODUCTION .................................................................................................................. 5
Technical Support ............................................................................................................................... 5
INSTALLATION ..................................................................................................................... 6
OPERATING ENVIRONMENT ............................................................................................................ 6
MOUNTING THE UNIT...................................................................................................................... 6
POWER SUPPLY AND GROUNDING ................................................................................... 7
COMMUNICATIONS WIRING.............................................................................................. 7
Bus Termination .................................................................................................................................. 9
Sensor/Transducer Wiring................................................................................................................... 9
General Wiring Considerations ........................................................................................................... 9
Normally Open/Normally Closed Dry Contacts ............................................................................... 10
1OK Thermistors ............................................................................................................................... 10
Analog Voltage Output Transducers (0-5VDC) .................................................................................. 11
4-20mA Current Loop Transducers ................................................................................................... 12
HOW THE UNIVERSAL INPUT MODULE WORKS.............................................................. 13
APPENDIX A: 10K THERMISTOR CURVE DATA .................................................................. 14
APPENDIX B: SPECIFICATIONS ......................................................................................... 15
APPENDIX C: TROUBLESHOOTING................................................................................... 16
APPENDIX D: REPLACEMENT PARTS .................................................................................. 17
APPENDIX E: RETURNING FOR SERVICE ........................................................................... 18
WARRANTY......................................................................................................................... 19
UIM-4
Introduction
The SCADA 3000 Universal Input Module is an optional component for use with the SCADA
3000 system. The input channels are identical to those included on the SCADA 3000 main unit.
The Universal Input Module features eight channels that can be configured to interface with
several different types of sensors and transducers, including: Normally Open/Normally Closed
dry contacts, digital logic, Run time Accumulation, 0-5V analog, 4-20mA analog and 10K
thermistor (ºC & ºF). The module features 12-bit resolution, differential inputs, 24V supply for
powering 4-20mA loops and low-power operation. Each input is protected by a 1500 Watt
transient suppressor. In addition, a microprocessor watchdog circuit is integrated to maintain
system reliability. LED indicators are provided to show system power and module operation via
a blinking pulse LED.
Technical Support
If any questions arise upon installation or operation of the Universal Input Module, please
contact Phonetics Customer Service Department at the number shown below and have the
following information:
Universal Input Module
• Date of purchase __________________
• Serial number __________________
Technical support is available from 8:00 AM to 5:00 PM, EST.
You can also contact technical support at any time via e-mail at: support@sensaphone.com
Phonetics, Inc.
901 Tryens Road
Aston, PA 19014
Phone: (610)558-2700
FAX: (610)558-0222
www.sensaphone.com
UIM-5
SCADA 3000 User’s Manual
I. Installation
This chapter provides information necessary to install the Universal Input Module. Correctly
installing the unit will ensure proper functioning and maximum service life. Please read the
entire chapter before attempting installation.
OPERATING ENVIRONMENT
The Universal Input Module should be mounted and operated in a clean, dry and safe environment. Do not mount the unit where it will be subject to shock and vibration. Do not mount
the unit where it will be subject to dirt, dust or moisture. Ideally the unit would be mounted in a
steel or a fiberglass NEMA-4 enclosure. Do not mount the unit or the expansion modules close
to motor starters, contactors or relays that switch inductive loads. These devices generate large
electromagnetic fields that can cause the Universal Input Module to malfunction. Where this is
unavoidable, mount the module(s) and main unit in a separate, grounded, steel enclosure. This
will shield them from harmful electrical interference.
The temperature range the Universal Input Module can operate in is 32°F to 158°F (0°C to
70°C). If you require Universal Input Module to operate in a below freezing environment, you
must take safe and practical measures to keep the module’s temperature above 32°F or it will not
operate reliably.
CAUTION: The Universal Input Module is a sensitive electronic device. Personnel and work area should be grounded before handling this device. Do not install a
SCADA 3000 system near any strong electrostatic, electromagnetic, magnetic or
radioactive fields. Do not expose it to fumes or corrosive vapors.
