4800 Gas Controller User Guide

Transcription

1 4800 Gas Controller User Guide Publish Date: April, 2007 Document Version 4.0

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3 Table of Contents Chapter 1: Description... 1 Overview... 1 Key features... 1 Expandable... 1 Easy to install and configure... 1 Easy to operate... 2 Communications capabilities... 2 Chapter 2: Installation and Setup... 3 Overview... 3 What is the Installation Process?... 3 Unpacking the Equipment... 3 Operating Environment... 3 Mounting the Equipment... 4 Main Power Connection... 5 AC Wire Size... 5 Proper Grounding... 5 Optional DC Power Connection... 6 Analog Input Wiring... 6 Relay Wiring... 9 Digital Input Cards... 9 RS-485 Wiring Chapter 3: Operation Overview How to use the Keypad Key summary Front Panel Light Indicators How to Enter Text for Names Operation Viewing the Display Automatic Alarm Screen RUN Mode screens Chapter 4: PROGramming Mode from the Keypad...20 Chapter 4: PROGramming Mode from the Keypad...21 Overview Display Selecting a menu item Display Changing a setting Quick Programming Steps Step 1 - Determine how relays are going to be controlled Step 2 Configure the sensor inputs Step 3 Enter relays into the Relay Lists Step 4 Save Programming System Wide Settings Sensor Channel Setting Analog Inputs Relay Outputs Digital Inputs Relay List Setup Relay Operations Chapter 5: Modbus RTU Master Overview... 31

4 Port 1 Configuration Initializing the Modbus Master Interface Mapping 4800 Channels to Modbus Registers Programming Channel Parameters Chapter 6: Modbus RTU Slave Overview Serial Port Settings Modem Settings Modbus Slave ID Register Mapping Error Returns Chapter 7: PC/Laptop Access Chapter 8: Datalogging Chapter 9: Glossary Programming Sheets Index Copyright and Trademark Information All Pages Copyright 2007 Industrial Scientific Corporation. All Rights Reserved. U.S. Government Users Restricted Rights. Use, duplication, or disclosure by the Government is subject to restrictions as set forth in applicable laws and regulations. Use of the materials by the Government constitutes acknowledgment of Industrial Scientific's proprietary rights in them. This manual may contain other proprietary notices and copyright information that should be observed. Information in this document is subject to change without notice. The software described in this document is furnished under a license agreement or nondisclosure agreement. The software may be used or copied only in accordance with the terms of those agreements. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser s personal use without the written permission of Industrial Scientific.

5 Chapter 1: Description Overview The 4800 Gas Controller monitors, displays, controls and communicates current sensor readings and alarm conditions for up to 40 wired sensors or up to 72 Modbus-connected sensors. The 4800 is available in configurations from 8 to 48 analog inputs, 4 to 24 relay outputs and from 8 to 72 Modbus RTU inputs. Input sensors can be gas sensors or any other sensor that produces a 0-20ma current or 0-10VDC voltage or a Modbus RTU digital output. All inputs are converted into engineering units for display, status annunciation Key features Supports common, low and high relays for groups and individual channels Relay deactivation based on sensor input or time elapsed since alarm Supports wide range of engineering units including ppm, ppb, %vol, %, %lel Any sensor can control any relay providing extreme flexibility Controls up to 9 local or remote relays from a single alarm condition Automatic detection and alarming of open loops, low battery, or power fail Event and data recording 24 hour battery backup Industry-leading 5-year warranty Modbus Master and Slave capability Voice prompts for programming and review Alarm notification to phones, cells, pagers and faxes Optional Internet programming and reporting Expandable Simple and affordable plug in cards for sensors, relays, or digital inputs Supports 8-48 input sensors Relay expansion using 4-channel cards Additional expansion through networking Easy to install and configure Five minute setup from keypad or PC connection Front panel display and voice prompts Works with any manufacturer s linear 4-20mA or low voltage sensors Meets and exceeds specs of virtually all fixed gas controllers Quick sensor setup 1

6 Easy to operate Bright front-panel LEDs enable rapid on-site diagnosis of warnings and alarms Function keys provide quick access to channel readings, alarms, alarm acknowledgement, peak readings, clearing peaks, disarming unit and more Printer port enables data dump of all system settings, states, and programming Optional remote access by Internet, phone, or cell phone Communications capabilities Alarm notification via fax, voice, pager Daily fax status reports Internet monitoring service Modbus Master to distributed sensors SCADA interface (Modbus Salve) Communicate between multiple 4800 Controllers Wireless communication 2

7 Chapter 2: Installation and Setup Overview This chapter provides information on installing the 4800 Gas Controller and confirming its initial operation. Performing a proper installation ensures the correct operation of the 4800 for maximum life. Please read the entire chapter before starting the installation. What is the Installation Process? Installation consists of the following steps: 1. Unpacking the Equipment 2. Mounting the Equipment 3. Connecting the Main Power 4. Connecting the Input and Output Cards 5. Testing the System Each step is described in detail in the remainder of this chapter. Unpacking the Equipment The 4800 Gas Controller is shipped with the following: The 4800 in either a NEMA 4X plastic enclosure or metal enclosure, A set of I/O cards installed, An installed backup battery, User Guide, and phone cord. Operating Environment The 4800 should be installed in an environment that is not subject to shock or vibration. The operating temperature of the 4800 is -40 to 150ºF (-40 to 66ºC). If the 4800 is going to be operating at temperatures below the operating temperature, we recommend that controlled heaters or heat strips be installed to keep the temperature adequately warm. Contact your local distributor, representative or the factory for additional information 3

8 Mounting the Equipment The 4800 Gas Controller is available in a NEMA 4X enclosure or panel/flush mount enclosure The NEMA 4X enclosure, which can be mounted indoors or outdoors. NEMA Enclosure Figure 1- NEMA 4X dimensions Panel/Flush Mount Enclosure Figure 2 Panel/Flush Enclosure Mounting Dimensions 4

9 Main Power Connection The 4800 Gas Controller operates on 100 to 240 VAC, 50-60Hz. There are no selections required by the user to select the input power. The main AC is connected to the 4800 using the AC terminal block located inside the unit. The terminal block is labeled L=Line (black), G=Ground (green or green/yellow), N=Neutral (white) Figure 3 - AC power wiring For the NEMA enclosure, you must drill an access hole to bring the wires into the unit. The access hole should be drilled on either the bottom or side of the enclosure. WARNING! Be sure to look inside the unit prior to drilling so that you can be sure there is sufficient clearance for the hole and the fitting that you are using. AC Wire Size The AC line wire should be 16 AWG or heavier wire. Proper Grounding Elite must be earth-grounded by connecting a true earth ground to the ground terminal designated by the symbol. NOTE The Ground (green or green/yellow) wire should be made at least 2 inches longer than the other wires as a safety precaution in the event that the line cord is pulled out of the unit. The 4800 can be damaged by power surges and lightning through the telephone line and power supply. Although the 4800 has built-in surge protection, we strongly recommend that additional protection be obtained for the unit and for any electronic equipment that is attached to your power supply and telephone lines. Power surge protection is especially important if you live in a lightning-prone area. NOTE Lightning damage is not covered under warranty. CAUTION Failure to supply a good earth ground for the AC power causes the 4800 s internal surge and lightning protection to be ineffective. 5

