User Manual for Sensata models including: DUALCON-6 24V AC or DC Powered Isolating Signal Converter, DUALCON-6, 24V AC or DC Powered Isolating Signal Converter, Isolating Signal Converter, Signal Converter, Converter
Signal Conditioner Help | Cynergy3
File Info : application/pdf, 16 Pages, 220.15KB
DocumentDocumentDUALCON-6 USER MANUAL DUALCON-6 24V AC or DC POWERED ISOLATING SIGNAL CONVERTER Whilst every effort has been taken to ensure the accuracy of this document, we accept no responsibility for damage, injury, loss, or expense resulting from errors or omissions, and reserve the right of amendment without notice. This document may not be reproduced in any way without the prior written permission of the company. AUG 2022 Sensata Technologies Page 1 220808 DUALCON-6 USER MANUAL CONTENTS 1. INTRODUCTION_____________________________________ 3 1.1 Hardware Features __________________________________ 3 1.1.1 Isolation Details __________________________________ 3 2. UNPACKING ________________________________________ 3 3. CONNECTIONS______________________________________ 4 4. CONFIGURING THE DUALCON _______________________ 5 4.1.1 Voltage Input: ____________________________________ 6 4.1.2 Current Input_____________________________________ 7 4.1.3 Millivolt (mV) Input _______________________________ 8 4.1.4 Potentiometer Input _______________________________ 9 4.1.5 Thermocouple Input ______________________________ 10 4.1.6 RTD Input______________________________________ 11 4.1.7 Output Configuration _____________________________ 12 5. CALIBRATING THE DUALCON_______________________ 13 6. INSTALLATION ____________________________________ 14 7. TROUBLESHOOTING _______________________________ 15 7.1 Incorrect Reading __________________________________ 15 7.2 Sensor Failure _____________________________________ 15 8. SPECIFICATIONS ( @ 25°C) __________________________ 16 Sensata Technologies Page 2 220808 DUALCON-6 USER MANUAL 1. INTRODUCTION 1.1 Hardware Features The DUALCON-6 is a universal input Isolating Signal Converter. It can accept virtually every type of analog input signal from millivolts to 40Vdc, mA, thermocouples, RTD's, etc. It also produces 3 types of analog output; voltage, mA source, or mA sink on either of 2 analog outputs. The unit can be powered by any DC voltage between 16 and 36Vdc or 18 and 32Vac. For mains AC voltage the DUALCON-3 is available which can be powered from any supply from 90Vac to 264 Vac at 50 or 60Hz. The instrument is packaged in a very compact 17.5mm wide enclosure which can be mounted on a standard TS35 DIN rail. 1.1.1 Isolation Details The DUALCON-6 has full 3 port isolation of 1000V between the Input Stage, Output Stage 1, Output Stage 2, and Power Supply for functional reasons. 2. UNPACKING The instrument should be carefully inspected for signs of damage that may have occurred in transit. In the unlikely case that damage has been sustained, DO NOT use the instrument, but please retain all packaging for our inspection and contact your supplier immediately. The instrument comes with the following items as standard: 1 DUALCON-6 Isolating Signal Converter 1 DUALCON-6 User Guide If the instrument has been factory configured the input and output details will be listed on the Serial number label on the side of the unit. If this label is blank then the unit will be set to its default configuration which is 4-20mA input and 2, 420mA source outputs. Please check that the details on the side label are correct, especially the power supply voltage. If re-configuration is required please refer to Section 4 of this manual. Sensata Technologies Page 3 220808 DUALCON-6 USER MANUAL 3. CONNECTIONS The DUALCON is housed in a compact DIN rail mounting enclosure, with 12 terminals, arranged