User Manual for Sensata models including: MATHSCON-6 24v AC or DC Powered Dual Input Mathematical Isolating Signal Converter, MATHSCON-6, 24v AC or DC Powered Dual Input Mathematical Isolating Signal Converter, Mathematical Isolating Signal Converter, Isolating Signal Converter, Signal Converter, Converter

ISOCON-6

Andrew Sime

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MATHSCON User Manual

MATHSCON-6
24V AC or DC POWERED DUAL INPUT MATHEMATICAL 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

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CONTENTS
1. INTRODUCTION _______________________________________________________3 1.1 Hardware Features _________________________________________________________ 3 1.2 Isolation Details ____________________________________________________________ 3 2. UNPACKING___________________________________________________________3 3. CONNECTIONS ________________________________________________________4 4. CONFIGURING THE MATHSCON ________________________________________5 4.1 Voltage Input ______________________________________________________________ 6 4.2 Current Input ______________________________________________________________ 7 4.3 Millivolt (mV) Input ________________________________________________________ 8 4.4 Potentiometer Input_________________________________________________________ 9 4.5 Thermocouple Input _______________________________________________________ 10 4.6 RTD Input _______________________________________________________________ 11 4.7 Output Configuration ______________________________________________________ 12 5. CALIBRATING THE MATHSCON _______________________________________13 5.1 Run Mode ________________________________________________________________ 13 5.2 Mode 1: Basic Calibration of Output __________________________________________ 13 5.3 Mode 2: Basic Calibration of Inputs 1 and 2____________________________________ 13 5.4 Mode 3: Advanced Scaling __________________________________________________ 14 5.5 Mode 4: Calibrate MATHSCON Output ______________________________________ 15 5.6 Reset the Calibration Values_________________________________________________ 16 6. INSTALLATION _______________________________________________________17 7. TROUBLESHOOTING__________________________________________________18 7.1 Incorrect Reading _________________________________________________________ 18 7.2 Sensor Failure ____________________________________________________________ 18 8. SPECIFICATIONS (@ 25°C)_____________________________________________19

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1. INTRODUCTION
1.1 Hardware Features The MATHSCON isolating signal converter can be user configured to carry out a wide range of mathematical functions on two isolated input channels. One input is a universal current, voltage, thermocouple, or RTD input and the other can be either voltage or current.
Each channel can be multiplied by a factor or linearised and then any of the following functions can be performed on these input channels Addition, Subtraction, Multiplication, Division, Square Root, High Signal Select, Low Signal Select, Absolute Difference.
The unit produces an isolated, scalable current or voltage output corresponding to the result of the required function.
The unit can be powered by any DC voltage between 16 and 36Vdc or AC voltage between 16 and 32Vac. The instrument is packaged in a compact 17.5mm wide enclosure which can be mounted on a standard TS35 DIN rail.
1.2 Isolation Details The MATHSCON has full 3 port isolation of 1000V between the Input Stage, Output Stage, 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 MATHSCON-6 Isolating Mathematical Signal Converter 1 MATHSCON-6 User Manual
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 on both inputs and 420mA source output, scaled as (A+B)/2.

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If re-configuration is required, please refer to sections 4 and 5 of this manual.
3. CONNECTIONS

The MATHSCON 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 and the power supply and analog outputs 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 1 IN 2 5 4 12 INPUT 1 IN 2 3 6 10

5 +ve 4 - ve Input 1: mA, Volts, mV, T/C

2 Wire RTD

125R to 1K 2 Wire Pot

2-wire transmitter

3 24V Tx Supply

4-20mA Sink

6

1K to 100K

3 Wire RTD 4 Wire RTD

3 Wire Pot

1 +ve Input 2: mA, Volts
10 - ve

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4. CONFIGURING THE MATHSCON

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

The MATHSCON 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 MATHSCON, 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, S5, and one link 201 as shown below:

Switch S3

1

12

Switch S2

1

12

Switch S5 1 2

Switch S1

1

12

Link 201

ON = 1

10 11 12

OFF = 0

Switch 10 is OFF Switch 11 is ON Switch 12 is OFF

Switch S1 and S2 configures input 1 type, S1 and S5 configures input 2 type, and S3 configures the output type and function. Link 201 should be fitted for a 3-wire potentiometer on input 1. 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.

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4.1 Voltage Input

Select the range from the table below and set Switch S1 to the required values. Note that Input 2 can be independently selected to be Voltage or Current for all types of Input 1 range and type.