10 Optional DC Power Connection For applications where standard AC power is not available, the 4800 can be powered by an external DC power source. The system operates exactly the same with the exception of the following: DC power source 4800 Gas Controller operation VDC Same as with AC VDC Same as with AC except the supplied backup battery is not charged by the 4800 To connect an external 15 to 18 VDC supply, disconnect the wiring harness that attaches the power supply mounted above the backup battery from the processor board mounted on the hinged door. The easiest way to disconnect this harness is to unplug the quick disconnect connector from the processor board and then unscrew the three (3) wires from the plug. Analog Input Wiring The analog input board has terminals for up to eight (8) channels to be connected. Each board is equipped with a quick disconnect socket that allows for easy connection of sensor wires. There are two (2) connections for each sensor, a (+) and a (-) as labeled on the board bracket. Inputs to the board may be any of the following for each individual channel: Unipolar Voltage Current 0 1 Volts 0 20ma 0 5 Volts 4-20ma 1 5 Volts 0 10 Volts The current inputs, 0 to 20ma and 4 to 20ma, require a supply of power to operate. You may power these inputs using the 24VDC supply that is on the side of the analog card or you may connect to an external power supply. The 24VDC supply can source up to 300ma on each analog input card, however the total available in an entire system is only 500ma. Each channel of the Analog input cards accept either current or voltage inputs, that are configurable through the programming. There are no switches or jumpers to set. NOTE The (-) return on each Analog Input channel is connected to ground. If you are going to daisychain a current loop, then the 4800 connection must be the last in the loop. Current inputs require power to be supplied to them. The power can originate from the Analog Input card, an external power source or the sensor itself may have a transmitter. Each input channel is independent of any other input channel. A fault on one channel does not affect the conversion result on the other channels. Industrial Scientific recommends that you use medium-gauge wire (14 to 24 AWG) twisted pair. 6

11 NOTE: The loop resistance is 240 ohms. The maximum current from the 24VDC supply on the analog card is 250ma. The entire Elite can supply 300ma. Figure 4 - Analog 4-20ma and Voltage connections for analog input cards 7

12 NOTE: The loop resistance is 240 ohms. The maximum current from the 24VDC supply on the analog card is 250ma. The entire Elite can supply 300ma. Figure 5 - Analog 4-20ma and Voltage connections for analog input cards with separate 24VDC connector 8

13 Relay Wiring Each relay output board has terminal connections for four (4) relays. The 4800 can be configured for a maximum of 24 relays, each independently controlled either directly or under alarm conditions. Each board is equipped with two quick-disconnect sockets that allow for easy connection of sensor wires. There are three (3) connections for each relay: Normally Open (NO), Common (C) and Normally Closed (NC) as labeled on the board bracket. Relay outputs are typically used to control other equipment, lights, horns or visual alarm indicators. Each relay output board has four (4) Form C Single-Pole Double-Throw (SPDT) relays. Switching capability of each relay is: 8 Amps at 125 VAC 6 Amps at 277 VAC 5 Amps at 30 VDC The following diagram shows proper wiring for a relay. Removable connector NOTE: top 2 connection points are NOT used Figure 6 - Relay wiring Digital Input Cards The digital input boards are 8 channel modules. Each board is equipped with a quick disconnect plug that allows for easy connection of sensor wires. There are two (2) connections for each sensor, a (+V) and a (IN) as labeled on the board bracket. Inputs to the board may be either: Dry contact, or 0-30VDC signals (0-6VDC is open, 6-30VDC is closed) 24 volts is used to complete the dry contact circuit to provide a means to break down the dielectric buildup on dirty switch contacts. The +V connection is 24VDC. Each digital input is designed to monitor a Normally Open (NO) or Normally Closed (NC) relay or voltage input. Terminals for all input channels are located on the opposite end of the card from the LEDs. There are separate quick disconnect connectors for each group of 4 inputs. The channel numbers are located on the metal housing next to each connector. 9

14 Notice that each connector has two (2) terminals, (IN) and (+V). If all of your inputs are originating from a location near each other, you can wire all of the (+V) signals together on the Elite connector and take a single (IN) signal to your sensors. See Figure 8. If your inputs are widely distributed, we recommend that you use two (2) wires for each input. See Figure 7. Medium gauge (18 to 22 WG) twisted pair wire such as Beldon #8205 or equivalent is acceptable. You may also use a multi-conductor cable if all your wiring is in the same panel. Normally Open Normally Closed Figure 7 - Preferred input wiring: two wires per channel. Daisy-chained wiring using a common voltage source Normally Open Normally Open Normally Closed Voltage input: 6-25 VDC Contact closes to ground. Input Channel State is set to Normally Closed. Figure 8 - Daisy-chained, direct voltage input and contact to ground wiring. The 24VDC signal (+V) must be daisy-chained to all common points on the sensors that are being monitored to supply a power signal that can be sensed by the Elite. 10

15 RS-485 Wiring The 4800 supports RS-485 communication through Port 1. Port 1 can be configured to use either the DB9 RS-232 port or the RS-485 port through the Options Setup (8). Both are located on the back of the large printed circuit board. The RS-485 connection is a removable screw-terminal connector. Open Term Gnd B A If the 4800 is on the end of the 485 communication line, move the jumper from the Open position to the Term position to terminate the RS-485 line. 11

16 Chapter 3: Operation Overview The 4800 Gas Controller provides real-time display and alarming of gas sensors. Gas sensors are connected to the 4800 as current or voltage signals to 8-channel analog input cards. There can be up to 6 8-channel cards in a system for 48 sensors total. Each sensor has several alarm limits associated with it, each of which can control a separate alarm relay. The 4800 has 4-channel relay cards to control lights, horns, blowers or other equipment. The display shows the current status of alarms, sensor readings, peak values, calibration times and all programming prompts and settings. Programming is performed by pressing keys on the keypad and listening to and viewing the programming prompts. LEDs are provided for each sensor and relay and indicate the current state of each. Display Microphone for recording voice alarm messages Keypad Speaker for voice prompts LEDs for system status LEDs for each sensor and relay Figure Gas Controller Front Panel 12

17 How to use the Keypad The keypad allows functions to be performed locally by pressing individual keys or sequences of keys. The keypad is divided into several sections, each with its own color. The red keys EXAMPLE The green keys The RED keys are the typical phone-pad keys and are used to enter numbers to navigate through menus, enter phone numbers, and select various options when programming. Several of the RED keys are split, where the top of the key has a number or symbol and the bottom of the key provides a function. 5 SpkrPh The 5 key has SpkrPh at the bottom, providing access to the Speaker Phone function. The GREEN keys provide quick single-key operation for specific functions. Each of the GREEN keys is split: The top of key indicates the operation performed when the system is in RUN mode, and The bottom of the key indicates what operation is performed when the system is in PROGramming mode. Disarm EXAMPLE Bksp The Disarm/Bksp key allows you to disarm the system when in RUN mode and erase the previous key entry when in PROGramming mode. The blue keys The BLUE keys, or Quick Access keys. The bottom row of the display has text above each key that defines the function that is performed when that F-key is pressed. 13

18 Key summary Below is a listing of each key in RUN mode and in PROGramming mode. Key When in RUN mode When in PROGramming mode 1 PROG Puts the 4800 into the PROGramming mode 1. 2 Run At the top level of the menu, puts the 4800 into RUN mode. When not at the top of the menu, functions like a System Status 4 Checks for a dial-tone 4. Phone (optional) 5 SpkrPh Enables the speaker phone 5. RED keys 6 6. Schedules (optional) 7 Enables activation/de-activation of specified relay lists 7. Relay List Setup 8 8. Serial Port, Modbus Master/Slave Setup 9 9. Channel Configuration 0 Status Speaks and displays status of specified channels. 0. * *. # Enter Completes entry or backs up the menu. Ack Clear Acknowledges all unacknowledged alarms Clears any entry made for the specified function GREEN keys Arm Reset Enables call-out of alarms Resets the entry made to the factory default value Disarm Bksp Disables call-out of alarms Erases the previous key entry Home Puts the 4800 at the top of the selection menu BLUE keys F1 F3 F2 F4 Quick Access key specific function is displayed above the key on the display. 14

