Devar - Model 3620 - Indicator/Controller Dual Relay - Manual

DEVAR Inc. 706 Bostwick Avenue, Bridgeport, CT 06605 TEL: 203-368-6751 FAX: 203-368-3747 1-800-566-6822 www.devarinc.com Model 332 ALARM / CONTROLLER INDUSTRIAL CONTROL EQUIPMENT MANUAL NO. 990620A TABLE OF CONTENTS Section Title Page No. I General Description …………………………… 1 II Specifications ………………………………….. 3 III Installation ……………………………………... 5 IV Operation ………………………………………. 7 V Recalibration …………………………………… 9 VI Power Supply Options ……………………….… 12 VII Troubleshooting ………………………………... 13 VIII Parts List ……………………………………….. 18 Addendum A Model 332-AP Pump Controller TABLES AND ILLUSTRATIONS Figure Title Page No. 3.1 General Dimensions 332W ……………………… 5 3.2 General Dimensions 332P ………………..……… 6 3.3 Field Wiring ……………………………………... 6 4.1 Dip Switch Setting Table ……………………...… 8 5.1 Input Range Calibration Table ............................... 10 5.2 Display Recalibration Procedure ............................ 11 5.3 Decimal Point Location .......................................... 11 6.1 Modification for 24 VDC Power ............................ 12 7.1 Schematic ................................................................ 14 7.2 Component Location, Display Board ..................... 15 7.3 Component Location, Circuit Board ....................... 16 7.4 Component Location, Power Supply ...................... 17 Page 1 SECTION I GENERAL DESCRIPTION 1.1 General The Devar Model 332 Alarm/Controller is a high accuracy multipurpose instrument, providing process indication, two separate alarm channels, independently adjustable set and reset points, substantial relay contact rating and simplicity of adjustment, with set and reset points read directly from the digital display. 1.2 Theory of Operation Used as a simple alarm, the 332 monitors a single voltage or current input signal and compares it to the trip point setting. When the input signal reaches the trip point setting an alarm is initiated and the internal relay, which is normally energized for fail-safe operation, will de-energize. 1.3 Dual Channel Operation The 332 monitors a single voltage or current input and provides two output channels with independent trip point adjustments and environmentally sealed, 10 amp, SPDT relays. Each channel can be set to alarm on an increasing or decreasing input signal by means of an internal DIP switch setting. A red LED turns on indicating which channel has alarmed and the bright red backlit display begins flashing on and off, alerting an observer to the alarm condition. The flashing display option can be disabled if desired. 990620 Page 2 1.4 Set Point and Reset Point A special feature of the 332 is the ability to set not only the alarm trip point, but also the reset point (e.g. the alarm could be set to trip if the input were to go above 75%, but not to reset until the input fell below 50%). Both set and reset points can be adjusted anywhere between -5% and +105% of the input range. This feature makes the 332 ideal as a simple on/off controller. A typical application could be level control in a tank. If the desired level was at 50%, a pump could be turned on when the level fell below 50% and turned off once the level rose above some pre-specified value. Should the level continue to drop (e.g. below 40%) a second pump could be activated until the level was corrected. 