MOUNTING THE UNIVERSAL INPUT MODULE
When you receive the Universal Input Module, carefully remove it from the box. On the top
and bottom of the enclosure are mounting holes to attach the unit to either a panel or wall. The
mounting surface should be sturdy enough to support 2 lbs. The unit should be mounted using
four #10-32 bolts where appropriate, or four #10 tapping screws. (The screw kit for the Universal Input Module includes 4 #10-32 screws, 4 #10-32 nuts, 4 #10 lockwashers, and 2 #6-32
screws, 2 #6-32 nuts, and 2 #6 lockwashers. The #6 hardware is for the power supply, if necessary.) When mounting the unit to a wall make sure the mounting screws fully engage a solid
member (for example, a stud) of the support structure. Mount the Universal Input Module in an
upright position so that you can easily connect wires to the terminal strips. The dimensions of
the full enclosure are: 6.1" x 6.3" x 1.2". See Figure 1.
UIM-6
0.25"
Universal Input Module
2.50"
Sensaphone
®
SCADA
3000
Phonetics, Inc.
0.20" DIA.
1.80"
6.11"
Figure 1: Module Mounting Dimensions
6.33"
5.83"
POWER SUPPLY AND GROUNDING
The Univseral Input Module operates on 10-15VDC. Typically the module is powered from the
AUX PWR terminals on the SCADA 3000 main unit. This is preferred because the AUX PWR
from the main unit is battery-backed in the event of a power failure, when a battery is connected
to the main unit. Alternately, you may connect the module to any 10-15VDC power source.
The module requires 1.5 Watts of power.
Universal Input Module
+
AUX
12VIN
+
OUT
24V
EG
ABYZ
RS232-DCE
COM 1
+++
012
15V
SPARE
FUSE
4A
AUX
+IN-
+PWR-
SCADA 3000
EG
BAT
+ -
24V
+
++++
3
5674
Connect to Electrical
Earth Ground
RS232-DTE
COM 2
Figure 2: Universal Input Module connected to SCADA 3000
UIM-7
SCADA 3000 User’s Manual
It is extremely important that the EG pin be connected to a good earth ground. This will
prevent communication errors due to differences in ground potential between modules in
addition to possible damage due to voltage transients and surges.
The two LED lights in the center of the module, marked Power and Pulse indicate that the
module is receiving power and operating properly. The Pulse LED will blink at a regular rate,
like a heartbeat, once it establishes communication with the main unit.
The module generates a 24V power supply for use with 4-20mA transducers. Module power
consumption will vary depending on how much power is being drawn from this supply. For
estimation purposes add 38mA to the power consumption specification for every 4-20mA loop
powered by the module. For example, since the module consumes 100mA by itself, if two 420mA transducers are connected to the 24V supply, then the estimated total power consumption
should be 176mA.
COMMUNICATIONS WIRING
The Universal Input Module communicates with the SCADA 3000 using a high-speed serial
communications bus. This 4-wire bus is used to connect up to 15 modules to the main unit to
provide additional inputs and/or outputs. Perform all wiring with power to the main unit and
modules turned off.
Modules may be located a maximum of 2000' away from the main unit and should be connected
in a daisy-chain fashion from one module to the next. Each module connects to the next via a 4wire communications cable connected to the terminals labeled A,B, Z & Y. The cable must be
4-Conductor Twisted Pair (shielded or unshielded) with a nominal impedance of 120Ω (for
example, Belden #8132 or 9842 cable). Use one pair for A & B and the other pair for Z & Y. The
proper wiring from the main unit to the modules, and from module to module, is shown in
Figure 3:
Module Module Module
Y
Z
B
A
reversed
SCADA 3000
Y
Z
B
A
straight-thru straight-thru
Y
Z
B
A
Module
Module
SCADA 3000
A
B
Z
Y
Figure 3: Correct daisy chain setup: Main unit on the end.
Module Module
UIM-8
Y
Z
B
A
Figure 4: Incorrect daisy chain setup: Main unit in the middle of the chain.
The Main Unit should always be on one end of the chain, never in the middle.
Y
Z
B
A
reversedstraight-thru
A
B
Z
Y
Y
Z
B
A
reversed
Y
Z
B
A
straight-thru
Universal Input Module
Each module must be configured with its own unique address using the BUS ADDRESS
jumpers. You may mix & match up to 15 modules to suit your application’s requirements. The
example below shows a Bus Address setting of 9.