19 Front Panel Light Indicators The LEDs associated with the System provide information about the primary power source, battery condition, telephone line condition, and the mode of the System LEDs are located to the left of the keypad. Each LED can have five unique states, which are described in the table below. LED Off Solid Green Blinking Green Solid Red Blinking Red Primary Power 4800 is off 4800 is being powered through the Primary Power source (either 120/240 VAC or 15VDC) In Bootloader. Will enter the application in 10 minutes or by pressing the HOME key 4800 is being powered by the internal backup battery, the alarm is acknowledged is being powered by the internal battery. The alarm condition is unacknowledged Battery Condition No battery or connection to battery has failed Battery is fully charged Battery is being charged Battery is low. The alarm is acknowledged. Battery is low. Alarm is unacknowledged. Phone Line Status Line OK or Phone channel is disabled Off hook Ring detected Line fault no dial tone detected Status In RUN mode In PROGramming mod e Disarmed 4800 does not control relays or call out on alarms How to Enter Text for Names The 4800 allows the user to enter names for the Site (Unit) and for each channel. Entering names is very similar to entering names on most cell-phones that are used today. On the bottom of each key, there are letters and numbers. To select a specific letter or number, press that key the designated number of times. For example, to enter the letter L, press the 5 key 3 times. NOTE The 4800 capitalizes the first letter of each word. All subsequent letters are lower case. Key to Number of times to press the key Press space A B C 2. 3 D E F 3, 4 G H I 4-5 J K L 5 * 6 M N O 6 # 7 P R S 7 / 8 T U V 8 Space 9 W X Y 9 Space 0 Q Z 0 * Erase 15

20 Operation The 4800 monitors all sensor inputs and evaluates all alarm conditions when in the RUN MODE. While in this mode, the 4800 automatically displays all enabled sensor channels. Enabled channels are those that have a green LED shown on the analog input card. In addition to the sensor input channels, digital inputs and relays, there are System Channels that are internal to the System channel # Channel name Function 01 Primary Power Monitors the 15VDC power connection to the main processor board. Alarms when voltage exceeds the Low or High limits. 02 Battery Power Monitors the 12VDC backup battery power. Alarms when the voltage exceeds the Low or High limits. 03 Phone The 4800 checks the phone line every 2 hours for a dial-tone. Alarms when there is no dial-tone. A relay can be driven on alarm, but no phone calls made. 04 Temperature Monitors the on-board temperature in degrees C. Alarms when the temperature exceeds the Low or High limits. 05 Auxiliary Power Monitors the 24VDC supply voltage for powering current loops. Alarms when the voltage exceeds the Low or High limits. 06 Communications When Modbus RTU Master or Slave communications are enabled this channel indicates if there is a communications failure because of: Complete loss of communication Invalid Modbus ID Invalid register number Incorrect baud rate 07 Sensor Loop Also known as a Sensor Fault. Monitors all enabled 4-20ma inputs for detection of an open-loop. Alarms when the input value on any enabled 4-20ma input drops below the Open Loop Low Limit set through Options Setup(8) > Analog Scaling(4) The default level is 0ma. 16

21 The channel numbering and function of each LED is shown below. SLOT 10 SLOT 20 SLOT 30 SLOT 40 SLOT 50 Analog Input Analog Input Analog Input Analog Input Relay Output Channel 52 Channel 47 LED Legend Off Green Amber Blinking Amber Solid Red Blinking Red Solid Disabled Normal Low Alarm Low Alarm Acknowledged High Alarm High Alarm Acknowledged Figure 10 - Channel numbering Viewing the Display If the 4800 is in the RUN MODE and there is no keypad activity for 30 seconds, an automatic scrolling or rotating display shows the current value of every analog channel that is enabled CLO2 0.3 ppm Ak Lo Peak < > Paus F1 F2 F3 F4 Current channel # and name Current reading Alarm states (Acknowledged and in Low Alarm) View Peak for this channel Move to previous or next channel Pause on this channel 17

22 Automatic Alarm Screen When any channel goes into alarm, the display automatically changes to show the current conditions of those particular channels. 31 LEL NW-section 11.5 %lel LO AL EXIT Paus If any channel goes into alarm, the Alarm Screen is automatically displayed. All channels that are in alarm are automatically shown one at a time. For example, Channel 31 is monitoring an LEL sensor in the NW section, which is at 11.5 %lel, has exceeded the Low (LO) limit and is in alarm (AL). 31 LEL NW-section 11.5 %lel 41 NW Light: On EXIT < > Scrl Pressing the Paus ( F4 ) key pauses the screen on a particular channel of interest. Displays all relays being controlled and the relay states. Press the < or > to move the previous or next channel. Press the Scrl ( F4 ) key to return to the scrolling display of all channels in alarm. RUN Mode screens Users can view sensor Data, Peaks, and Calibrations on the screen through the following process: User Input Display Shows RUN MODE display F1 to go to the View Channel display F2 to go to the Print Reports display F3 to go to the Channels in Alarm display F4 to go to the Clear Peaks display RUN MODE 05/10/03 08:00:00 SITE ID View Prnt Alms Clr F1 F2 F3 F4 View Channel display F1 to return to the RUN MODE display F4 to go to the Scrolling Sensor display Enter a channel number to go to the View Data display. View Channel Enter Ch# [01-98]: Exit Scrl F1 F2 F3 F4 18

23 User Input Display Shows View Data F1 to go to View Peaks F2 to move to the previous channel F3 to move to the next channel F4 to go to the Scrolling Sensor display 31 - CLO2 0.1 ppm Peak < > Scrl F1 F2 F3 F4 NOTE: If the channel is a Modbus sensor channel there is an additional 2-character field in the upper right-hand corner that indicates the seconds after the minute that the last successful reading from the sensor was performed. This value changes every time a successful read occurs. 71 Bldg. X14 O % Peak < > Scrl F1 F2 F3 F4 View Peaks F1 to go to the View Cals display F2 to move to the previous channel F3 to move to the next channel F4 to go to the Scrolling Sensor display 31 CLO2 Peak:.4 ppm At: 02/06/03 07:22 Cal < > Scrl F1 F2 F3 F4 View Cals F1 to go to the View Data display F2 to move to the previous channel F3 to move to the next channel F4 to go to the Scrolling Sensor display 31 CLO2 Cal: 06/12/03 12:00 End: 06/12/03 12:08 Data < > Scrl F1 F2 F3 F4 Scrolling Sensor display F1 to go to the RUN MODE display F4 to go to the View Data display Automatically scrolls through all enabled sensor channels. NOTE: This is displayed automatically when the 4800 has not had any input for 1 minute. Clear Peaks F1 to go to the RUN MODE display F4 to clear all peaks Enter a specific channel to clear the peaks. 33 H2S 11 ppm Lo Alm Ack Exit Paus F1 F2 F3 F4 Clear Peaks Chan #[11-68]: Exit All F1 F2 F3 F4 NOTE: User is required to confirm clearing any peaks 19