1.5 Display The 332 provides a large 3-1/2 digit display with bright red backlit digits, which can be easily seen in bright ambient light or in total darkness. This display is used to monitor the input signal as well as to set the alarm trip and reset points. The display is calibrated to read in percent, however, it can be factory calibrated to read directly in engineering units such as °F, °C, PSI, GPM, etc. 1.6 Packaging and Shielding The 332 is housed in a rugged steel enclosure and is available in either panel mounted or wall mounted versions. The internal relays are epoxy encapsulated in a separate steel box mounted inside of the larger enclosure. This method of assembly provides environmental isolation for the relays as well as electrical shielding for the electronic circuitry. In addition, all lines going to the electronic circuitry have been RFI filtered. 1.7 Power The 332 is powered from 115 VAC, however, 230 VAC and 24 VDC operations are also available. When AC powered, The 332 provides a 24 VDC output which can used to power an external two wire transmitter. 990620 Page 3 SECTION II SPECIFICATIONS 2.1 General a. Repeatability ........................................................................ 0.1 % of span b. Resolution Trip Adjust ........................................................ 0.1 % of span c. Display Accuracy ...................................................... Reading ± 2 Counts d. Indication ................................................. Input, Set Points, Reset Points; Scale 0 to 100% Standard (Non-standard Ranges Between ± 1999 Counts) e. Set Point (dual) .................................................................... -5% to +105% f. Reset Point (dual) ................................................................. -5% to +105% g. Operating Temp. Alarm ....................................................... -10 to +70° C h. Operating Temp. Display ........................................................ 0 to +60° C i. Storage Temperature ............................................................. -20 to +80° C j. Temperature Effect .......................................................... 0.018%/°C, max. k. Display …………………………………… 1/2 inch High, 3.5 Digit LCD Backlit, Red Digits on Black l. Power ..................................................................... 115 V, 50/60 Hz, 6 VA Option E71: 230 V, 50/60 Hz, 6 VA Option E92: 24/28 VDC, 90 mA (Non-isolated) 2.2 Inputs a. Standard Ranges ………………………………. 332-1 0/5 mA, Ri = 200 Ohms -2 1/5 mA, Ri = 200 Ohms -3 4/20 mA, Ri = 50 Ohms -4 10/50 mA, Ri = 20 Ohms -5 0/10 mA, Ri > 10 meg -6 0/5 V, Ri > 10 meg -7 0/1 mA, Ri = 1K Ohms -8 0/1 V, Ri > 10 meg -9 1/5 V, Ri > 10 meg -X Non-standard, Specify 990620 Page 4 2.3 Alarm Contacts a. Relays .............................................................. (2) SPDT, Epoxy Encapsulated b. Mechanical Life……………………………… 20 Million Operations c. Electrical Life……………………………...… 100,000 Operations at 8 Amps, 240 VAC, 24 VDC, Resistive 50,000 Operations at 10 Amps (N.O. contact) 5 Amps (N.C. contact) 120 VAC, Resistive 30,000 Operations at 7.2 Motor Run Amps, 45 Lock Rotor Amps, 120 VAC 10,000 Operations at 5 Motor Run Amps, 30 Lock Rotor Amps, 240 VAC d. Maximum Switched Power………………….. 200 W DC, 2000 VA AC e. VDE Contact Rating…………………………. 8 Amps, 250 VAC f. UL Contact Rating…………….........………... 10 Amps, 240 VAC, Resistive, 8 Amps, 24 VDC, Resistive 1 /3 HP, 120 VAC 1 /2 HP, 240 VAC 2.4 Housing a. Indoor Type………………………………….. Panel or Wall Mounted, Gray Baked Enamel Over Zinc Plated Steel b. Weight ............................................................. 2.3 lbs. 990620 Page 5 SECTION III INSTALLATION 3.1 Mounting The 332 Alarm/Controller is available, either as a wall mounted (332W) or as a panel mounted (332P) unit. The wall mounted unit is attached to the wall by means of two #6 or #8 screws (see fig. 3.1). The panel mounted unit is inserted through the front of the panel then locked in place by a U-shaped bracket, which is screwed to the rear of the housing using two #6 screws (see fig. 3.2). 