Model 1600A-N1R NEMA 1 Control Panel Operator’s Installation and Instruction Manual DETCON, Inc. 3200 Research Forest Dr., A-1 The Woodlands, Texas 77381 Ph.281.367.4100 / Fax 281.298.2868 www.detcon.com April 01, 2009 • Document # 3464 • Revision 0.
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1600A-N1R Table of Contents 1.0 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 3.4 4.0 4.1 Introduction .............................................................................................................................................1 System Configuration .............................................................................................................................2 Hardware Configurations ..........................................................................................................
1600A-N1R Figure 6 Interface wiring Terminals..................................................................................................................... 6 Figure 7 Interface PCA......................................................................................................................................... 6 Figure 8 I/O Module Installation........................................................................................................................
1600A-N1R 1.0 Introduction The Detcon Models 1600A-N1R is a “user-configurable” multi-channel alarm controller. The 1600A is configurable for up to 16 channels. Through the use of I/O modules the 1600A can receive analog inputs from either 4-20mA or contact closure modules, and can alternatively poll serial sensors via RS-485 Modbus™. The 1600A-N1R controller uses a modular design approach that allows the user to customize the selection of stand-alone input and output modules.
1600A-N1R 2.0 System Configuration 2.1 Hardware Configurations The Model 1600A-N1R is a “user configurable” alarm controller platform. The basic 1600A-N1R Controller includes the NEMA 1 19” Rack Mount enclosure with Controller Module (including display), Power Supply, two AC and one DC breakers, and DC over-voltage protection module. NOTE: I/O modules are factory installed unless specifically instructed otherwise. A maximum of 1 I/O modules will fit on the standard N1P enclosure.
1600A-N1R NOTE: The set-up configuration is fully field-programmable and can easily be executed by the user in the field, refer to Section 4.0 Setup. Modifications to the set-up configuration are expected to take place at the customer’s site due to requirement changes and/or system expansions. 2.
1600A-N1R 3.0 Installation Securely mount the Model 1600A-N1R in a suitable 19 inch rack. Allow at least 16” of depth for wiring. 19.00" 18.25" Model 1600A-N1P Multi-Channel Gas Detection Control System 5.75" 8.75" Figure 3 Unit Mounting and Dimensional Connect 110/220VAC input wiring to the terminals labeled “ACV (L1)”, “Neutral (L2)”, and “Ground” (See Figure 4). The Power Supply is capable of handling AC inputs from 100-240VAC 50-60Hz without degradation.
1600A-N1R POWER SUPPLY TOUCH SCREEN DISPLAY MADE IN CHINA V ADJ H GROUND (Grounding Stud) Green/Yellow Black White Black Black Black Red Red Red Red D2 D1 Red Red Black Black Red L+ M L+ M COMMUNICATIONS MODULE L+ M 2.7 2.6 2.5 2.4 2.3 2.2 2.1 2.0 1.7 1.6 1.5 2M ° 1.7 1.6 1.5 1.4 1.3 1.2 1.1 1.0 2L+ 2M 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 1L+ 1M 1 + 2 3 + 4 1.4 1.3 1.2 1.1 1.0 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.
1600A-N1R A B + RESET A B C NO NC Connect the RS-485 wiring from remotely located I/O devices to the terminals located on the Back Panel. These terminals are labeled RS-485 “A” (+), “B” (–), and “Shld” (shield) for primary RS-485 communication (Figure 6). RS-485 wiring should consist of a two conductor, shielded twisted pair (Belden cable P/N 9841 is recommended). Also available are two output terminal blocks to provide 24VDC to external RS-485 devices.
1600A-N1R The No Communications Fault Relay is connected to a set of Terminal Blocks on the DIN Rail (Figure 7 and Figure 5.) The Terminal Blocks are labeled “NO COMM” “C”, “NO” and “NC”. The Interface PCA, mounted on the back of the Display Panel, will de-energize the No Comm/Fault relay in the event there is a Communication Fault with any activated device.
1600A-N1R 3.2 Connecting to the I/O Modules 4-20mA Gas Sensors Connect 4-20mA type gas sensors to the Model DA4 4-20mA input modules. There are four 4-20mA inputs in each Model DA4 module.
