Model 1600A-N4X NEMA 4 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 Aug 20, 2009 • Document # 3437 • Revision 0.
1600A-N4X 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.
1600A-N4X Table of Contents 1.0 2.0 2.1 2.2 2.3 3.0 3.1 3.2 3.3 3.4 3.5 3.6 4.0 4.1 Introduction .............................................................................................................................................1 System Configuration .............................................................................................................................2 Hardware Configurations ..................................................................................................
1600A-N4X Table of Figures Figure 1 Interface Diagram .................................................................................................................................. 1 Figure 2 System Configurations........................................................................................................................... 2 Figure 3 Unit Mounting and Dimensional............................................................................................................
1600A-N4X 1.0 Introduction The Detcon Models 1600A-N4X 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 can alternatively poll serial sensors via RS-485 Modbus™. The 1600A-N4X controller uses a modular design approach that allows the user to customize the selection of stand-alone input and output modules.
1600A-N4X 2.0 System Configuration 2.1 Hardware Configurations The Model 1600A-N4X is a “user configurable” alarm controller platform. The basic 1600A-N4X Controller includes the NEMA 4 panel enclosure with Controller Module (including display), Power Supply, two AC and one DC breakers, and a DC over-voltage protection module. NOTE: I/O modules are normally factory installed unless specifically instructed otherwise. A maximum of 12 I/O modules will fit inside the standard N4X enclosure.
1600A-N4X 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. 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-N4X 3.0 Installation 1. Securely mount the Model 1600A-N4X enclosure. ALARM RESET 17.85" 16.75" Model 1600A-N4X Muiti-Channel Gas Detection Control System 8.75" 12" 16" Figure 3 Unit Mounting and Dimensional 2. Connect 110/220VAC input wiring to the terminals labeled “ACV (L1)”, “Neutral (L2)”, and “Ground” (Figure 4). The Power Supply is capable of handling AC inputs from 100-240VAC 50-60Hz without degradation.
1600A-N4X 4. 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 5). 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-N4X 3.1 1600A Interface Board The 1600A Interface Board Figure 8 is connected to a set of Terminal Blocks on the DIN Rail (Figure 6 and Figure 7.) 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-N4X 4 SCRN GND 5 PLC PWR 6 PLC GND 7 NO COM 8 FLT 9 RST 10 POWER IN XPSN GND SCRN PWR U1 A J3 + - J5 A B Shld 12 J1 - RS 4 8 5 SHLD B 11 + G C NO NC 3 G R NO COMM FAULT / NO COM 2 G R XPSN R PWR RST FAULT RESET 1 U2 J4 Figure 8 1600A Interface PCA 1600A Interface PCA (located on back of Display Panel) LEDS: RST —This LED is normally off. It glows red when the external reset switch is pressed FAULT —This LED is normally red.
1600A-N4X closed switch to these terminal blocks. If more than one switch is to be connected, the switches must be connected in series. NOTE: The Remote Alarm Reset switch should be a ‘Normally Closed’ Switch and should be wired as such. Failure to wire the switch correctly will cause the Enclosure Alarm Reset and all subsequently connected Remote Alarm Reset Switches to be non operational. 3.3 Installing I/O Modules A maximum of 12 I/O modules may be installed in the 1600A NEMA 4 enclosure.
1600A-N4X Figure 10 Model DA-4 and 4-20mA Gas Sensor Connections Sensor 4 Sensor 3 COMM Typical Sensors M S D L S D 4-20mA INPUT Sensor 1 Sensor 2 Figure 11 Model DA-4 and 4-20mA Gas Sensors RS-485 Modbus™ Gas Sensors Connect the five wires from the Modbus™ gas sensors (Detcon Model 600 and Model 700 Series types) to the din rail mounted terminals labeled RS-485 “A”, “B”, and “Shld” and VDC “+” and “-”. Note: the controller power supply is only capable of handling 3Amps accumulative.
1600A-N4X Figure 12 Modbus™ Gas Sensor Connections Relay Output Contact Modules There are four ‘Form C’ 5 Amp relay contacts in each Model RL4 module. These can be used to control annunciating devices or as signal inputs to other control devices. Connections to the relay contacts of the Model RL4 module are shown in Figure 13. Note that the 5Amp rating of the relay contact should not be exceeded.
1600A-N4X Figure 14 Model AO-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) Figure 15. This adds a 120: resistor to the end of the line. If applicable, add a 120: resistor to the last Modbus™ gas sensor.
00A-N4X 3.5 Initial Power Checks Before applying power, make sure that all I/O Modules are correctly installed and that all wiring connections between I/O modules and external devices are made correctly. NOTE: Applying power with devices hooked up incorrectly may cause damage. Turn the applicable AC and DC Breaker Switches to the ON positions. Verify that the main touch-screen LCD comes on displaying gas readings.
1600A-N4X 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 5.3 for more information. Figure 17 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.
1600A-N4X selections have been made for the current active gas channel. The Channel Information is displayed for the current channel being set-up. To exit the channel touch MAIN, Channel Setup, PREV or NEXT. To exit Channel Setup touch Program Menu or Main. Figure 19 Individual Channel Setup Channel Activation: If the channel is active, touch the ACTIVE button to disable it; touch the ENTER button to save change.