3.2 Field Wiring Field wiring connections are made to a 12 point, compression type terminal block, which can accept up to 14 AWG wire (see fig. 3.3). Figure 3.1 – General Dimensions 332W 990620 DEVAR INC.4.38"(111 mm)4.00"(101.6 mm)2.68"(68 mm) 4.72"(120 mm)INPUTSET SETRESET RESETModel 332W+ – 24VGNDACACBAMOUNTING HOLES0.169 DIA, 4 IN. ON CENTER Page 6 Figure 3.2 – General Dimensions 332P Figure 3.3 – Field Wiring 990620 4.60"(117 mm)3.90"(99 mm)INPUTSETSETRESET RESETA B2.95"(75 mm)PANEL CUTOUT3.67" (93.2 mm) × 2.71" (68.8 mm)TOLERANCE ±0.015 (±0.38 mm)MODEL 332PALARM CONTROLLERDEVAR Inc.CASEAC ACGNDGND+24 VDCCOMMON+ INPUTALARMB117 VAC(OPTION E71, 220 VAC)ALARMA4 WIRETRANSMITTERPOWER++--2 WIRETRANSMITTER-++24 VDC(OPTION -E92)OR Page 7 SECTION IV OPERATION 4.1 High-Low Selection Each channel of the 332 Alarm/Controller can be independently configured for high alarm or low alarm operation by setting the internal dip switches. To do this remove the cover from the top of the 332 and set the dip switches to the proper positions as specified in figure 4.1. 4.2 Alarm Indication The 332 has been factory configured so that if either channel goes into alarm the display will begin to flash. The display will continue to flash as long as one of the channels remains in the alarm condition. If this feature is not desired it can be disabled by removing diodes D3 and D4 from the PC board. See figure 7.3 for the location of diodes D3 and D4. An alarm condition is also indicated by two red LEDs, one for channel A and one for channel B. These LEDs will light on alarm. The operation of the LEDs is not affected by disabling the flashing display. 4.3 Trip Point Selection To set the trip point turn the selector knob to the Set position then adjust the trip point pot until the desired trip point appears on the display. To set the reset point, turn the selector knob to the Reset position, then adjust the reset pot until the desired reset point appears on the display. For a high alarm, the reset point should be set at least 0.1% below the trip point, and for a low alarm, at least 0.1 % above the trip point, this is to prevent relay chattering when the input is exactly at the trip point. However, we recommend a dead band setting of 1% or more, in order to exceed the noise normally found on the input signal, in factory environments. Once the trip and reset points are set for both channels, turn the selector knob to Input (the center position). The input will now be displayed. 4.4 Trip Point Monitor The set and reset points can be set whenever power is applied to the unit. An input signal is not required. The set and reset points can also be monitored at any time, while the unit is in operation. Turning the selector switch to display the trip or reset point has no effect on the operation of the unit. 990620 Page 8 ALARM ACTION ON POSITIONS OFF POSITIONS HI 1, 2 3, 4 A LOW 3, 4 1, 2 HI 5, 6 7, 8 B LOW 7, 8 5, 6 Figure 4.1 – Dip Switch Setting Table 990620 1 2 3 4 5 6 7 8SPAN ZERO OFFONTOP VIEW OF CIRCUIT BOARD SIDE VIEWOF SWITCH Page 9 SECTION V RECALIBRATION 5.1 Standard Input Calibration The 332 Alarm/Controller is calibrated to display 00.0 to 100.0 for any standard input range. To change the input from one standard range to another standard range, the proper values for resistors R107, R109 and R110 must be selected. The value of these resistors, for standard input ranges, is listed in figure 5.1. The location of these resistors can be found in figure 7.3. 5.2 Span and Zero Adjustment Once the proper calibrating resistors have been installed, turn the selector switch to the Input position and apply an input signal to the unit. Adjust the span and zero pots (see fig. 7.3) until the display is calibrated to read 00.0 to 100.0. 