Address Jumper Code
1 A B B B
2 B A B B
A B
1
2
3
4
BUS
ADDRESS
Figure 5: Setting the Bus Address
3 A A B B
4 B B A B
5 A B A B
6 B A A B
7 A A A B
8 B B B A
9 A B B A
10 B A B A
11 A A B A
12 B B A A
13 A B A A
14 B A A A
15 A A A A
Bus Termination
Located on each module is a jumper labeled BUS TERM. This jumper is used to terminate the
4-wire communications bus.
BUS TERM
IN OUT
Figure 6: Bus Termination jumper
0
Termination is required at the extreme ends of the communications network to minimize signal
reflections that would otherwise cause data communication errors. To activate the Bus Termination, move the jumper to the IN position. Note that this should only be activated if the module
is at the very end of the network. All other modules in between should have the termination set
to the OUT position. As a result, only 1 module should ever have the termination activated.
The diagram below illustrates proper termination of the communications bus.
Main
Unit
In
Out
Figure 7: Correct bus termination
Out
Out
In
Sensor/Transducer Wiring
The Universal Input Module is compatible with a wide variety of electrical signal sources
including contacts, 10K thermistors, analog voltage outputs and 4-20ma current sources. Each
UIM-9
SCADA 3000 User’s Manual
type of signal requires the configuration jumpers, located behind the terminal strip, to be installed in the proper position for each type of signal. Follow the instructions below to properly
wire and configure the inputs for each type of electrical signal. Note: Needlenose pliers will be
required to move the jumpers.
Warning: The inputs are designed to work with low voltage signals from 0-5V. DO
NOT connect differential voltages greater than 5V to the inputs. DO NOT connect
120VAC to the inputs. In the 4-20mA jumper position and when no jumper is
installed, the inputs are differential and will work with signals that are +/-12V away
from power supply ground. This allows the use of multiple 4-20mA circuits on one
loop. See circuit schematics for more information.
General Wiring Considerations
Most dry contact sensors can be connected to the module using inexpensive 2-conductor cable as
small as #24 AWG. For thermistor, 0-5V and 4-20mA sensors, use the wire chart below as a
reference for selecting the appropriate wire gauge. Note that if the sensor is located far from the
module or if you are running cable in an electrically noisy environment, you should seriously
consider using twisted pair shielded cable. This will shield the signal from electrical interference
thereby preventing false readings and/or damage to the module.
Wiring Minimum
Distance Wire Gauge
700' #24 AWG
1500' #22 AWG
2500' #20 AWG
Normally Open/Normally Closed Dry Contacts
Dry contact sources consist of relays or switches that are isolated and have no external voltage
applied. These devices can be connected directly to the input terminals without regard for
polarity. Choose an input and connect the wires to the corresponding screw terminals for that
input. The configuration jumper should be set to the TMP/DRY position. The figure below
shows how to connect a dry contact sensor:
Jumper
in
TMP/DRY
position
Universal Input Module
+—+—+—+
1234ABYZ
—
UIM-10
NO/NC
Dry Contact Sensor
Figure 8: Wiring a Dry Contact Sensor
Universal Input Module
1OK Thermistors
The Universal Input Module is compatible with 10K thermistors that match the curve data
listed in the table in Appendix A. The monitoring temperature range of the 10K thermistor is 80 to 300ºF (-62º to 149ºC). These devices can be connected directly to the input terminals
without regard for polarity. Choose an input and connect the wires to the corresponding screw
terminals for that input. The configuration jumper should be set to the TMP/DRY position.
The figure below shows how to connect a dry contact sensor:
Jumper
in
TMP/DRY
position
Universal Input Module
—+—+—+—
+
0123ABYZ
Thermistor
Figure 9: Wiring a Thermistor
Analog Voltage Output Transducers (0-5VDC)
The Universal Input Module is compatible with transducers that produce an analog output of 0
to 5VDC. You can program High and Low table values from the SCADA 3000 Software to scale
the signal to the appropriate values.
Analog voltage output devices can be connected directly to the input terminals but be sure to
following the polarity markings on the module. Choose an input and connect the wires to the
corresponding screw terminals for that input. The configuration jumper should be set to the
storage position as indicated in the diagram below:
Jumper in
Storage Position
for 0-5V.