1600A-N4X Press the ‘ENTER’ key after the completed set-up selections for each gas channel are made 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.
1600A-N4X Example: The 1600A is to be set up for two Model DA4 input modules. Make sure that the switch setting for the first Model DA4 module is set to 01, representing the first gas input and is wired to terminal connection #1, for position 1 on the module’s wiring connector. The first Model DA4 module would look like this: CH # 01 thru 04 DA4 Address 01 Hex 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.
1600A-N4X Figure 24 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-N4X Figure 25 Accessing Serial Setup Figure 26 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-N4X NOTE: The 1600A Device # is in decimal format, and the serial address switch setting for the 600 or 700 Series Sensor is in hexadecimal format. This means that device number 10 decimal on the 1600A corresponds to the 600 or 700 Series Sensor at address 0A hexadecimal. 4.1.5 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.
1600A-N4X 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-N4X 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-N4X 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-N4X 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-N4X Figure 31 On-Screen Keyboard Figure 32 Password Screen 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.
1600A-N4X 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 Channel 3 Reading Channel 4 Reading Channel 5 Reading Channel 6 Reading Channel 7 Reading Channel 8 Reading Channel 9 Reading Channel 10 Reading Channel 11 Reading Channel 12 Reading Channel 13 Reading Channel 14 Reading Channel 15 Reading Channel 16 Reading 40016 Fault Status Bits High Byte Bit 7 1 = Channel 16 Fault Bit 6 1 = Channel 15 Fault Bit 5 1 = Channel 14 Fault Bit 4 1 = Channel 13 Fault Bit 3 1 = Chan
1600A-N4X Bit 0 1 = Channel 1 Alarm 1 40018 Alarm 2 Status Bits High Byte Bit 7 1 = Channel 16 Alarm 2 Bit 6 1 = Channel 15 Alarm 2 Bit 5 1 = Channel 14 Alarm 2 Bit 4 1 = Channel 13 Alarm 2 Bit 3 1 = Channel 12 Alarm 2 Bit 2 1 = Channel 11 Alarm 2 Bit 1 1 = Channel 10 Alarm 2 Bit 0 1 = Channel 9 Alarm 2 Low Byte Bit 7 1 = Channel 8 Alarm 2 Bit 6 1 = Channel 7 Alarm 2 Bit 5 1 = Channel 6 Alarm 2 Bit 4 1 = Channel 5 Alarm 2 Bit 3 1 = Channel 4 Alarm 2 Bit 2 1 = Channel 3 Alarm 2 Bit 1 1 = Channel 2 Alarm 2
1600A-N4X Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1 = Channel 8 Cal 1 = Channel 7 Cal 1 = Channel 6 Cal 1 = Channel 5 Cal 1 = Channel 4 Cal 1 = Channel 3 Cal 1 = Channel 2 Cal 1 = Channel 1 Cal 0 = Channel 8 no Cal 0 = Channel 7 no Cal 0 = Channel 6 no Cal 0 = Channel 5 no Cal 0 = Channel 4 no Cal 0 = Channel 3 no Cal 0 = Channel 2 no Cal 0 = Channel 1 no Cal 5.6 Firmware Upgrade The 1600A-N4X is capable of firmware upgrades for both the PLC and touch screen device.
1600A-N4X 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. Touch screen version can be found in the top right corner of the “Screen Utilizes” menu. Program Menu Ź Screen Utilities: HMI v.XX 5.6.2 PLC Upgrade 1.
1600A-N4X 6.0 Spare Parts Recommended spare parts list: Detcon Part # 975-041400-000 976-041400-000 975-041401-000 320-283934-700 320-283931-800 360-SWS150-024 Description RL-4 Relay Module (As applicable) DA-4 4-20mA Input Module (As applicable) AO-4 4-20mA Output Module (As applicable) VAC (230VAC) Over Voltage Module VDC (24VAC) Over Voltage Module 24VDC Power Supply 7.0 Warranty Detcon, Inc.
1600A-N4X 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-N4X 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-N4X Figure 37 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-N4X Figure 38 Unbalanced Data Bus The addition of 2 repeaters (Figure 39) 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 39 Data Bus using two repeaters Be sure to check the equipment being installed.
1600A-N4X 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 41. 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-N4X 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 43. 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-N4X 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-N4X 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
1600A-N4X Appendix C Revision Log Revision 0.1 0.2 Date 04/1/2009 08/20/2009 1600A-N4X Instruction Manual Changes made Unit wiring and firmware changed. Images: revised screen shots and wiring diagram. Added image of 1600A interface board. Text: removed references to DI module, Spare parts no longer in assembly Rev. 0.
1600A-N4X Appendix D Drawings and Diagrams 1. 1600A-N4X Dimensional Overview 2. 1600A-N4X Unit Overview 3. 1600A-N4X Wiring Diagram 1600A-N4X Instruction Manual Rev. 0.
1600A-N4X 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 • 1600A-N4X Instruction Manual Rev. 0.
1600A-N4X 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 • 1600A-N4X Instruction Manual Rev. 0.
1600A-N4X 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 • 1600A-N4X Instruction Manual Rev. 0.
1600A-N4X 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 • 1600A-N4X Instruction Manual Rev. 0.