Voltage Range Input 1 0-1V 0-2V 0-4V 0-5V 0-7.5V 0-8V 0-10V 0-15V 0-20V 0-30V 0-40V 1-5V -5 to +5V
-10 to +10V Input 2 0-10V 1-5V

Switch S1

1 2 3 4 5 6 7 8 9 10

0000101100

0001

0

0010

0

0100

0

1000

0

0011

0

0101

0

1001

0

0110

0

1010

0

0111

0

0100

1

1100

1

1101101100

11 12

10

11

Then select the required setting from the table below for switch S2 and S5.

Input 1

Switch S2

Voltage Range 1 2 3 4 5 6 7 8 9 10 11 12

0-30V & 0-40V

Ranges

001100110000

All other Ranges

Listed Above 0 0 1 0 1 0 1 0 0 0 0 0

Input 2

Switch S5

Voltage Range 1 2

0-10V and 1-5V 0 0

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.2 Current Input
Select the range from the table below and set Switch S1 to the required values. Note that Input 2 can be independently selected to be Voltage or Current for all types of Input 1 range and type.

mA Range Input 1 0-1mA 0-2mA 0-4mA 0-5mA 0-8mA 0-10mA 0-15mA 0-20mA 0-30mA 4-20mA 4-40mA 4-30mA
-5 to +5mA -10 to +10mA
Input 2 4-20mA 0-20mA

Switch S1

1 2 3 4 5 6 7 8 9 10

0000101110

0001

0

0010

0

0100

0

0011

0

0101

0

1001

0

0110

0

1010

0

0110

1

0111

1

1010

1

1100

1

1101101110

11 12

00

01

Then select the required setting from the table below for switch S2 and S5.

Input 1 mA Range Using Internal 24V Tx Supply for 4 to 20mA transmitter

Switch S2 1 2 3 4 5 6 7 8 9 10 11 12
110100100010

All other Ranges Listed Above

110010100000

Input 2 mA Range 4-20mA and 0-20mA

Switch S5 12 11

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.3 Millivolt (mV) Input

To set input 1 as a mV input type select the range from the table below and set Switch S1 to the required values.

mV Range

Switch S1

Input 1

1 2 3 4 5 6 7 8 9 10 11 12

0-25mV

0000111100

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 1 1 1 1 0 0

And then select the required setting from the table below for switch S2.

Input 1 mV Range All Ranges Listed Above

Switch S2 1 2 3 4 5 6 7 8 9 10 11 12
010010100000

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.4 Potentiometer Input
To set input 1 as a potentiometer select the range from the table below and set Switch S1 to the required values.

Potentiometer

Switch S1

Range Input 1

1 2 3 4 5 6 7 8 9 10 11 12

2 Wire 0-125R 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 1 1 1 0 1

3 Wire from 0-1K to 0-100K 0 0 0 0 1 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 0 0 0 0 1

3 Wire

also fit link 201 (see page 5 for details)

Potentiometer 0 0 1 1 0 0 1 0 0 0 1 0

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.5 Thermocouple Input Select the range from the table below and set Switch S1 to the required values.

Switch S1 for Thermocouple Input 1

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

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

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.

Input 1 Thermocouple

Switch S2

1 2 3 4 5 6 7 8 9 10 11 12

All Ranges

010011100000

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.6 RTD Input

Select the range from the table below and set Switch S1 to the required values.

Range in °C
0 to 100 0 to 200 0 to 400 0 to 800 -50 to 50 -50 to 150 -50 to 250 -50 to 350 -100 to 50 -100 to 100 -100 to 200 -100 to 400 -200 to 200 -200 to 400 -200 to 600 -200 to 800

Switch S1

1 2 3 4 5 6 7 8 9 10 11 12

0000

100

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

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.

Input 1 RTD

Switch S2

1 2 3 4 5 6 7 8 9 10 11 12

2 Wire RTD 3 Wire RTD 4 Wire RTD

010010000001 010000001001 010000000100

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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4.7 Output Configuration Output type and maths operation is selected with Switch S3.

