Weidmuller Ltd.
10 Spy Court
Markham, ON L3R 5H6
Tel: (905)475-1507
Fax: (905)475-5855
Weidmuller Ltd
821 Southlake Blvd.
Richmond, VA 23236 U.S.A.
Tel: (804)794-2877
Fax: (804)794-0252
ISO 9001 Registered
Electronic Interface Modules
G478 Ultra SlimPak®
Frequency Input,
Field Configurable Isolator
• field configurable via DIP switches for different inputoutput combinations
• provides an isolated DC output in proportion to the
input frequency
• easy field configurable input ranges from 2Hz to
10,000Hz
• eliminates ground loops with 1800Vdc input-to-output
isolation
• 5 field configurable output ranges 0-5V, 0-10V,
0-1mA, 0-20mA, 4-20mA
• 50mV to 150V input amplitude level
• advanced “touch-sample” technology for simplified
ranging
• flexible power supply accepts 9 to 30Vdc
• ASIC technology for high reliability
• CSA approved, UL recognized, CE marked
Description
Application
‘Touch-Sample’
Technology
Status LEDs
The Ultra SlimPak Model G478 is a DIN rail mount, frequency input signal conditioner with 1800Vdc
isolation between input, output and power. The field configurable input and output offer flexible, wide ranging
capability for variable frequency drives, magnetic pick-ups, turbine flow meters, and other pulse or frequency
output transducers.
The input of the G478 can be configured for any frequency span from 2Hz to 10,000Hz. The input amplitude
threshold sensitivity can be adjusted from 150mVp to 10Vp to ensure accurate frequency measurement and
minimize transient noise related errors. The maximum input amplitude is 150 Vrms. The output can be set for
either 0-5V, 0-10V, 0-1mA, 0-20mA or 4-20mA.
Advanced digital technology allows the G478 to be field configured for virtually any frequency input to DC
signal output within the ranges specified. Calibration utilizes 'Touch-Sample' technology where the user
simply applies the minimum and maximum input frequencies, touching a recessed button to configure the
corresponding minimum and maximum output range.
The very narrow Ultra SlimPak housing enables installations of up to 24 unit per linear foot. The wide ranging
power supply is inverter isolated and accepts any voltage between 9 and 30Vdc.
The Ultra SlimPak G478 field configurable frequency input signal conditioner is useful in eliminating ground
loops and interfacing pulse output transducers, such as turbine flow meters and magnetic pick-ups, to data
acquisition and control systems.
Advanced digital technology, combined with ASIC technology, provides a stable output at low frequencies for
higher accuracy, and three way isolation which completely eliminates ground loops from any source.
The G478 utilizes 'Touch-Sample' technology which greatly simplifies configuration. To set the input
frequency range, the user simply applies the high input frequency and pushes the CAL button while the
INPUT LED is lit. The low input frequency is then input and pushing the CAL button again stores the low
frequency input. The high and low ranges are stored in non-volatile memory and correspond to the high and
low output range which is selected via DIP switches. To precisely adjust the output, the user adjusts the
input frequency while the OUTPUT LED is lit until the desired output level is achieved. The output levels are
locked-in by pushing the CAL button. Status LEDs show the operation mode of the device.
The G478 utilizes three status LEDs. One is a dual function LED signal monitor. This green LED indicates DC
power and input signal status. Active line power is indicated by an illuminated LED. If the input signal is 10%
more than full scale range, the LED will flash at 8Hz. Below 0%, the flash rate is 4Hz. The yellow INPUT LED,
when on, denotes input programming modes. The red OUTPUT LED, when on, denotes output
programming modes (see Configuration, Calibration and Figure 1 for details).
Figure 1:
G478 calibration
flow chart
Table 1: Output switch settings
(SW1, 1 through 8)
Table 2: Input amplitude threshold
sensitivity settings
A major advantage of the G478 is its wide ranging capabilities and ease of configuration. The G478 enables
virtually 99% zero and span adjustability. Any 2Hz range from 0 to 10,000Hz can be converted to a full scale
output signal (e.g. 0-2Hz/4-20mA or 9998-10,000Hz/ 4-20mA).
Unless otherwise specified, the factory presets the Model G478 as follows:
Input Range: 0 to 1000Hz
Sensitivity: 1V RMS
Output Range: 4 to 20mA
Note: "Sensitivity" refers to the noise rejection level or the trigger threshold of the input.
For other I/O ranges, refer to Table 1 for output range (SW1, 1 through 8) switch settings and to Table 2 for
sensitivity switch setting (SW1, 9 & 10). For quick and easy calibration mode reference, see the step-by-step
flow chart in Figure 1.
1. With DC power off, choose the desired output voltage/current range from Table 1 and set position 1
through 8 of the output switch selector (SW1).
2. Set the Input sensitivity switch (SW1, 9 & 10) to LO for input amplitudes between 150mVp and 50Vrms,
with noise rejection to 1Vp. Set SW2 to HI for input amplitudes between 500mVp and 150Vrms, with noise
rejection up to 10Vp
Do not attempt to change any DIP SWITCH settings for the output (SW1) while power is applied.