Universal Input Module
+—+—+—+
0123
—
+
Figure 10: Wiring a 0-5V transducer
0-5V
transducer
UIM-11
SCADA 3000 User’s Manual
4-20mA Current Loop Transducers
The Universal Input Module is compatible with transducers that produce an analog output
current of 4 to 20mA. You can program High and Low table values from the SCADA 3000
Software to scale the signal to the appropriate values.
Analog 4-20mA output devices typically require a 24VDC power supply to operate. The Universal Input Module has an internal 24VDC power supply available for this purpose. The
24VDC power supply has enough capacity to power up to eight 4-20mA devices. Follow the
wiring diagrams below for connecting a 4-20mA device. The configuration jumper should be
set to the 4-20mA position as indicated in the following diagrams:
Jumper in
4-20mA
Position
AUX
+
12V IN
Universal Input Module
EG
24V
+
OUT
++
12
+
Figure 11: Wiring a 4-20mA device using the internal 24 VDC supply.
Universal Input Module
Jumper in
4-20mA
Position
24V
Power
Supply
+
AUX
+
12V IN
+
24V
OUT
EG
+
4-20 mA
Transducer
4-20 mA
Transducer
++
12
UIM-12
Figure 12: Wiring a 4-20mA device using an external 24VDC power supply.
Universal Input Module
HOW THE UNIVERSAL INPUT MODULE WORKS
The Universal Input Module provides eight inputs that can be configured for use with a variety
of sensors. Each input has a configuration jumper that conditions the signal appropriately based
on the attached sensor. The module continuously reads the signal at each input and communicates the value back to the SCADA 3000 via the 4-wire communications bus. The SCADA 3000
will allow you to set customized tables to scale the input accordingly. The value of each input
can be used in the ladder program or C-program to perform control functions. You may even
choose just to monitor or datalog an input and activate alarms based on high and low set-points.
The SCADA 3000 User’s Manual provides information on how to take advantage of all the
possibilities. Listed below are some of the possible applications for the Universal Input Module:
Temperature
Humidity
Power (Voltage level, Current level, Power consumption)
Pressure
Flow
Gases (Carbon Monoxide, Carbon Dioxide, Oxygen,…)
Liquid Level
Refrigerant Leak Detector
Water Detector
Weather (wind speed, wind direction, barometric pressure, rainfall)
Vibration
Sensors to monitor just about any condition are available. See the Accessories listing in Appendix
G of the main unit User’s Manual or contact Phonetics for more information.
UIM-13
SCADA 3000 User’s Manual
Appendix A: 10K Thermistor Curve Data
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73-53-K06.302
53-03-K06.371
23-52-K03.841
92-02-K01.721
62-51-K02.901
32-01-K70.49
12-5-K32.18
81-0 K23.07
51-5 K20.16
21-01K70.35
9-51K72.64
6-02K24.04
4-52K93.53
1-03K60.13
253K13.72
404K60.42
754K42.12
0105K97.81
3155K56.61
6106K87.41
8156K51.31
1207K27.11
4257K64.01
7208K53.9
0358K83.8
2309K25.7
5359K57.6
83001K80.6
14501K84.5
44011K59.4
74511K74.4
94021K50.4
25521K76.3
55031K33.3
85531K13.3
06041K67.2
36541K25.2
66051K03.2
96551K01.2
17061K29.1
47561K67.1
77071K16.1
08571K84.1
38081K63.1
68581K52.1
88091K61.1
19591K70.1
49002K89.0
79502K19.0
UIM-14
Appendix B: Specifications
Universal Input Module
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UIM-15
SCADA 3000 User’s Manual
Appendix C: Troubleshooting
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erusekaM.noitisoptcerrocehtnisitupniehtrofrepmujnoitarugifnocehterusekaM:noituloS
UIM-16
Appendix D: Replacement Parts
This appendix provides a list of replacement parts and part numbers for the FGD-3010 Universal Input Module. Contact the Phonetics Customer Service Department at (610)558-2700 for
availability.