1600A-N1R Relay Output Contact Modules There are four ‘Form C’ 5 Amp relay contacts in each Model RL4 module. These can be used to fire annunciating devices or as signal inputs to other control devices. Connect to the relay contacts of the Model RL4 module as shown Figure 11. Note that the Amp rating of the relay contact should not be exceeded. Figure 11 Model RL-4 Relay Module 4-20mA Output Modules There are four 4-20mA outputs in each Model AO-4 module.
1600A-N1R Figure 13 Model DI-4 Module General Wiring Notes: When I/O Modules are located at a remote distance from the controller, an end-of-line terminating resistor is required to enhance communications reliability. Identify the last I/O Module in the loop, and open the module casing using the clip release points. Locate and install the jumper on JP6 (TERM). This adds a 120: resistor to the end of the line. If applicable, add a 120: resistor to the last Modbus™ gas sensor.
1600A-N1R For a unit that has not been properly configured, the I/O modules must be serially addressed to establish correct communications. Typically, the I/O modules will be identified from 01 to FF starting from the module on the right hand side of the stack. The I/O module’s identification is established by setting the two rotary switches to the correspondingly correct position. The top rotary switch sets the most significant bit (MSB). The bottom rotary switch sets the least significant bit (LSB).
00A-N1R 4.0 Setup 4.1 Program Menu Selections To enter the Program Menu touch Program Menu and see Passwords in Section 5.4. NOTE: If any configuration changes are made to the system, the Modbus must be reset to ensure the system operates normally. See section 5.3for more information. Figure 15 Program Menu 4.1.1 Channel Setup The individual Channel set up screen is used to activate/disable each channel for which the 1600A is currently programmed. The 1600 has a maximum of 16 active input channels.
1600A-N1R Figure 17 Individual Channel Setup Channel Activation: If the channel is active, touch the ACTIVE button to disable it; touch the ENTER button to save change. If the channel is disabled, touch the DISABLED button to activate it; touch the ENTER button to save change. The main display will show “DISABLED” if a channel is selected as disabled. Tags/Labels: The Main, Zone 2 and individual channel screens displays the current tag names assigned to each active gas channel.
1600A-N1R 4.1.2 DA4 set up Touch the Analog Input/DA4 button. This function enables up to 4 DA4 modules. They are identified as CH 1-4, CH 5-8, CH 9-12, and CH13-16. There are four sensor inputs for each DA4 module, labeled 1 – 4. The address for each module is: CH 1-4 CH 5-8 CH 9-12 CH 13-16 01 Hex 05 Hex 09 Hex 0D Hex The DA4 menu is entered by pressing the Analog Input from the Program Menu. Channels 1 thru 4 are in Module 1-4. Channels 5 thru 8 are in Module 5-8 and so on.
1600A-N1R The second Model DA4 module with identification switches set to 05 and handling sensor inputs 5 – 8, would appear as follows: CH # 05 thru 08 4.1.3 DA4 Address 05 Hex Relay Activation and Configuration. For the Relay Output set-up, follow the same logic as with the gas channel set-up. Press the enable “ENABLE” key for the CH1-4 box to use the first RL4 module and then set its Device# to 41. Note, the block now shows as “ENABLED”.
1600A-N1R Figure 22 Setting up Relay Outputs NOTE: This selection controls the output state for that relay regardless of how many alarm/fault conditions for which the relay output may be used. A single relay output can only be set up in one configuration. The set-up for the first Model RL4 module would look like this: Relay # 01 thru 04 RL4 Address 41 Hex The second Model RL4 module set to 69 (45Hex) and handling relays 5 – 8, would appear as follows: Relay # 05 thru 08 4.1.
1600A-N1R Figure 23 Accessing Serial Setup Figure 24 Serial Setup screen Addressing Serial Sensors When connecting to a Detcon Model 600 or Model 700 Series sensor, the addressing procedure is different. First, note how the gas sensors are addressed. Each sensor must be set to a different address. The addresses start from 01 and count up to 16 (hex 10). An example is shown below to explain the procedure.