5.3 Nonstandard Input Calibration The 332 Alarm/Controller can also be calibrated for nonstandard input ranges. To do this the values of resistors R107, R109, and R110 must be calculated so that the new input range will produce an output voltage of 0 to 4.75 V at pin 14 of amplifier U2. See figure 7.1 for the circuit schematic and figure 7.3 for the location of amplifier U2. Once the resistors have been installed, an input signal must be applied and the span and zero pots adjusted, as described in paragraph 5.2. 5.4 Engineering Units The display of the 332 Alarm/Controller can also be calibrated to read directly in engineering units. To do this requires the removal of jumper J2, the selection of resistors R28 and R29, and the positioning of jumper J1, for decimal point selection. These components are located on turret terminals on the PC board, behind the display (see fig. 7.2). 990620 Page 10 5.5 Display Recalibration To recalibrate the display, the value of resistors R28 and R29 can be calculated by following the steps outlined in figure 5.2. See figure 5.3 for decimal point selection. Once these resistors and jumpers have been installed the unit must be calibrated. To do this, apply a signal to the input terminals of the 332. Input the bottom of the range and adjust the zero pot for the proper display reading, then input the top of the range and adjust the span pot. Repeat this procedure until the display is calibrated. See figure 7.3 for the location of the span and zero pots. R109 R110 R107 Input Range Ohms Part No. Ohms Part No. Ohms Part No. 0/1 mA 1,000 223737-0021 84,500 223737-0036 243,000 223737-0131 0/5 mA 200 514490-2000 84,500 223737-0036 243,000 223737-0131 1/5 mA 200 514490-2000 82,500 223737-0076 4/20 mA 49.9 514490-0499 82,500 223737-0076 10/50 mA 20 223737-0181 82,500 223737-0076 1/5 V 4,320 223737-0026 82,500 223737-0076 0/1 V 84,500 223737-0036 243,000 223737-0131 0/5 V 3,320 223737-0138 243,000 223737-0131 0/10 V 1,500 223737-0059 243,000 223737-0131 Figure 5.1 – Input Range Calibration Table 990620 Page 11 To Recalibrate Display Example 1. Specify New Range -45.0 to 150.0 °F 2. Calculate Span Counts (Ignore decimal point) 1500 -(-) 450 1950 counts 3. Note offset counts -450 counts 4. Calculate Scaling Factor a = (span) × 4.2283 × 10-5 (1950) × 4.2283 × 10-5 = 0.08245 5. Calculate Resistor R19 45300 × a 1-a 45300 × 0.08245 1- 0.08245 6. Select Closest Standard 1% Resistor, 50 PPM/°C or better R19 = 4020 Ohms 7. Calculate millivolt Offset V = (± Offset) × 2 × 10-4 (-450) × 2 × 10-4 = -0.09 Volts 8. Calculate Offset Resistors Using R28 = 20,000 9. Select Closest Standard 1% Resistor, 50 PPM/°C or better R28 = 20K R29 = 4.53K Figure 5.2 – Display Recalibration Procedure Figure 5.3 – Decimal Point Location 990620 D3D3D2 D2J1J1J1J1D1D1R19 = = 4070.6 6.2355 + 0.09-1 × 20,000 = 4499R29R286.2355 -V= -1 Page 12 SECTION VI POWER SUPPLY OPTIONS 6.1 Conversion to 230 VAC Power To change the power supply operation from 115 to 230 VAC, a jumper "J3" must be added on the power supply board and the track must be cut in two places. Reference figure 7.1 for the circuit schematic and figure 7.4 for the location of the jumper and the cut tracks. 6.2 Conversion to 24/28 VDC Power For 24 to 28 VDC operation, remove transformer "TI" and diode bridge "DB1" from the power supply board, add diode IN4002 (380666-01) and jumpers "J4" and "J5". Reference figures 6.1, 7.1, and 7.4. Figure 6.1 – Modification for 24 VDC Power 990620 Page 13 SECTION VII TROUBLESHOOTING 7.1 Check Points If the 332 Alarm/Controller is not operating properly, check the following: a. That the unit is receiving power. b. That all terminals are wired correctly and that terminal screws are tight. c. That the reset point is below the set point for a high alarm. d. That the reset point is above the set point for a low alarm. 