Switch S3 - Output Configuration

1

23456

7

8 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 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

0 0 4-20mA / 2-10V 0 1 0-20mA/ 0-10V 1 0 0-10mA / 0-5V 1 1 2-10mA / 1-5V
0 0 0 Add 1+2 0 0 1 Multiply 1 * 2 0 1 0 Highest 1 or 2 0 1 1 Lowest 1 or 2 1 0 0 Subtract 1 - 2 1 0 1 Square Root (Subtract 1-2) 1 1 0 Difference 1 1 1 Divide 1/2

Switch S3 Examples

1 2 3 4 5 6 7 8 9 10 11 12

4-20mA Source 1 0 1 0 1 0 0 0 0 0 0 0

0-20mA Source 1 0 1 0 1 0 0 0 0 0 0 1

0-10V

101011000001

4-20mA Sink

110100000000

All these examples have the Add 1+2 maths function and High Burnout

! WARNING !

!

DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

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5. CALIBRATING THE MATHSCON
When the unit is shipped the MATHSCON 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 on input 1 and input 2 and 4-20mA source output. The maths function will be Add 1+2, with scaling equivalent to Input 1 0-50%, Input 2 0-50%, output 0-100%.
The MATHSCON is programmed and calibrated using a multimeter and one or preferably two input sources. The led on the front panel is used to indicate if the unit is in run mode (green) or one of the four programming modes (red or amber).
5.1 Run Mode In run mode the LED is green and the MATHSCON is working normally. Modes are selected by pressing either the up or down button on the front panel. After each press, the green LED will flash between 1 and 4 times to indicate which programming mode it will next enter (1 flash is mode 1, 2 flashes mode 2, etc.). To enter a programming mode both buttons must be simultaneously pushed and released.
5.2 Mode 1: Basic Calibration of Output The output must be calibrated to the output range selected with Switch S3. For example, if the output range selected is 4-20 mA :
· In run mode choose mode 1 (1 flash of the green led) · Push and release both buttons on the front panel, LED will flash once and then
go red · Adjust output to be 20 mA using the up and down buttons on the front panel · Push and release both buttons, LED will go amber · Adjust output to be 4 mA · Push and release both buttons, and the LED will go green, it is in run mode again
5.3 Mode 2: Basic Calibration of Inputs 1 and 2 The inputs must be calibrated to the two input ranges selected with switches S1, S2, and S5. Four values are learned in this order: Input 1 Span then Zero, Input 2 Span then Zero. For example, if Input 1 is 0-10V and Input 2 is 4-20mA.
· In run mode choose mode 2 (2 flashes of the green LED) · Push and release both buttons, LED will flash twice and then go red · Inject 10V into input 1. The output will take a few seconds to stabilize as the
input value is averaged to ensure an accurate reading is taken.

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· Wait until the output is stable then push the up button to confirm the value. · Push and release both buttons, the LED will go amber · Inject 0V into input 1 · Wait until the output is stable then push the up button to confirm the value · Push and release both buttons, the LED will go red · Inject 20mA into input 2 · Wait until the output is stable then push the up button to confirm the value · Push and release both buttons, the LED will go amber · Inject 4mA into input 2 · Wait until the output is stable then push the up button to confirm the value · Push and release both buttons, the LED will go green, it is in run mode again Note: if the up button is not pressed and released, the input value won't be learned.
5.4 Mode 3: Advanced Scaling If the input ranges are weighted differently (e.g., Input 1: 5-80%, Input 2: 18-65%), scaling must be applied to each input before the maths operation is applied. Four scaling values must be programmed to achieve this (e.g., a value represents 5, another 80, then 18 and 65). The scaling values are programmed into the MATHSCON by adjusting the output to proportionately represent the weighting of
ScalingVal = x *(OutputSpan - OutputZero) + OutputZero
Biggest
Where x is the %value to be represented (eg 5,80,18 or 65 in example), Biggest
is the biggest of the 4 %values (80), OutputZero and OutputSpan are the
values calibrated in Mode 1, for example 4 - 20mA the two inputs.
This equation allows us to calculate four scaling values: Input 1: 5-80% is 5 mA to 20 mA Input 2: 18-65% is 7.6 mA to 17 mA The four scaling values are learned in this order: Input 1 Span (20 mA) then Zero (5 mA), Input 2 Span (17 mA) then Zero (7.6 mA).
· In run mode choose mode 3 (3 flashes of the green led) · Push and release both buttons, the LED will flash 3 times then go red · Adjust output to be 20 mA using the up and down buttons on the front panel · Push and release both buttons, the LED will go amber · Adjust output to be 5 mA · Push and release both buttons, the LED will go red · Adjust output to be 17 mA · Push and release both buttons, the LED will go amber