24 RUN MODE 05/10/03 08:00:00 View Prnt Alms Clr F1 F2 F3 F4 Clear Peaks Clear Peak Chan # [11-68]: Exit All F1 F2 F3 F CLO2 0.1 ppm Al Lo Exit < > Cfg Alarms F1 F2 F3 F4 Print Reports Exit Evt I/O Sys Print F1 F2 F3 F4 View View Channel Enter Ch# [01-98]: Exit Scrl F1 F2 F3 F CLO2 0.1 ppm Peak < > Scrl F1 F2 F3 F4 F1 31 CLO2 Peak:.4 ppm At: 02/06/03 07:22 Data < > Scrl F1 F2 F3 F4 Figure 11 - RUN mode display options 20

25 Chapter 4: PROGramming Mode from the Keypad Overview PROGramming mode allows the user to: Change system wide settings Name of the unit Date/Time PROGramming Access Code Assign sensors to unused channels Change the sensor on a channel Change the settings for a sensor Low and High limits Scaling Relays to control Name of the channel Engineering units PROGRAM MODE is entered by pressing the 1 PROG key while on the RUN mode display. RUN mode is re-entered by pressing the 2 Run key from the PROGRAM MODE display. NOTE If an Access Code has been entered, the user is prompted to enter it before PROGramming mode is entered. Display Selecting a menu item SYSTEM SETUP Enter Sel[0-8]: MENU or Sub-Menu Valid selections are 0 through 8. Display Changing a setting SYSTEM SETUP Prgm/Run Delay [ mins]: 60 MENU Setting to change/view Valid Values Current setting 21

26 Quick Programming Steps While there are a large number of options available in the 4800, it is very easy to get the system up and operating if you first decide on what sensors are being monitored and what relays are going to be controlled. Step 1 - Determine how relays are going to be controlled - A single relay for low, single relay for high and single relay for fault - A separate relay for low and high for each sensor and a separate relay for fault - Multiple relays for low, high and fault - etc. The following table should help in deciding which relays to control for which alarm conditions. System Channel Relay list Actions Communication (06) Sensor Fault (07) Sensor Channel Low Relay List Actions High Relay List Actions Relay List Number Position 1 Position 2 Position 3 Position For example, System Channel Relay List Action into/out of Sensor Fault (07) 6 Energize / Deenergize Sensor Channel Low Relay List Action into/out of High Relay List Action into/out of 11 CO Area 1 1 Energize / Deenergize 2 Energize / Deenergize 12 CL Area 1 1 Energize / Deenergize 2 Energize / Deenergize 13 CO Area 2 3 Energize / Deenergize 4 Energize / Deenergize 14 CO Fan Energize / Disable 30 minute duration Relay Channel Pulse Duration 31, 32, 33, seconds Relay List Number Position 1 Position 2 Position 3 Position light horn light 41 - DCS horn 42 - DCS fan light 22

27 Step 2 Configure the sensor inputs For each sensor input, perform the following actions. Keystrokes Actions HOME 1 9 <channel number> UP and DOWN arrows (F2, F3) ENTER key ENTER key or new value ENTER key or new value ENTER or Lo Alarm Relay List Number ENTER or Hi Alarm Relay List Number ENTER or 1 to energize, 2 to do nothing ENTER or 0 to deenergize, 2 to do nothing ENTER or 1 to energize, 2 to do nothing ENTER or 0 to deenergize, 2 to do nothing ENTER or 0 or 1 1 ENTER or 1 to record a channel message ENTER or 1 to enter a channel name (press the F1, F2 and F4 for letters) ENTER - Select the channel to program - Select the sensor type desired. - Accept your selection - Low limit - High limit - Enter a Relay List number - Enter a Relay List number Energize the relay when in the Low Alarm Deenergize the relay when back to Normal Energize the relay when in the High Alarm Deenergize the relay when back to Normal - 0 Relay stays energized if alarm is acknowledged - Select option 1 for Channel Name - Enter channel message for each sensor channel - Enter channel name for each sensor channel - Enter another channel number if desired HOME - Entry complete Step 3 Enter relays into the Relay Lists For each Relay List, enter the physical relays into that List. NOTE Each physical relay is automatically inserted as the first relay in a Relay List of the same number. For example, if your system has physical relays 31-34, then relay 31 is in Relay List 31, relay 32 is in Relay List 32, etc. If you are not going to have more than one relay in a list, you do not have to complete any Relay Lists just enter the physical relay number. Keystrokes Actions HOME nn - Activate Relays options - Setup Relay Lists - Relay List 1 [11-98] - Relay List Position 1 [1-9] - Enter physical relay number (e.g. 31) - Enter next position for another relay number if desired HOME - Entry complete 23

28 Step 4 Save Programming Press HOME 2 to save programming into non-volatile memory. System Wide Settings These settings affect the overall operation of the system. These settings are typically adjusted during the initial installation, but can be modified at any time. NOTE Press the # key to: move to the next program setting or to move up a level in the menu or to accept your entry PROGramming MODE display 3 to enter System Setup PROGRAM MODE System Ready Enter Sel[0-9]: System Setup display 0 System Identification 1 Access Code 2 Ring Count 3 Date and Time 4 System Delays 5 Code Version Number 6 Reset to System Defaults (Backup/Restore) 7 Reset Counters 8 Local Speaker Volume SYSTEM SETUP Enter Sel[0-8]: 24

29 Sensor Channel Setting These settings affect the operation of the channel monitoring a sensor. These settings are typically adjusted during the initial installation, but can be modified at any time. When you select a sensor, the High and Low limits, engineering units, display resolution, and relay controls are automatically set. The following table shows the various sensors and their setting that can be selected. NOTE Selecting the General sensor type allows you to connect other analog inputs like temperature, humidity, pressure, etc. to the 4800 Selection Default Name Range Low Limit High Limit Units Alarm Mode Into Low Alarm Relay Control Out of Low Alarm Into High Alarm Out of High Alarm 0 General <none> 0 on off on off 1 CO ppm 3 on off on off 2 H2S ppm 3 on off on off 3 NO ppm 3 on off on off 4 NH ppm 3 on off on off 5 NO ppm 3 on off on off 6 SO ppm 3 on off on off 7 CL ppm 3 on off on off 8 HCN ppm 3 on off on off 9 HCL ppm 3 on off on off 10 PH ppm 3 on off on off 11 CL ppm 3 on off on off 12 O %vol 0 on off on off 13 H ppm 0 on off on off 14 LEL %lel 3 on off on off 15 CO_H ppm 3 on off on off 16 ETO ppm 3 on off on off 17 O ppm 3 on off on off 18 CO % 3 on off on off NOTE Press the # key to: move to the next program setting or to move up a level in the menu or to accept your entry 25

30 9 to enter Channel Configuration CHAN CONFIGURATION Enter either a physical channel number or a Modbus channel number. Chan Num[01-98]: NOTE Channel numbers are 2 digits, the first digit is the SLOT the second digit is the CHANNEL in the slot. Analog Inputs Select a sensor type using the F2 and F3 keys. Analog Input Chan xx Sens = <1-CO> Modify the Low and High limits if desired. Analog Input Chan xx CO Low Limit: 35 Modify the Low and High limits if desired. Enter a Low Alarm Relay List and the state the relay should take upon entering the Low Alarm area and upon returning to the Normal state. Low Alarm Relay List CO List#[0-64]: Enter a 0 if no relays are to be controlled. Valid relay states are: 0 De-energize the relay 1 Energize the relay 2 Do not change the relays state (disabled) Low Alarm Relay List Relay Low Alarm State Energized [1-2]: 1 NOTE: Physical relays are entered into Relay Lists. Each Relay List can contain from 1 to 9 physical relays. There are a total of 64 Relay Lists that can be created. Low Alarm Relay List CO Relay Low Norm State Deenergized [0,2]: 0 REPEAT FOR THE HIGH ALARM RELAY LIST If relays are left on after a sensor has left an alarm condition, the relay can be de-energized by pressing the Ack key if enabled for this channel. To enable this function, enter a 1. CHAN CONFIGURATION Off on Ack[0-1]: The default is to leave the relays energized [0]. 26