in 4 rows of 3 terminals. Two rows are at the top of the front panel and 2 rows are at the bottom. All the sensor input terminals are on the bottom rows together with the second analog output, and the power supply and first analog output are on the top terminals. The diagram below shows how to connect all the different input, output, and power supply types. PSU 21 x OUTPUT 1 97 x 2 16-36Vdc / 18-32Vac 1 0V 9 +ve 7 - ve 0-10V Voltage Source 0(4)-20mA Current Source 24V Supply 4-20mA Sink Current Sink INPUT OUT2 5 4 12 INPUT OUT2 3 6 10 5 +ve 2 Wire RTD 4 Input: mA, Volts, mV, T/C - ve 2-wire transmitter 125R to 1K 2 Wire Pot 3 24V Tx Supply 4-20mA Sink 6 1K to 100K 3 Wire RTD 4 Wire RTD 3 Wire Pot 1 +ve 10 - ve 0-10V Voltage Source 0(4)-20mA Current Source 24V Tx Supply 4-20mA Sink Current Sink Sensata Technologies Page 4 220808 DUALCON-6 USER MANUAL 4. CONFIGURING THE DUALCON ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED The DUALCON is an extremely versatile device that can support many different types of input. The unit is configured by turning the power off, selecting the internal switch settings required, and turning the power back on. To open the DUALCON, 2 catches just below the outer terminal blocks must be pushed in gently, one at a time. The front of the case can then be pulled and the unit will come out of the box. Press here gently There are 4 switch banks, S1, S2, S3, and S4, located inside the DUALCON as shown below: Switch S3 1 12 Switch S4 1 12 Switch S2 1 12 Switch S1 1 12 ON = 1 10 11 12 OFF = 0 Switch 10 is OFF Switch 11 is ON Switch 12 is OFF Switch S1 and S2 configure the input type and range and switch S3 and S4 configure the output types, ranges, and a few additional functions. The switch settings are explained in the next few pages. The diagrams refer to switch positions 0 and 1, with 0 being OFF and 1 being ON. This is illustrated in the picture above. Sensata Technologies Page 5 220808 DUALCON-6 USERS GUIDE 4.1.1 Voltage Input: Select the range from the table below and set Switch S1 to the required values. Voltage Switch S1 Range 1 2 3 4 5 6 7 8 9 10 11 12 0-1V 000001001100 0-2V 0001 0 0-4V 0010 0 0-5V 0100 0 0-7.5V 1 0 0 0 0 0-8V 0011 0 0-10V 0 1 0 1 0 0-15V 1 0 0 1 0 0-20V 0 1 1 0 0 0-30V 1 0 1 0 0 0-40V 0 1 1 1 0 1-5V 0100 1 -5 to +5V 1 1 0 0 1 -10 to +10V 1 1 0 1 0 1 0 0 1 1 0 0 Then select the required setting from the table below for switch S2 Switch S2 Voltage Range ! WARNING ! ! DO 1NOT2OP3EN U4NIT5OR6ADJ7UST8SW9ITC1H0ES1W1 IT12H POWER SUPPLY, INPUT OR OUTPUT CONNECTED 0-30V & 0-40V Ranges 001100110000 All other Ranges Listed Above 001010100000 Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 6 220808 DUALCON-6 USERS GUIDE 4.1.2 Current Input Select the range from the table below and set Switch S1 to the required values. Switch S1 mA Range 1 2 3 4 5 6 7 8 9 10 11 12 0-1mA 000000001110 0-2mA 0001 0 0-4mA 0010 0 0-5mA 0100 0 0-8mA 0011 0 0-10mA 0101 0 0-15mA 1001 0 0-20mA 0110 0 0-30mA 1010 0 4-20mA 0110 1 4-40mA 0111 1 4-30mA 1010 1 -5 to +5mA 1 1 0 0 1 -10 to +10mA 1 1 0 1 0 0 0 0 1 1 1 0 Then select the required setting from the table below for switch S2 Switch S2 mA Range 1 2 3 4 5 6 7 8 9 10 11 12 Using Internal 24V Tx Supply for 4 to 20mA 110100110010 Unipolar Ranges (e.g. 0-20mA, 4-20mA) 110000110000 Bipolar Ranges (e.g. -10 to +10mA) 1 1 0 0 1 0 1 0 0 0 0 0 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 7 220808 DUALCON-6 USERS GUIDE 4.1.3 Millivolt (mV) Input Select the range from the table below and set Switch S1 to the required values. Switch S1 mV Range 1 2 3 4 5 6 7 8 9 10 11 12 0-25mV 000000011100 0-50mV 0001 0-100mV 0010 0-125mV 0100 0-150mV 1000 0-200mV 0011 0-250mV 0101 0-300mV 1001 0-500mV 0110 0-600mV 1010 0-1000mV 0111 0-1200mV 1011 -125 