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· Adjust output to be 7.6 mA · Push and release both buttons, led will go green, it is in run mode again
5.5 Mode 4: Calibrate MATHSCON Output The MATHSCON must be taught what the output should be for two different sets of input values, ideally at either end of the output scale. Best results are obtained with two input sources, but it is usually possible to do this calibration with only one. If one of the inputs is not connected, the value of that input will default to the %value of its zero point, so if the input is scaled from 0% and multiplication is carried out, the result will always be zero, regardless of the value on the other input. Similarly, for a "lowest" maths operation, two input sources are required to set up an output value that is not zero.
The two points are learned in this order: Output Span point then Zero point.
E.g.: Input 1 is 0-10V and Input 2 is 4-20 mA Input 1 is scaled 5-80% and Input 2 is scaled 18-65% Output is 4-20mA, maths operation is Add, Output is scaled 23% to 145%
If 2 input sources are available : · In run mode choose mode 4 (4 flashes of the green led) · Push and release both buttons, the LED will flash 4 times then go red · Inject 10V into input 1, 20 mA into input 2 · Adjust output to be 20 mA using the up and down buttons on the front panel · Push and release both buttons, the LED will go amber · Inject 0V into input 1 and 4 mA into input 2 · Adjust output to be 4 mA · Push and release both buttons, the LED will go green, it is in run mode again
If 1 input source is available (say 0-10V), calculate what the output should be with one input at full scale, the other at zero Output span point = ((80+18)-23)/(145-23)*(20-16)+4=13.836 mA · In run mode choose mode 4 (4 flashes of the green led) · Push and release both buttons, the LED will flash 4 times and then go red · Inject 10V into input 1, leave input 2 disconnected · Adjust output to be 13.836 mA using the up and down buttons on the front panel · Push and release both buttons, the LED will go amber · Inject 0V into input 1 leave input 2 disconnected · Adjust output to be 4 mA · Push and release both buttons, and the LED will go green, it is in run mode again

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If an input is not connected, the input value that the output uses will correspond to the value learned in Mode 2 when the zero-scale input was learned. In other words, the input is clipped at the bottom end. Inputs are not clipped at the top end, however.
5.6 Reset the Calibration Values
To reset the Mode 4 output calibration, change one of switches 11 or 12 and power on, off then change the switch back again. To reset the Mode 3 maths scaling, change one of switches 8, 9, or 10 and power on, off then change the switch back again.

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6. INSTALLATION
The MATHSCON'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 MATHSCON unit clips directly onto the `Top Hat' (TS35) symmetrical DIN rail. Ideally, mounting orientation should be vertical. Good airflow around the unit will maximize the reliability of the instrument.
The use of 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.

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7. TROUBLESHOOTING

The MATHSCON has some built-in self-diagnostic functions. If the LED on the front panel is flashing, then the fault can be found by counting the number of flashes between gaps and using the table below to locate the problem.

No of Flashes
0 (Green On)
2,3,8,9, 10,11,12
green 7 green
No LED

Nature of Fault
Unit Working ­ no suspected fault Hardware Error, extreme noise, poor supply RTD / Thermocouple burnout Power Failure

7.1 Incorrect Reading

Corrective Action
Check Wiring and switch settings
Switch off the unit, check switch settings, and wiring, and retry. If still faulty please contact the supplier Repair RTD, T/C, or wiring
Check supply lines and voltage

· Check that Unit is configured for the correct Sensor · Check that Input Scaling is as required. · Check that Linearisation has been set correctly. · 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 MATHSCON 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.

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8. SPECIFICATIONS (@ 25°C)

Operating Temperature Operating Altitude Humidity Power Requirements DC Supply
AC Supply Current Consumption
Transmitter Power Supply
Calibration accuracy Linearity Temperature Stability

0 to 55 °C Sea Level to 2000m 0-90% RH 16 to 36Vdc 16 to 32Vac 55mA @24VDC (20mA in & out) 85mA @24VDC (maximum load, tx supply) 200mA@16VDC (maximum load, tx supply) 260mA for 50ms on 24VDC power up 22V to 29V @ up to 24mA Depending on supply voltage and load ±0.05% full scale ±0.05% full scale 50ppm / °C

Input Impedance:

Current Input

15 ohms

Voltage Input

1 M ohm

Millivolt Input

Greater Than 10 M ohm

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

DIN Rail TS35

Connections

Screw Clamp with pressure plate

Conductor Size

0.5 to 4.0 mm

Insulation Stripping

12 mm

Maximum Terminal Torque

0.4 Nm

Weight EMC

Approx. 106g BS EN61326

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