31 Modify channel parameters: Selections 0 through 6 allow you to modify the default settings or adjust any settings you desire. Full descriptions of each setting are found in the Glossary. 0 Channel Conversion Input Type [0-5] Decimal Position [0 to 9] Engineering Units [0-34] Scale Input [0-1] Zero Scale (value at 4ma or 0V) Full Scale (value at 20ma, 5V or 10V) Min Counts (786 = 4ma) Max Counts (3931 = 20ma) 1 Channel Message (voice recorded) Alphanumeric ID (channel name) 2 Channel Mode [0-6] (limits are under this selection) 3 Alarm Delay [ seconds] 4 Continue alarm notification if return to normal 5 Telephone List [1-16] 6 Low and High Relay Lists [0-98] Analog Input Chan 11 CO Enter Sel[0-6]: NOTE: To change the Scaling of a channel, modify the Zero and/or Full Scale settings. Enter these values with the assumed Decimal Position. e.g. If the Decimal Position is 1, a value of 50 would be entered as 500, with 1 digit being to the right of the decimal point. Relay Outputs After you have entered a channel number that corresponds to a Relay Output, you have 4 options: 0 Pulse duration for the relay to stay on 1 Channel message and name 2 Channel Mode (0-disabled, 1-Status Only (enabled)) Relay Output Chan xx Channel Name Enter Sel[0-2]: 0 Pulse Duration Amount of time the relay is energized until it automatically deenergizes. This can be used to keep fans on after a sensor alarm event has gone back to normal Relay Output Chan xx Pulse Duration [ sec]: 1 Channel Message You can enter a 20 character name to identify the relay channel. This is displayed, shown on faxes and status reports to the Internet. Use the F1 and F2 keys to move up and down the alphabet, use F4 to select the character. Relay Output Chan 11 Relay ID Messaage: 27

32 Channel Name You can enter a 20 character name to identify the relay channel. This is displayed, shown on faxes and status reports to the Internet. Use the F1 and F2 keys to move up and down the alphabet, use F4 to select the character. Relay Output Chan 11 Channel Name: Chan xx 2 Channel Mode 0 disables the relay from being used. The LED is turned off. 1 Status Only enables the relay for use. Green LED indicates relay is de-energized, Red LED indicates the relay is energized Relay Output Chan xx Chan Mode[0-1]: 1 Status Only Digital Inputs Modify channel parameters: 0 Channel State 0 Normally Open 1 Normally Closed 1 Channel Message (voice recorded) Channel Name 2 Channel Mode [0-3] 0 Disabled 1 Status Only (no action on alarm) 2 Call on Alarm 3 Call on Limit Violation 3 Alarm Delay [ seconds] 4 Continue alarm notification if return to normal 5 Telephone List [1-16] 6 Relay [11-98] Digital Input Chan xx Channel Name Enter Sel[0-6]: 28

33 Relay List Setup When a sensor input goes into a Low or High alarm condition, a list of relays can be controlled. Each list can contain up to 9 physical relays (located in the same controller or communicated with via Modbus). There are a total of 98 Relay Lists available, numbered 1 to 98. Using Relay Lists allows the user to define different relay activation combinations once and then reference the Relay List for several sensor inputs. This is particularly useful for controlling multiple relays (like a light and a contact to a DCS system) for all sensor inputs. By default, any physical relays are automatically included in a Relay List using the channel number as the Relay List number. For example, if there is a relay card in slot 40, then Relay List 41 has relay 41 in position 1, Relay List 42 has relay 42 in position 1, Relay List 43 has relay 43 in position 1 and Relay List 44 has relay 44 in position 1. This makes it easy for the user to reference single relays as they do not have to setup any relay lists. Relay Lists can be set up at anytime. Relay Operations From the Program Mode. There are 2 main operations available from the Relay function (Keypad 7). Activating/deactivating relays in a Relay List Assigning relays to a Relay List ACTIVATE RELAYS 1) Activate List 2) Setup List [1-2]: Press 2 to Setup List Enter the Relay List number that you want to create. NOTE: Enter the list number as a 2-digit value (e.g. 02) NOTE: The only significance to the List number is to help identify them. Each Relay List can have 9 relays. Enter the position within the List that you want to add/delete a physical relay. ACTIVATE RELAYS Relay List Setup List #[1-98]: ACTIVATE RELAYS List nn Relay List Pos Pos [1-9]: Enter 00 to delete the current entry. - or Enter a physical relay on this unit (11-14, 21-24, 31-34, 41-44, 51-54, 61-64) - or Enter a Modbus Relay Channel on this unit - (11 98) ACTIVATE RELAYS List nn Pos n Relay#[00-98]: 29

34 PROGRAM MODE 1 System Ready Enter Sel[0-9]: 0 SYSTEM STATUS 0 I/O slots report 1 channel status Enter Sel[0-1]: 2 RUN MODE 05/05/03 11:34:54 View Prnt Alms Clr 3 SYSTEM SETUP Enter Sel[0-8]: 0 System ID 1 Access Code 2 Ring Count 3 Date/Time 4 System Delays 5 Version # 6 Reset to defaults 7 Reset Counters 8 Speaker Volume 4 PHONE SETUP Enter Sel[0-2]: 0 Primary Phone List 1 Secondary Phone List 2 Call in Acknowledge Redial after Acknowledge Delay Redial when Busy Message Repeat 5 SPEAKERPHONE Phone Num: 6 SCHEDULE SETUP Enter Sel[0-2]: 0 Status Notification Schedule 1 Telephone List Schedule 2 Holiday Calendar 7 ACTIVATE RELAYS Relay Chan Num: 8 OPTIONS SETUP Enter Sel[0-5]: 0 Serial Port 1 1 Serial Port 2 2 Serial Port 3 3 Modbus Master Setup 4 Analog Input Setup 5 Acknowledge input channel 9 CHAN CONFIGURATION Chan Num[01-98]: Sensor Type Low Limit High Limit Alarm Relays 0 Conversion 1 Names 2 Mode 3 Alarm Delay 4 Alarm rtn to normal 5 Phone list 6 Relays Figure 12 - PROGRAMMing mode functions 30

35 Chapter 5: Modbus RTU Master Overview The Modbus Master Interface enables the 4800 Gas Controller to read input values from a Modbus sensor, PLC or Modbus Slave device and write relay control values to a Modbus sensor, PLC or Modbus Slave device. The connection uses the serial RS-232 connector or RS-485 connection on the The protocol is Modbus RTU, where the 4800 is the Master and the Modbus sensors, PLC or Modbus I/O is the Slave. The option supports a combination of up to 72 total I/O channels up to 48 of which can be physical I/O in the The I/O in the Modbus Slave can be any combination of analog (holding registers) or digital points (coils). Values that are read from the Modbus Slave are interpreted by the 4800 the same as if they were physical I/O in the All the alarm and control logic within the 4800 operate on data coming from Modbus registers. The communications link between the 4800 and the Modbus slave devices is monitored several times a second. If the communications link stops functioning after repeated attempts, a Communications Channel (06) alarm is initiated. This alarm is treated exactly like any other system alarm allowing the system to call out, drive local relay or issue reports. The RS-232 port is configured as a DTE device Pin 2 RCV Pin 3 XMT Pin 5 GND Port 1 Configuration Port 1 is configured from PROGramming mode through the Options Setup (8). NOTE Port 1 can be configured as either RS-232 OR RS-485. If it is set to RS-232, then use the DB9 connection, if using RS-485, then use the 3-position removable wiring plug labeled Gnd-B-A User Input Display Shows From the Program Mode. Press 0 to setup Serial Port 1 OPTIONS SETUP Enter Sel [0-4]: Enter 3 for the Mode Master. NOTE: 0 None, 1 Debug, 2 Slave, 3 Master, 4 - Web Port 1 Setup Mode [0-4]: None Enter the Baud Rate. NOTE: 2400, 4800, 9600, 19200, 38400, Port 1 Setup Baud:

36 User Input Display Shows Press ENTER or enter a new Maximum Idle time in characters. The Max Idle is the number of character times the 4800 waits after the last character received until it terminates the message. For fastest performance, this should be as short as possible. Port 1 Setup Max Idle[1-500]: 10 NOTE: If it is too short the entire response from the Modbus Slave device may not be received. Press ENTER or enter a new Maximum Wait time in characters. The Max Wait is the number of character times the 4800 waits after sending a message for any response from the Slave device. Port 1 Setup Max Wait [ ]: Set the Modbus ID for Serial Port 1. Port 1 Setup ID[1-247]: 0 to disable the RS485 and use the RS-232 connection. 1 to enable the RS-485 connection. Port 1 Setup RS485:[0-1]: The RS485 On Delay specifies the amount of time the 4800 will wait between activating the 485 transceiver and transmitting the first character. Port 1 Setup RS485 On Delay[0-9]: 1 msec The RS485 Off Delay specifies the amount of time the 4800 will wait between sending the last character of a transmission and deactivating the 485 transceiver. Port 1 Setup RS485 Off Delay[0-9]: 1 msec 32

37 Initializing the Modbus Master Interface The Modbus Master Interface is setup by defining the: Serial port baud rate default is Modbus Master ID default is 1 Defining 4800 I/O slots to be identified as Modbus I/O default is that no slots are enabled as Modbus I/O slots. There are 8 Modbus I/O channels per Slot. You can enable as many slots as you have purchased. For example, if you purchased a 32-channel Modbus Master configuration, then you can enable any 4 slots which do not have physical I/O cards attached. All of these can be defined either through the integral keypad or remotely via a phone. PROGramming MODE display 8 to enter Options Setup PROGRAM MODE System Ready Enter Sel[0-9]: Options Setup display Press 3 OPTIONS SETUP Enter Sel[0-4]: Enter the number of seconds between each request of ALL the Modbus Slave devices. For example, 2 means to read all Slave devices every 2 seconds. MODBUS Master Setup Scan Rate[1-60]: 1 secs Press 2 Run Enter the slot number (from 1 through 9) to set as Modbus RTU channels. Each slot has 8 channels and they can be any input or output type. MODBUS Master Setup Slot Number: 1 enabled Press 1 to Enable or 0 to Disable the slot. NOTE: slots with physical I/O cannot be Modbus slots 33

38 Mapping 4800 Channels to Modbus Registers I/O channels in the 4800 are mapped to Modbus registers by providing three (3) pieces of information: Modbus ID ID of the Modbus Slave Register type which corresponds to Function Code Register number number of the register for the particular Function Code All of these items are entered in the Channel Configuration ( Function 9) section for each individual channel. Supported Register Types 4800 Register Type Description Type of channel in the 4800 Modbus Function Code 1 Read Coil Status Digital 01 2 Read Input Status Digital 02 3 Read Holding Register Analog 03 4 Read Input Register Analog 04 5 Write Coil Relay 05 Programming Channel Parameters Programming a Modbus channel requires the mapping information to be entered prior to changing limits, channel names, etc. For a Modbus channel, enter Channel Configuration with a 9 : Enter the Sensor type using F2 and F3 to make your selection 0 - General 6 SO2 10 PH3 16 ETO 1 CO 7 CL2 11 CL02 17 O3 2 H2S 8 HCN 12 O2 18 CO2 3 - NO 9 HCL 13 H2 4 NH3 10 PH LEL 5 NO2 11 CL02 15 CO_H2 MODBUS I/O Chan 71 <channel name> Sens = <0 General> Enter the Modbus Slave ID of the sensor NOTE: Press the RESET key to set the ID back to 0 MODBUS I/O Chan 71 <channel name> Slave ID: 0 The default register type is 3 Read Holding. Press # if this value is correct or enter the desired register type. NOTE: 0 to disable MODBUS I/O Chan 71 <channel name> IO Reg Type[0-5]: 3 Read Holding (AIN) 34

39 Enter the register number. NOTE: 0 to disable MODBUS I/O Chan 71 <channel name> Reg#[0-9999]: 102 Read Holding (AIN) If the Modbus Sensor has a Calibration register, this can be entered and automatically read to check if the channel is in Calibration. The default is a Holding Register which contains the value of the calibration. If the Calibration register is a coil, then a value of 1 indicates the channel is in calibration. MODBUS I/O Chan 71 <channel name> Cal Reg Type[0-5]: 3 Read Holding (AIN) NOTE: 0 to disable Enter the Calibration register number. NOTE: 0 to disable MODBUS I/O Chan 71 <channel name> Reg#[0-9999]: 105 Read Holding (AIN) Low Limit enter a new value if desired Hi Limit enter a new value if desired MODBUS I/O Chan 71 <channel name> Low Limit: 25.0 Enter a Relay List Number for the Low and High relays. NOTE: If only a single relay is to be controlled, enter the physical relay number. When the 4800 is set to the factory defaults, a Relay List is created for each physical relay, with each list containing just that physical relay. MODBUS I/O Chan 71 <channel name> Low Alm Relay List List #[0-98]: 0 35

40 Chapter 6: Modbus RTU Slave Overview The Modbus RTU interface allows the 4800 Gas Controller to become a Modbus slave device to communicate with any product that supports the Modbus master protocol. Typical devices that support the Modbus master protocol are: SCADA/HMI packages like: Wonderware, Intellution, Lookout, Bridgeview, FactoryLink, P-CIM, OI-2000 or a host of other products. The Modbus RTU interface allows the SCADA/HMI software to read and write information into the 4800 from: a direct connection via an RS-232 port (port 1, 2, or 3) a direct connect to the secondary RS-232 port if the 4800 is also a Modbus Master or, over a modem. The information available to the SCADA/HMI software is: Read current analog (sensor) channel values Read current relay channel states (energized/de-energized) Read current digital channel states (open/closed) Read current alarm state for each channel (in/out of alarm) Read current alarm acknowledge state (acknowledged/not acknowledged) Write relay channel (energize/de-energize) Radio Modem Direct Connection Modem Figure 13 - Modbus RTU Slave connections 36

41 Serial Port Settings The 4800 is configured to operate with one or more serial port set as follows: Baud rate: (2400 to ) Data bits: 8 Parity: None Stop bits: 1 Flow control: None Port 1is an RS-232 port configured as a DTE device Pin 2 RCV Pin 3 XMT Pin 5 GND User Input Display Shows From the Program Mode. Press 0 to setup Serial Port 1 Press 1 to setup Serial Port 2 Press 2 to setup Serial Port 3 OPTIONS SETUP Enter Sel [0-4]: Enter 2 for the Mode Slave NOTE: 0 None, 1 Debug, 2 Slave, 3 Master, 4 Web NOTE: Ports 2 and 3 only have options 0-2 Serial Port 1 Setup Mode [0-4]: None Enter the Baud Rate. NOTE: 2400, 4800, 9600, 19200, 38400, Serial Port 1 Setup Baud: 9600 Press ENTER or enter a new Maximum Idle time in characters. The Max Idle is the number of character times the 4800 waits after the last character received until it terminates the message. For fastest performance, this should be as short as possible. Serial Port 1 Setup Max Idle[1-500]: 10 NOTE: If it is too short the entire response from the Modbus Master device may not be received. Set the Modbus ID for the Serial Port. Serial Port 1 Setup ID[1-247]: 37