1600A-N1R 4.1.5 DI4s / Switch inputs DI4s set up The DI4 module is used to provide a switch input. The 1600A will display it as 0 for an open switch and 100 for a switch closure. The modules are CH 1-4, CH 5-8, CH 9-12, CH13-16. Each module takes 4 channels and has 4 inputs. The module address for each module is: CH 1-4 CH 5-8 CH 9-12 CH 13-16 01 Hex 05 Hex 09 Hex 0D Hex To activate a DI4 module, enter the Program Menu and press the Digital Input/DI4 button.
1600A-N1R Figure 27 Model DI-4 Module 4.1.6 4-20mA Output Setup This menu entry is used to address Detcon AO-4 modules 4-20mA output. NOTE: If there are no AO-4 modules being used, do not enter any device and address information on this screen. Misinformation entered here will cause the controller to generate a ‘No Communication Fault’. Figure 28 Set-up 4-20mA Outputs For example, assume setting up two AO-4 modules. Make sure to set each AO-4 module to a unique ID# using the front panel switches.
1600A-N1R 5.0 System Operation 5.1 Using the Touch-screen Display The Operator Interface is conducted through a graphic touch-screen backlit display. A suitable small blunt device such as the Detcon stylus wand should be used to conduct touch-screen interaction. NOTE: Sharp objects such as pens, pencils, screwdrivers, etc, are not permissible as they may permanently damage the display and will void the warranty.
1600A-N1R The controller may be configured to have less than eight channels per ‘Zone’. Only those ‘Zones’ with active channels will be displayed. Channels that have been disabled will show “DISABLED” in lieu of sensor information. When any channel in a ‘Zone’ has an alarm or fault condition the controller will automatically display the channels in that ‘Zone’. When there are alarms or faults in multiple ‘Zones’, the controller will display each zone for 10 seconds and rotate to the next ‘Zone’.
1600A-N1R Transfer Mode To place the 1600A in transfer mode, press the “TRANSFER” key. The system will begin shutting down and automatically go into transfer mode. Transfer mode allows the user to load critical updates from Detcon, Inc to the touch screen. Clean Screen The touch screen can be cleaned while the 1600A-N1R is operational. To do this, the user must press the “CLEAN SCREEN” key. Once the cleaning screen is activated, touch screen operation is locked for 30 seconds.
1600A-N1R Figure 32 On-Screen Keyboard 5.5 Secondary Modbus™ Port Model 1600A controllers feature Modbus™ compatible communications protocols and are addressable by a PLC, PC/HMI, DCS, or other Modbus™ RTU master device. Communication is accomplished by two wire half duplex RS-485, 9600 or 19,200 baud, 8 data bits, 1 stop bit, no parity, with the 1600A Controller secondary port setup as a slave device. Wiring should be brought directly to the back of the controller (See section 3.0 and).
1600A-N1R Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Low Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1 = Channel 15 Fault 1 = Channel 14 Fault 1 = Channel 13 Fault 1 = Channel 12 Fault 1 = Channel 11 Fault 1 = Channel 10 Fault 1 = Channel 9 Fault 0 = Channel 15 no Fault 0 = Channel 14 no Fault 0 = Channel 13 no Fault 0 = Channel 12 no Fault 0 = Channel 11 no Fault 0 = Channel 10 no Fault 0 = Channel 9 no Fault 1 = Channel 8 Fault 1 = Channel 7 Fault 1 = Channel 6 Fault 1 = Channel 5 Fault 1 = Ch
1600A-N1R Bit 3 Bit 2 Bit 1 Bit 0 1 = Channel 4 Alarm 2 1 = Channel 3 Alarm 2 1 = Channel 2 Alarm 2 1 = Channel 1 Alarm 2 40019 Alarm 3 Status Bits High Byte Bit 7 1 = Channel 16 Alarm 3 Bit 6 1 = Channel 15 Alarm 3 Bit 5 1 = Channel 14 Alarm 3 Bit 4 1 = Channel 13 Alarm 3 Bit 3 1 = Channel 12 Alarm 3 Bit 2 1 = Channel 11 Alarm 3 Bit 1 1 = Channel 10 Alarm 3 Bit 0 1 = Channel 9 Alarm 3 Low Byte Bit 7 1 = Channel 8 Alarm 3 Bit 6 1 = Channel 7 Alarm 3 Bit 5 1 = Channel 6 Alarm 3 Bit 4 1 = Channel 5 Alarm 3
1600A-N1R Figure 33 S7-200 USB/PPI Cable 5.6.1 Touch Screen Upgrade 1. Disconnect blue DB9 cable from PLC Communications Module (Figure 34). 2. Using a Gender Changer, connect the USB/PPI cable to the DB9 Cable disconnected from the PLC Communications Module, and connect the USB end of the USB/PPI cable to a PC or laptop. Enclosure Lid DB9 Cable Connector PLC Communications Module Figure 34 Display Back Panel 3.