to +125mV 1 1 0 0 -125 to +1000mV 1 1 1 1 0 0 0 1 1 1 0 0 And then select the required setting from the table below for switch S2 mV Range All Unipolar Ranges (e.g. 0-500mV) Switch S2 1 2 3 4 5 6 7 8 9 10 11 12 010000110000 Bipolar Ranges (e.g. -125 to +125mV) 0 1 0 0 1 0 1 0 0 0 0 0 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 8 220808 DUALCON-6 USERS GUIDE 4.1.4 Potentiometer Input Select the range from the table below and set Switch S1 to the required values. Potentiometer Switch S1 Input 1 2 3 4 5 6 7 8 9 10 11 12 2 Wire 0-125R 0 0 0 0 0 0 0 1 1 1 0 1 2 Wire 0-250R 0 0 0 1 2 Wire 0-500R 0 0 1 0 2 Wire 0-625R 0 1 0 0 2 Wire 0-750R 1 0 0 0 2 Wire 0-1K 0 0 1 1 0 0 0 1 1 1 0 1 3 Wire from 0-1K to 0-100K 0 0 0 0 0 1 0 1 1 1 1 0 Then select the required setting from the table below for switch S2 Potentiometer Switch S2 Input 1 2 3 4 5 6 7 8 9 10 11 12 2 Wire Potentiometer 0 1 0 0 1 0 0 1 0 0 0 1 3 Wire Potentiometer 0 0 1 1 0 0 1 1 0 0 1 0 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 9 220808 DUALCON-6 USERS GUIDE 4.1.5 Thermocouple Input Select the range from the table below and set Switch S1 to the required values. Switch S1 for Thermocouple Input Temperature Range in °C Switch K J R S N E B T 1 2 3 4 5 6 7 8 9 10 11 12 0 to 100 400 to 500 0 to 50 0 0 0 0 00 0 0 to 200 400 to 600 0 to 100 0 0 0 1 0 to 400 400 to 800 0 to 200 0 0 1 0 T/C 0 to 800 400 to 1200 0 to 400 0 0 1 1 Type 0 to 125 400 to 525 -50 to 50 0 1 0 0 000 K 0 to 250 400 to 650 -50 to 100 0 1 0 1 001 J 0 to 500 400 to 900 -50 to 200 0 1 1 0 010 R 0 to 1000 400 to 1400 -50 to 400 0 1 1 1 011 S 0 to 150 400 to 550 -100 to 50 1 0 0 0 100 N 0 to 300 400 to 700 -100 to 100 1 0 0 1 101 E 0 to 600 400 to 1000 -100 to 200 1 0 1 0 110 B 0 to 1200* 400 to 1600 -100 to 400 1 0 1 1 111 T 0 to 175 400 to 575 -200 to 50 1 1 0 0 0 to 350 400 to 750 -200 to 100 1 1 0 1 0 to 700 400 to 1100 -200 to 200 1 1 1 0 0 to 1400** 400 to 1800 -200 to 400 1 1 1 1 00 0 Linearisation ON 0 Linearisation off 1 * n/a for types N and E ** n/a for types K, J, N and E CJC ON 0 CJC off 1 Then select the required setting from the table below for switch S2 Switch S2 Thermocouple 1 2 3 4 5 6 7 8 9 10 11 12 All Ranges 0 1 0 0 1 1 1 0 0 0 0 0 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 10 220808 DUALCON-6 USERS GUIDE 4.1.6 RTD Input Select the range from the table below and set Switch S1 to the required values. Range in °C Switch S1 1 2 3 4 5 6 7 8 9 10 11 12 0 to 100 0 0 0 0 00 100 0 to 200 0 0 0 1 0 to 400 0 0 1 0 0 to 800 0 0 1 1 -50 to 50 0100 -50 to 150 0 1 0 1 -50 to 250 0 1 1 0 -50 to 350 0 1 1 1 -100 to 50 1000 -100 to 100 1 0 0 1 -100 to 200 1 0 1 0 -100 to 400 1 0 1 1 -200 to 200 1 1 0 0 -200 to 400 1 1 0 1 -200 to 600 1 1 1 0 -200 to 800 1 1 1 1 00 100 RTD linearisation ON 0 RTD linearisation off 1 PT100 0 PT1000 1 RTD 2 or 4 wire 0 RTD 3 wire 1 And then select the required setting from the table below for switch S2 RTD 2 Wire RTD 3 Wire RTD 4 Wire RTD Switch S2 1 2 3 4 5 6 7 8 9 10 11 12 010010010001 010000001001 010000010100 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 11 220808 DUALCON-6 USERS GUIDE 4.1.7 Output Configuration Select the range for Output 1 from the table below and set Switch S3 to the required values. Switch S3 - Output Configuration 1 23456 78 9 10 11 12 0 1 0 1 0 mA Source 1 0 1 0 0 mA Sink 0 1 0 1 1 Voltage 0 Normal 01 1 Inverted o/p 0 Buttons Disabled 1 Buttons Enabled High Burnout 0 Low Burnout 1 Output value if fault on input signal Front panel buttons can be disabled to allow tamper-proof operation of the unit 4-20mA / 2-10V 0 0 0-20mA / 0-10V 0 1 0-10mA / 0-5V 1 0 2-10mA / 1-5V 1 1 Examples: 4-20mA Source 0-20mA Source 0-10V 4-20mA Sink Switch S3 Examples 1 2 3 4 5 6 7 8 9 10 11 12 101010000100 101010000101 