Severe damage will result!
1. Connect the input to a calibrated frequency source and apply power. Wait 1 hour for thermal stability
before monitoring the voltage or current output.
2. Adjust the input frequency to the desired maximum and observe that the output has increased and is
sensing the input. If this is not observed, turn the sensitivity potentiometer in a counter-clockwise direction
until the output changes proportionally to the input.
3. With the green LED on press the CAL button once to enter the calibration mode. The yellow and green
LEDs should now be on.
4. Input the maximum desired frequency (if not done already) and press the CAL button to store. The yellow
LED should now be the only LED on.
5. Input the minimum desired frequency and press the CAL button to store. The green and red LEDs should
now be on.
Note: The most reliable way to input 0Hz is to short circuit the input pins (41&42).
6. To precisely adjust the maximum output, adjust the input frequency until the output reads within ±0.1% of
the maximum selected output range. This typically occurs near 90% of the HI input frequency. Press the
CAL button to store the value. The red LED will now be on.
7. To precisely adjust the minimum output, lower the input frequency until the output reads within ±0.1% of
the minimum selected output. This typically occurs near 10% of the HI input frequency. Press the CAL
button to store the value. The yellow and red LEDs should be on. The green LED should be dim.
8. Press the CAL button one final time to exit the calibration mode. The green LED should now be on.
9. Check the minimum and maximum input-to-output calibration. Repeat steps 1 through 8 if calibration is
not within desired specifications.
Note 1: To skip Steps 6 and 7 (output adjustment), press CAL button two times after Step 5.
Note 2: Removing power to the unit at any time before Step 8 will restore previous settings and calibration.
If the amplitudes of the input frequency is within the sensitivity parameters (i.e. 150mVp - 1Vp for LO and
0.5Vp - 10Vp for HI), then the sensitivity parameters can be set for optimum noise rejection.
1. Set the input near midrange (50% input) or to a frequency that exhibits the minimum pulse amplitude.
2. Turn the sensitivity pot (SENS) clockwise (CW) until the output drops to minimum.
3. Turn the sensitivity pot counter-clockwise (CCW) a turn or two until the output returns to the previous
level.
4. Run the input through the full frequency range to make sure that the pulses are sensed at both the low
and high input frequencies. If the output drops out during this test, when the input freq. >0% then turn the
sensitivity pot counter-clockwise another turn or two until the output picks up. Repeat to validate sensitivity
settings.
Configuration
WARNING:
Calibration
Optimal Sensitivity
Rated data
Input
Range
Impedance
Maximum ratings / type of protection
Field device excitation
Other input specification
Output
Range
Load
Burnout level
Zero / Span adjustment
Protection
Other output specification
Other output specification
Supply
Range
Consumption
Other supply specification
General
Accuracy
Linearity
Temperature coefficient (drift)
Transmission frequency
Response time. 90% span
Other general specification
Status LED
Isolation (# of ports)
Operating / Storage temperature
Housing (mounting)
Dimensions (L x W x H)
Wire range (conductor size)
Insulation stripping length
Tightening torque
Approvals
Ordering data
Ultra SlimPak
Heat sink (width)
Shunt resistor
Frequency signal (any wave shape)
Frequency: 0-2Hz to 0-10kHz, selected with Advanced ‘Touch-Sample’ calibration button
Amplitude: 150mVp to 150Vrms
>10kM
20kHz, 180Vrms
DC current or voltage
0-1mA, 0-20mA, 4-20mA, 0-5Vdc or 0-10Vdc, DIP switch selectable
<7.5kM (0-1mA), <600M (0/4-20mA), >500M (0-5V), >1000M (0-10V)
0 to 99% of full scale input (9998Hz) / 1 to 100% of full scale input (2Hz)
Sensitivity adjustment: HI (0.5-10Vpeak) or LO (150mV - 1Vpeak), switch selectable, potentiometer adjustable
DC voltage
9 to 30Vdc, inverter isolated
1.5W typ., 2.5W max. (300mA inrush at 9Vdc)
±0.1% of selected range at 25°C
included in accuracy
±0.025% of selected range/°C maximum
500mS or 100 times the period of full scale frequency
input green, programming yellow (input range status), programming red (output
range status)
1800V (3 port) between input, output and power
0 to 55°C / -25 to 70°C
EG8 (TS32 and TS35)
90mm x 12.7mm x 112.7mm max.
22-12AWG (0.5-4.0mm2)
7mm
0.4-0.8Nm
CSA (file LR-42272), UL (file E99775), CE marked (EMC dir. 89/336/EEC, LV dir. 73/23/EEC: Input<75Vpeak only)
Cat. No.
G478 (factory calibration: 0-1kHz, 120Vac amplitude, 1Vpeak sensitivity, 4-20mA Out)
HS01-A (1.6mm) (conditionally required depending on installation, see heat sink data)
Note: G478-000X where X is the revision level
Specifications subject to change without notice. 99990005 - 8/98 Printed in Canada
12.6
110.2
TS32 RAIL
88.5
105.2
TS35 RAIL
90.0
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