2500-YSAdraoBtiucriCeludoMtupnIlasrevinU
7200-NOCgulPkcolBlanimreTnoitisoP61
3300-NOCtnuhSrepmuJnoitisoP2
4300-NOCgulPkcolBlanimreTnoitisoP4
8800-NOCgulPkcolBlanimreTnoitisoP5
8010-NOCtnuhSrepmuJnoitisoP4
5000-SUF )1400050273#nnamkciW(esuFgaL-emiTelyts-5RTV052Am005
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UIM-17
SCADA 3000 User’s Manual
Appendix E: Returning Module for Service
In the event that the Universal Input Module does not function properly, we suggest that you do
the following:
1) Record your observations regarding the Universal Input Module malfunction.
2) Call the Customer Service Department at (610)558-2700 prior to sending the
unit to Phonetics for repair.
If the module must be sent to Phonetics for Servicing, please do the following:
1) Disconnect all wiring and unplug the unit.
Note that the terminal blocks can be unplugged from the unit to maintain
your input wiring.
2) Carefully pack the module to avoid damage in transit. Use the original container
(if available) or a sturdy shipping box.
3) You must include the following information to avoid shipping delays:
a) Your name, address and telephone number.
b) A note explaining the problem.
4) Ship your package to the address below:
SERVICE DEPARTMENT
Phonetics Inc.
901 Tryens Road
Aston, PA 19014
5) Ship prepaid and insured via UPS or US Mail to ensure a traceable shipment with
recourse for damage or replacement.
Important Information for Canadian Customers
In the event that your Sensaphone SCADA 3000 unit does not function properly, Canadian
customers have the option of shipping the unit to one of the following Phonetics-authorized
Canadian Repair facilities:
Microwise Computer Systems G.A.S. Analytical Systems, Ltd.
100 Covington Crescent Head Office
Kitchener, Ontario N2N 2X3 Bay V, 1338 36 Avenue NE
(519) 744-9892 Calgary, Alberta T2E 6T6
(403) 253-6576
Please record your observations regarding the unit’s malfunction and follow the procedures
outlined on the previous page.
UIM-18
For Technical Support questions, you may call Phonetics Technical Service Department at (610)
558-2700, or by E-mail at support@sensaphone.com.
Universal Input Module
3 YEAR LIMITED WARRANTY
1. WARRANTOR: Dealer, Distributor, Manufacturer
2. ELEMENTS OF WARRANTY: This Product is warranted to be free from defects in
materials and craftsmanship with only the limitations and exclusions set out below.
3. WARRANTY AND REMEDY: Three-Year Warranty — In the event that the Product
does not conform to this warranty at any time during the time of three years from
original purchase, warrantor will repair the defect and return it to you at no charge
This warranty shall terminate and be of no further effect at the time the Product is (1)
damaged by extraneous cause such as fire, water, lightning, etc. or not maintained as
reasonable and necessary; (2) modified; (3) improperly installed; (4) repaired by someone other than warrantor; (5) used in a manner or purpose for which the Product was
not intended; or (6) sold by original purchaser.
WARRANTORS’ OBLIGATION UNDER THIS WARRANTY IS LIMITED TO REPAIR OR
REPLACEMENT OF THE PRODUCT. THIS WARRANTY DOES NOT COVER PAYMENT
OR PROVIDE FOR THE REIMBURSEMENT OF PAYMENT OF INCIDENTAL OR CONSEQUENTIAL DAMAGES.
It must be clear that the warrantors are not insuring your premises or guaranteeing that
there will not be damage to your person or property if you use this Product. The
warrantors shall not be liable under any circumstances for damage to your person or
property or some other person or that person’s property by reason of the sale of this
product or its failure to operate in the manner in which it is designed. The warrantors’
liability, if any, shall be limited to the original cost of the Product. The warrantors
assume no liability for installation of the Product and/or interruptions of the service due
to strikes, riots, floods, fire, and/or any cause beyond Seller’s control.
4. PROCEDURE FOR OBTAINING PERFORMANCE OF WARRANTY: In the event
that the Product does not conform to this warranty, the Product should be shipped or
delivered freight prepaid to a warrantor with evidence of original purchase.
5. LEGAL REMEDIES: This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state to the extent allowed by law expressly
in lieu of any other express or implied warranty, condition, or guarantee.
Effective date: 1 June 1999
Phonetics, Inc.
901 Tryens Road
Aston, PA 19014
Phone: (610) 558-2700 Fax: (610) 558-0222
UIM-19
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