7.2 Troubleshooting If the cause of the problem is not found, disconnect all connections, except power, from the terminal block. Make the following tests to determine in, which part of the circuit the problem lies. a. Check for +24 volts between field terminals 3(+) and 2(-). b. Turn the selector switch to the set and reset positions and check to see that the display responds to adjustment of set and reset pots. c. Short input terminals 1 and 2, and turn the selector switch to the input position. For a 0 to 100% display, the reading should be 00.0, if the unit has been calibrated for a zero based input such as 0 to 10 volts. The display should read -25.0 if the unit has been calibrated for an input with a 25% offset such as 4 to 20 mA. d. To troubleshoot the circuit, refer to the schematic, figure 7.1 and component location drawings, figures 7.2, 7.3, and 7.4. 7.3 Replacement Parts Replacement parts may be ordered, by their part number from Devar Inc. Most capacitors, diodes and resistors are readily obtainable from local electronics distributors. Reference Section VIII for a complete list of parts used in the 332. 990620 Page 14 Figure 7.1 - Schematic 990620 +2BRNRED1DR2312MC120.1uFLED2C180.047uFR1124.3K0/4.75VAL1564YELORNDK111C190.047uFS1K216+28V+28VK1R208.06KLED1K2R218.06KBLUD1+R110U2C10 1uFP2 10KAL2COMPARATORR33 1KS1R32 1KAL1COMPARATORU1R3040.2KOSCILLATORA48LO18101413142 3 4LOHIHIHIHILO LO6 7 85SHEETDWG NO.SHREVDESCRIPTIONARELEASE ECN 3020BTERMINAL SCREWTURRET TERMINALRIBBON CABLE CONNECTORFEED THROUGH CAPACITORFERRITE BEADTRACE CUTS SQ15C70.047uF C30.047uFU2R316.5KR216.5KU1R3140.2KR416.5KU2R516.5KU1C90.047uFAC60.047uF214767 123 11+15V1031 OF 1SIZESCALEWTDRAWING NO.NONEPREPAREDCHECKEDMECHELECDESIGNAPPROVEDAPPROVEDCONTRACT NO.RNTFINISHMATERIALNEXTASS'Y NO.R291.2MR281.2M13A6R2249.9KD3 D4D6D5D1312R1016.5K-1.2VAU1U29 1011RELEASE ECN 3020B, CHANGE R20 & R21,CHANGE LED 1 & 2, ADD R28, R29, D3, D6C DADD R30 & R31, ECN 3136E FADD C200, ECN 3253GADD R34, ECN 3278HADD C100, ECN 3223C10.047 uFCR113VR116.5KR640.2KR109C111uFC80.047uF5 3R740.2KACHANGE R26 & R27, ADD C18, C19,R30, 31, 32, 33, ECN 3020C9C20.047uFR107203AC12AC11+24VCUT FOR220 VACGRN6 7 83 4 1 2+28VINU3OUTU5U442358C1510uFC1710uFA D16C1610uF+5V-5VCR32.5VCR22.5VR271.21KC1000.1µFAAC20010µFC14 330 uFBLKBLK14CR41.2VR26806OUTQ10Q8Q7Q9R34100KC130.1uFSS17171818574 892SSQ3-1.2VQ5S SQ619C200.001uFC190.001uFL2L111 12-1.2V+15V+–DB1T15D220Q5Q612AR930.1KP1 10KR87.87K+5V+15V14C50.047uFZEROAC40.047 uF111-1.2VGND10897SPANAAA+15VAA+15VD131J3220 VAC09/12/05AL2INPUT–+15V+28VBDEVAR Inc.UNSPECIFIED DIMENSION TOLERANCE DECIMAL +/- 0.005" FRACTION +/- 1/64" ANGLE +/- 1/2 DEGREEBM 515407This Drawing is the sole property of DEVAR Inc., and is submitted on the understanding that the contents hereof are not published and are not to be disclosed.to third persons withoutprior permission.IN+ -- +Q4- +- ++-Q2-+ +-R251.2M Q11R2412M--N/A--N/A-1515436332 ALARM/CONTROLERSCHEMATICREDRAWN, ECN 3311706 Bostwick Avenue, Bridgeport, Conn. 06605TEL: (203) 368-6751 FAX: (203) 368-37475154360.8VV??2P3 20K3P4 20KP5 20KR143.57KP6 20K109J2+5VR133.57K-5VJ1DISPLAY-1.2VR1845.3KR29R171.07KTRIP1RESET2RESET1TRIP2R28RFLRFHD3D2D1IN LONC+V131+5V-1.2VR1625.5K–R153.57KR123.57K1211ROHIN HICOMTST-VA+19R30100R3110020POWER SUPPLY BOARDCIRCUIT BOARDS22354 1RESET14TRIP15INPUTTRIP2RESET28 7 6CIRCUIT BOARDDISPLAY BOARD6FILTER BOXAPPROVEDAGAG AG AGAGAG AG AGDATE10-20-9303-24-9201-05-9404-16-9704-20-0004-30-0106-14-011-19-06REVR19 2KH Page 15 PAGE 16 FIGURE 7.3 Figure 7.2 - Component Location, Display Board 990620 Page 16 Figure 7.3 - Component Location, Circuit Board 990620A Page 17 Figure 7.4 - Component Location, Power Supply 990620 Page 18 SECTION VII PARTS LIST 7.1 Parts relating to calibration can be found in Fig. 5.1, The Input Range Calibration Table. To order spare or replacement parts, contact your local Devar Inc. representative. Whenever possible, specify items by description and part number. 