101011000101 110100000100 Repeat the process for Output 2 using the table below for switch S4: Switch S4 - Output 2 Configuration 1 23456 78 9 10 11 12 1 0 1 0 1 0 mA Source 0 Normal 1 1 0 1 0 0 mA Sink 1 Inverted o/p 0 1 0 1 1 Voltage Normal 0 High Burnout 0 Square Root 1 Low Burnout 1 4-20mA / 2-10V 0 0 Output value if fault on input signal 0-20mA / 0-10V 0 1 0-10mA / 0-5V 1 0 2-10mA / 1-5V 1 1 ! WARNING ! ! DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED Please note that PC Software is available to provide information on switch settings for your input and output requirements. Sensata Technologies Page 12 220808 DUALCON-6 USERS GUIDE 5. CALIBRATING THE DUALCON When the unit is shipped the DUALCON will be calibrated for the input and output types and ranges noted on the side label. If this label is blank then the unit will be calibrated for 4-20mA input and 2 x 4-20mA source outputs. If the unit is re-ranged by the user it is necessary to re-calibrate the unit to obtain the maximum accuracy. The calibration is achieved by using both switches on the front panel to select the zero or span to adjust mode and then using the switches as raise/lower buttons to adjust the output to the value required. The mode the unit is in is indicated by the color of the LEDs for both channels: Green - Normal Operation Red - Span Adjust Yellow - Zero Adjust The setting of the zero and span points is non-interactive, so each point need only be set once. A typical calibration sequence would be as follows: LED CH1 Green RED Green YELLOW Green Green Green Green LED CH2 Green Green Green Green Green RED Green YELLOW Mode Normal Output 1 Span Adjust Normal Output 1 Zero Adjust Normal Output 2 Span Adjust Normal Output 2 Action Apply full-scale input. Press and release both buttons together to enter output 1 span mode Press the raise / lower buttons to adjust the output 1 value. Press and release both buttons together to return to normal mode Apply zero scale input Press and release both buttons together to enter output 1 zero mode Press the raise / lower buttons to adjust the output value. Press and release both buttons together to return to normal mode Apply full-scale input. Press and release both buttons together to enter output 2 span mode Press the raise / lower buttons to adjust the output 2 value. Press and release both buttons together to return to normal mode Apply zero scale input Press and release both buttons together to enter output 2 zero mode Press the raise / lower buttons to adjust Sensata Technologies Page 13 220808 DUALCON-6 USERS GUIDE Green Green Zero the output 2 value. Press and release both Adjust buttons together to return to normal mode Normal Use product The unit is now calibrated and ready for use. Note: The unit will retain the new settings on power down. When the unit is used to convert a thermocouple input it is important when calibrating to ensure that the thermocouple simulator employed is switched to automatic cold junction compensation and is at the same ambient temperature as the DUALCON. Note that this is not always easy to achieve, especially if the DUALCON is mounted in a warm cabinet. An alternative method is to use an icepoint reference and a mV source. 