42 Modem Settings The 4800 is configured to operate with a modem set as follows: Init string NOTE X2 The 4800 assumes that the Modbus Master software has relaxed the character timing to allow for modem delays. The 4800 character timing is adjustable by Industrial Scientific for any unit, but has not been made accessible to the user. If adjustments are necessary please call Industrial Scientific customer service toll-free at 800- DETECTS. The default receive timeout delay for a direct serial connection is 20ms and for a modem connection is 200 ms. Modbus Slave ID The default Slave ID is 126. This is adjustable from the Options Menu (function 8, option 1, 2 or 3 depending on which port is going to be used) Register Mapping The 4800 Modbus RTU interface supports 2 methods of reading/writing register values. Read/write in counts (legacy systems support this method) Read/write in unscaled engineering units The following defines the mapping for values in counts: 0xxxx (R/W) coils (relays in the 4800) 1xxxx (R) input status (digital inputs, alarm state, acknowledge state) 4xxxx (R/W) holding registers (analog inputs, digital totalizers, digital duration counters) The Modbus function codes that are supported by the 4800 are: Function Code Description 1 Read coil status 2 Read input status 3 Read holding register 5 Force a single coil 6 Preset a holding register 15 Force multiple coils 16 Preset multiple holding registers If a slot is empty, does not have the correct I/O type or a channel is disabled on the 4800, then a 0 will be returned for that corresponding register. 38

43 The following mapping returns values in unscaled engineering unit values. Coils (0xxxx) Relays (Read/Write) All relay types in the gas controller are represented via relay lists, i.e. physical, MODBUS read coil, and MODBUS write coil. By default, a physical relay, read coil or write coil channel is assigned to the list having the same number as that channel. For example, if there is a relay card in slot 4, then relay channel 41 is put into list number 41, relay channel 42 is put into list 42, and so on. If a MODBUS write coil is in channel 83, then that channel is put into relay list 83. If a read is done from these register addresses, a 0 will be returned unless there is a physical relay at the requested address. A value of 1 indicates the relay is to be energized or is already energized, 0 indicates the deenergized condition. Modbus Address 4800 I/O channel (0)0101-(0)0110 Slot 0, Chan1-8 (N/A) (or relay lists 1-10) (0)0111-(0)0120 Slot 1, Chan (or relay lists 11-20) (0)0121-(0)0130 Slot 2, Chan (or relay lists 21-30) (0)0131-(0)0140 Slot 3, Chan (or relay lists 31-40) (0)0141-(0)0150 Slot 4, Chan (or relay lists 41-50) (0)0151-(0)0160 Slot 5, Chan (or relay lists 51-60) (0)0161-(0)0170 Slot 6, Chan (or relay lists 61-70) (0)0171-(0)0180 Slot 7, Chan (or relay lists 71-80) (0)0181-(0)0190 Slot 8, Chan (or relay lists 81-90) (0)0191-(0)0198 Slot 9, Chan (or relay lists 91-98) 39

44 Holding Registers (4xxxx) Analog Inputs or Modbus Sensor Inputs (Read Only) The following addresses represent scaled analog inputs and scaled MODBUS holding register values and are accessible via a single register read. They are scaled to the zero and full scale for the given channel. Getting the correct reading requires placing the decimal point to match the decimal point parameter for that channel. The range of values in these registers is to If you know the value will never exceed this range, read from these registers. If the value is too large to fit in a single register, a value of 9999 is returned. For values larger than this range, use the double register read method described below. Modbus Address 4800 I/O channel (4)0101-(4) Slot 0 Analog Input Primary Power (0-17.2V) Battery Power (0-17.2V) Phone Fault (0-good, 1-fault) 4800 Temperature ( C) 24VDC Supply (0-33.7V) Communications (0 Normal, 1 alarm) Sensor Loop (0 Normal, 1 alarm) (4)0109-(4)0116 Slot 10 Analog Input (or Modbus Sensor Input) (4)0117-(4)0124 Slot 20 Analog Input (or Modbus Sensor Input) (4)0125-(4)0132 Slot 30 Analog Input (or Modbus Sensor Input) (4)0133-(4)0140 Slot 40 Analog Input (or Modbus Sensor Input) (4)0141-(4)0148 Slot 50 Analog Input (or Modbus Sensor Input) (4)0149-(4)0156 Slot 60 Analog Input (or Modbus Sensor Input) (4)0157-(4)0164 Slot 70 Analog Input (or Modbus Sensor Input) (4)0165-(4)0172 Slot 80 Analog Input (or Modbus Sensor Input) (4)0173-(4)0180 Slot 90 Analog Input (or Modbus Sensor Input) 40

45 The following addresses represent scaled analog inputs and scaled MODBUS holding register values and are accessible via double register reads. They are scaled to the zero and full scale for the given channel. Getting the correct reading requires placing a decimal point to match the decimal point parameter for that channel. The value for a given channel is requested by reading two consecutive registers. A read to an odd register returns the high word of the value. A read to an even register returns the low word of the value. The range of the double register is to If you know the value in the register will never exceed to , you may read the even register (low word) only, or use the single register read method described above. Example: To read the scaled engineering value from slot 3, channel 5, read from MODBUS registers 1057 and Modbus Address 4800 I/O channel (0)1001-(0)1016 Slot 0, Chan1-8 (N/A) (0)1017- (0)1032 Slot 1, Chan (0)1033- (0)1048 Slot 2, Chan (0)1049 -(0)1064 Slot 3, Chan (0)1065- (0)1080 Slot 4, Chan (0)1081- (0)1096 Slot 5, Chan (0)1097- (0)1112 Slot 6, Chan (0)1113 -(0)1128 Slot 7, Chan (0)1129 -(0)1144 Slot 8, Chan (0)1145- (0)1160 Slot 9, Chan

46 Read Input Status (1xxxx) Alarm State and Acknowledge State Alarm State a returned value of 1 indicates the specified channel is in alarm, a return value of 0 indicates the channel is not in alarm. Acknowledge State - a returned value of 1 indicates the specified channel is in alarm and acknowledged, a return value of 0 indicates the channel is not acknowledged regardless of the alarm state. Alarm State Modbus Address 4800 I/O channel Alarm State Modbus Address (0)0101-(0)0108 Slot 0, Chan 1-8 (0)0201-(0)0208 (0)0109-(0)0116 Slot 1, Chan (0)0209-(0)0216 (0)0117-(0)0124 Slot 2, Chan (0)0217-(0)0224 (0)0125-(0)0132 Slot 3, Chan (0)0225-(0)0232 (0)0133-(0)0140 Slot 4, Chan (0)0233-(0)0240 (0)0141-(0)0148 Slot 5, Chan (0)0241-(0)0248 (0)0149-(0)0156 Slot 6, Chan (0)0249-(0)0256 (0)0157-(0)0164 Slot 7, Chan (0)0257-(0)0264 (0)0165-(0)0172 Slot 8, Chan (0)0265-(0)0272 (0)0173-(0)0180 Slot 9, Chan (0)0273-(0)0280 Error Returns If the 4800 detects an error in the request, then the following standard Modbus exceptions are returned: Condition Exception returned Exception Code Register address is out of range or the starting address plus the number of registers exceeds the address range of the Number of registers requested is too large, i.e. beyond the range of the 4800 ILLEGAL_ADDRESS 2 ILLEGAL_VALUE 3 Unsupported function code is received. ILLEGAL_FUNCTION 1 If the slave cannot respond because the response message is too large (too much data was asked for) SLAVE_DEV_FAILURE 4 42