1600A-N1R NOTE: This operation may take some time, depending on the type of connection selected. NOTE: Before entering Program Menu, an appropriate username and password may be required. 12. “Downloading successful” will display on the ProSave software once firmware upgrade has completed. 13. Remove USB/PPI cable from touch screen. 14. Cycle the power on the Model 1600A. 15. Verify the proper touch screen firmware version has been loaded.
1600A-N1R 6.
1600A-N1R Appendix A RS-485 System Integration Wiring RS-485 is a generic electrical specification only. It does not specify connector types, protocols, or cable type. It is the responsibility of the installer to provide a correct physical installation for the RS-485 network to function properly. RS-485 is very inexpensive and inherently rugged, allowing multiple devices to communicate over a single twisted pair of wires.
1600A-N1R The characteristic impedance of the cable must be between 100 to 120 ohms. Twisted pair is used because if the cable does run near a noise source both conductors will pick up the same amount of noise; therefore, effectively canceling it out. Incorrect Wiring Schemes Among the biggest problems with an RS-485 bus is the use of incorrect wiring schemes mixed with improper or no line termination.
1600A-N1R Figure 38 Recommended RS-485 communications set-up Grounding Another problem that can occur with RS-485 is incorrect grounding. Neither one of the two conductors in the cable is ground. Both of the conductors are supplying a current to maintain a voltage level relative to an external reference. A third conductor must be supplied to establish a reference through earth ground. RS-485 is specified be able to work normally with a ±7V ground potential difference and survive ±25V surges.
1600A-N1R Figure 39 Unbalanced Data Bus The addition of 2 repeaters (Figure 40) can solve this problem. The repeaters look like short stubs to the main bus, and at the same time they create 2 new buses that have all the same characteristics as the main bus. Each leg must have termination resistors to balance the new data bus. Figure 40 Data Bus using two repeaters Be sure to check the equipment being installed.
1600A-N1R Device Hook-Up Installation should begin by deciding where devices will be located and how the connections between devices and the master will be established. The ideal scenario would look like Figure 42. The example shows the 880 Controller connected to 11 slave devices using a daisy-chain wiring scheme. This would require 2 different twisted pair cables, one pair for power, and the other for the RS-485 data bus.
1600A-N1R In this case it is impossible to balance the data bus because there is no distinct beginning or end to the cable run. The best way to make this type of installation successful is to install repeaters in a few key areas as shown in Figure 44. Repeaters are used to eliminate the t-taps or stubs, which can cause communication problems. The location and number of stubs will dictate where repeaters need to be installed. Four repeaters are installed to eliminate the stubs.
1600A-N1R Appendix B Hexadecimal Table ID# none 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 SW1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 SW2 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A 1600A-N1R Instruction Manual ID# 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85
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1600A-N1R Appendix C Drawings and Diagrams 1. 1600A-N1R Dimensional Overview 2. 1600A-N1R Unit Overview 3. 1600A-N1R Wiring Diagram 1600A-N1R Instruction Manual Rev. 0.
1600A-N1R Page intentionally blank Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com 1600A-N1R Instruction Manual Rev. 0.
1600A-N1R Page intentionally blank Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com 1600A-N1R Instruction Manual Rev. 0.
1600A-N1R Page intentionally blank Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com 1600A-N1R Instruction Manual Rev. 0.
1600A-N1R Page intentionally blank Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com 1600A-N1R Instruction Manual Rev. 0.