6. INSTALLATION The DUALCON's input and output circuits are classed as Separated Extra Low Voltage (SELV). This means that they must not be externally connected to voltages exceeding 30V ac or 60V dc, nor do they generate voltages above these limits internally. Where a higher voltage input is required a specially designed DIVIDER unit can be used to condition the input signal before connection to the process input terminals. The DUALCON unit clips directly onto the `Top Hat' (TS35) symmetrical DIN rail. Ideally, mounting orientation should be vertical, with the power supply situated on the top face to minimize temperature rise. Good airflow around the unit will maximize the reliability of the instrument. The use of bootlace ferrules is recommended for wiring terminations. Do not exceed the terminal torque rating of 0.4 Nm use an appropriate screwdriver. The unit can be removed from the DIN rail by sliding a small screwdriver into the slot at the rear of the enclosure on the lower face and gently levering the metal clip, whilst lifting the unit from the rail. Sensata Technologies Page 14 220808 DUALCON-6 USERS GUIDE 7. TROUBLESHOOTING The DUALCON has some built-in self-diagnostic functions. If the LEDs on the front panel are flashing then the fault mode can be found by counting the number of flashes between gaps and using the table below to locate the problem. No of Nature of Fault Corrective Action Flashes 0 Unit Working no suspected Check Wiring and switch (Green On) fault settings 2,3,4,5,6,8,9, Hardware Error, extreme Switch off the unit, check 10,11,12 noise, poor supply switch settings, and wiring, and green retry. If still faulty please contact the supplier 7 green RTD / Thermocouple Repair RTD, T/C, or wiring burnout 3 or 4 Red Span point is too close to Change input span value and zero point retry 3 or 4 Zero point is too close to Change input zero value and Yellow span point retry No LED Power Failure Check supply lines and voltage 7.1 Incorrect Reading · Check that Unit is configured for the correct Sensor · Check that Input Scaling is as required. · Check that Linearisation has not been set incorrectly. · Check that Thermocouples have correct compensation cables and polarity. · Check that RTD is set for correct option 2, 3, or 4 Wire. · Check that RTD leads are connected to appropriate terminal pins. 7.2 Sensor Failure · Check that sensor wiring is correct. · Check Thermocouple polarity. · Check that all RTD leads are connected to the correct terminals. · Check that the DUALCON is configured for the correct sensor. · Check that the applied voltage is not out of range. · Check that the applied current is not out of range. · Check that the applied millivoltage is not out of range. Sensata Technologies Page 15 220808 DUALCON-6 USERS GUIDE 8. SPECIFICATIONS ( @ 25°C) Operating Temperature Operating Altitude Humidity Power Requirements DC Supply AC Supply Current Consumption Transmitter Power Supply Calibration accuracy 0 to 55 °C Sea Level to 2000m 0-90% RH 16 to 36Vdc 18 to 32Vac 95mA ±5% @ 24Vdc (20mA in & out) 120mA ±5% @ 24Vdc (maximum load) 200mA ±5% @ 16Vdc (maximum load) 280mA for 75ms on 24Vdc power up 21V to 28V @ up to 24mA Depending on supply voltage and load ±0.05% full scale Linearity Temperature Stability ±0.05% full scale 50ppm / °C Input Impedance: Current Input 15 ohms Voltage Input 1 Mohm Millivolt Input Greater Than 10 Mohm Thermocouple Burn Out Current: 500nA Nominal Cold junction compensation accuracy ±0.5°C over operating range Maximum Voltage Output 11.5 V into a minimum of 7Kohm Maximum Current Output 23.0 mA into a maximum of 1Kohm Time Response (90% of a step change): 50ms ± 10ms The unit has full 3 port Isolation to 1kV between Power Supply, Input, and Output. The unit can also withstand transients of 2.5kV for 50 µsecs. Dimensions 114.5 mm x 99mm x 17.5mm (H x D x W) Mounting Connections DIN Rail TS35 Screw Clamp with pressure plate Conductor Size Insulation Stripping Maximum Terminal Torque Weight EMC Emissions EMC Immunity LVD Standards Installation Category (IEC 664) Pollution Degree (EN61010-1:1993) Equipment Class (IEC 536) 0.5 to 4.0 mm 12 mm 0.4 Nm Approx. 115g EN50081-1:1992 EN50081-2:1993 EN50082-1:1997 EN61010-1:1993 II 2 II Sensata Technologies Page 16 220808Microsoft Word for Microsoft 365