47 Chapter 7: PC/Laptop Access The 4800 Gas Controller can be accessed from a PC or laptop to view the current status of all channels, view the event log, modify programming, etc. The connection to the 4800 is via the serial port 1 (DB9), port 2 or port 3. NOTE The serial port must be in the Diagnostics mode, which means it cannot be used when the 4800 is also active as a Modbus Master. Follow these steps to bring up the Diagnostics Menu: 1. Set serial port baud rate PROG Enable diagnostics port Set the desired port to Debug Mode (1) 3. Connect your serial cable 4. Press the ENTER key Password: is displayed 5. Enter the password ISC The following menu is displayed The following is the main menu and Site setup sub-menu as shown in Hyperterminal. (under Accessories > Communication is Windows) Password: XXXXXXXXXXX Industrial Scientific Controller Ver: /18/07 00) Show System Config 01) Show Chan Config 02) Show System State 03) Show Chan Data 04) Show Event Log 05) Data Logging 06) Timers 07) Preset Counters 08) Status Reports 09) Activate Relays 10) Site Setup Cmd => 10 ******** Site Setup ******** 1) System 2) Channels 3) Relay Lists 4) Comm Ports 5) MBUS Slot Enable...> 43

48 The following is the Channel Configuration to view or program Gas Controller v3.0.1 Channel Configuration Chan# [11-98]: 11 Chan Name: CO Phone List [1-16]: 1 Call On Return To Normal [0-1]: 0 Alarm Delay (secs) [ ]: 3 Type [0-5]: 5 (4-20mA) Mode [0-6]: 3 (Above a Limit) Decimal Position [0-5]: 0 Engineering Units [0-34]: 22 (ppm) Scaling Factor [0-6] 5 (/100) Zero Scale Sign [0-1]: 1 Zero Scale [ ]: 0 (0 ) Full Scale [ ]: 999 (999 ) Low Alarm Limit [ ]: 35 (35 ) High Alarm Limit [ ]: 70 (70 ) +Rate of Change Limit [ ]: -1 (disab) -Rate of Change Limit [ ]: -1 (disab) Rate of Change Interval (mins) [0-60]: 0 Deenergize Relays On Ack [0-1]: 0 Alm Relay List# [11-99]: 21 Norm to Low Alm Relay State [0-2]: 1 (Energize) Low Alm to Norm Relay State [0-2]: 0 (Deenergize) Norm to High Alm Relay State [0-2]: 1 (Energize) High Alm to Norm Relay State [0-2]: 0 (Deenergize) Chan# [11-98]: 44

49 Chapter 8: Datalogging The 4800 Gas Controller can log up to 10,000 separate time-stamped data values. The data is formatted in either a comma-separated value (CSV) or ASCII tabular format. When datalogging is enabled, the 4800 logs ALL analog channels that are NOT disabled. The data can be accessed via a direct serial connection to the RS-232 port when in Diagnostics mode (as discussed in the previous chapter) or via a modem Hyperterminal or other terminal emulation connection. The following is the main menu and Show Data Log sub-menu. Password: XXXXXXXXXXX Industrial Scientific Controller Ver: /18/ ) Data Logging Cmd => 5 ******** Data Logging Option ******** Data Logging: disabled Max Data Recs: Tail Index: 0 Head Index: 0 Start: 00:00 Intvl: 0 mins Next Log: 00:00:00 Log Fmt: CSV 1) Enable Logging 2) Set Start/Interval 3) Show Data Log 4) Clear Data Log...> Start Time: 00:00 New Start Time [00:00:00]: Interval(mins) [0-1440]: Format [0=ASCII/1=CSV]:...> Hit ESC to stop... CSV format example 1,05/26/04 14:48:00,22,West-CO,20,ppm 2,05/26/04 14:48:00,21,Storage-O2,20.4,%vol 3,05/26/04 14:46:00,22,West-CO,20,ppm 4,05/26/04 14:46:00,21,Storage-O2,20.4,%vol 5,05/26/04 14:44:00,22,West-CO,19,ppm 6,05/26/04 14:44:00,21,Storage-O2,20.5,%vol 7,05/26/04 14:42:00,22,West-CO,20,ppm 1 05/26/04 15:12:00 22 West-CO 20 ppm 2 05/26/04 15:12:00 21 Storage-O %vol 3 05/26/04 15:10:00 22 West-CO 20 ppm 4 05/26/04 15:10:00 21 Storage-O %vol 5 05/26/04 15:08:00 22 West-CO 19 ppm 6 05/26/04 15:08:00 21 Storage-O %vol ASCII format example 45

50 Chapter 9: Glossary 24VDC Channel Abort Phone Call Access Code Acknowledge Alarms Acknowledge Input Channel AK AL Alarm Code Alarm Delay Alarm message Channel 05 monitors the 24VDC supply voltage. Pressing the HOME key while a call is in progress will immediately cancel the call. A 4-digit code that can be entered to prevent any unauthorized personnel from entering the Programming Mode. When entering Programming Mode, either locally or remotely, the access code must be entered. To Change PROG 3 1 Alarms are acknowledged from the keypad by pressing the ACK key. Remotely by pressing the 9 key on the phone when requested to Please Acknowledge When alarms are acknowledged, any alarm notification call-outs are stopped. Any channel can be designated to acknowledge alarms when it changes from the normal condition to the non-normal condition. This channel is defined in the Options Menu (Function 8, selection 5) in Program Mode. Shown on the display and in reports. Indicates the channel is in alarm and has been acknowledged. Shown on the display and in reports. Indicates the channel is in alarm. The Elite uses alarm codes on the display, status reports and alphanumeric pager alarms to indicate the condition of an alarm or input OP open on a digital input CL closed on a digital input CM communication alarm on a Modbus input/output OL open-loop condition on an analog input LO low limit alarm on an analog input HI high limit alarm on an analog input The amount of consecutive seconds an input needs to exceed a Limit before it goes into alarm. [ seconds] (default is 3 seconds) Channel LED blinks green during this time. To Change PROG 9 <chan num> # # # # 3 A 6-second message can be recorded for the alarm condition for each channel. This message is spoken when the channel is in alarm and the 4800 calls out or a user calls-in for status. To Change PROG 9 <chan num> # # # # 1 46

51 Alarm Mode Above a Limit This mode defines a normal region that is below a Low and above a High Limit. To Set PROG <chan num> # # # # 2 5 Alarm Mode Below a Limit This mode defines a normal region that is above a Low and High Limit. The Low Limit is below the High Limit. To Set PROG <chan num> # # # #

52 Alarm Mode Inside a Range This mode defines 2 normal operating regions, one above a High Alarm Limit and one below a Low Alarm Limit. To Set PROG <chan num> # # # # 2 6 Alarm Mode Outside a Range This mode defines a normal region that is above the Low Limit and below the High Limit. To Set PROG <chan num> # # # # 2 2 Alarm Screen When any channel goes into an alarm state, the display is automatically changed to show the current conditions of those channels. The user has the option to Pause on a channel of interest to view all relays which are being controlled by that channel. Alarm State When a sensors value exceeds a Low or High Limit, the channel goes into an Alarm State. When these transitions occur, Relay Lists can be controlled. Specify what condition you want the relay to assume when these transitions occur. 0 Deenergized 1 Energized 2 No change (disabled) 48