7.2 Resistors, 1% Metal film Part Number R1,2,3,4,5,10 16.5K 223737-0099 R6,7,30,31 40.2K 223737-0048 R8 7.87K 223737-0042 R9 30.1K 223737-0009 R11 24.3K 223737-0137 R23,24 12M (5%) 221862-0024 R25,28,29 1.2M (5%) 222087-0015 R12,13,14,15 3.57K 223737-0063 R16 25.5K 223737-0008 R17 1.07K 223737-0053 R18 45.3K 223737-0085 R19,20,21,27 2K 223737-0058 R26 1.5K 223737-0059 R32,33 1K 223737-0021 7.3 Potentiometers P1,2 10K, 3006Y 381098-0010 P3,4,5,6 20K, 3299W 381355-0011 7.4 Capacitors C1 thru C9,18,19 0.047µF, 50WV, Ceramic 382473-0001 C10,11,15,16,17 10µF, 20WV, Tantalum 380767-0001 C12,13 0.1µF, 50WV, Ceramic 382473-0001 C14 330µF,50WV, Electrolytic 514491-0001 990620 Page 19 7.5 Semiconductors Q1 thru Q11 N Channel, V-MOS 514404-0001 D1,2,3,4,5,6 Diode, IN4153 222095-0001 CR1 Zener, 13V, IN5243B 381071-0005 LED1,2 LED, HLMP-4700 514472-0002 DB1 Diode Bridge, PF10 380766-0002 7.6 Integrated Circuits U1,2 Op-Amp, Quad, TLC27L4IN 514841-0001 U3 Regulator, 15V, LM340T-15 381584-0001 U4 DC to DC Converter, TSC7660 514735-0001 U5 Regulator, 24V, MC7824CT 513410-0001 CR2,3 Reference, 2.5V, LM385B-2.5 382209-0003 CR4 Reference, 1.2V, LM385B-1.2 382209-0001 7.7 Switches S1 Switch, DIP 513655-0002 S2 Switch, Rotary 515416-0001 7.8 Transformer T1 Power Transformer 514797-0004 7.9 Display 515413-0001 7.10 Cable Assembly BM 515433-0001 7.11 Filter Box Assembly BM 515412-0001 Includes: Relays, Terminal Block and EMI Filters, Epoxy Encapsulated 990620 Model 332-AP Alternating Duplex Pump Controller The specifications for the Model 332 Alarm/Controller and the Model 332-AP Duplex pump controller are exactly the same except for the action of the relays. The Model 332-AP is specifically designed for pump control applications. The 332-AP has two channels, one for each pump. Each channel provides independently adjustable trip (pump-on) and reset (pump-off) set points. As with the standard 332, the alarm action (high or low) must be preset for each of the two channels. For pump-up applications, the alarm action for both channels is set to low. For pump-down applications the alarm action for both channels is set to high. Note that with the 332-AP the alarm action for both channels will always be the same. Note also that for pump-up applications the reset (pump-off) point must be set above the set (pump-on) point and for pump down applications the reset (pump-off) point must be set below the set (pump-on) point. When the input level crosses the first trip point one of the two output relays will energize and the normally open contact will close, turning the pump on. Output relays alternate each time the trip point is crossed. This allows the work load to be shared between the two pumps, with only one pump working at a time. Should the input level cross the second trip point, then the pump that is not operating will also turn on and both pumps will run simultaneously until the first reset point is reached. Unlike the standard 332 the relay coils are energized while in the tripped (pump-on) state, therefore if power is removed from the 332-AP the relay contacts will go into the pump-off position. Manual 990620A Addendum A