Model 12B Single Channel Control Module Operator’s Installation and Instruction Manual Covers all Model 10C Control Modules DETCON, Inc. 4055 Technology Forest Blvd. Suite 100, The Woodlands, Texas 77381 Ph.281.367.4100 / Fax 281.298.2868 www.detcon.com April 25, 2012 • Document #1953 • Revision 1.4 Model 12B This page left intentionally blank 12B Control Module Instruction Manual ii Model 12B Table of Contents 1.0 Description .......................................................................................................................................... 1 2.0 Specification........................................................................................................................................ 2 3.0 Controller models ............................................................................................................................... 2 4.0 Alarm functions and settings.............................................................................................................. 3 4.1 Alarm set points .............................................................................................................................. 3 4.2 Latching or non-Latching Relays ..................................................................................................... 4 4.3 Relay Contact Output Select ............................................................................................................ 4 4.4 Energized or De-energized............................................................................................................... 5 4.5 Ascending or Descending Alarms .................................................................................................... 5 4.6 Alarm Reset..................................................................................................................................... 5 4.7 Alarm Disable ................................................................................................................................. 5 5.0 POWER INPUT OPTIONS ............................................................................................................... 6 6.0 ANALOG 4-20 MA SIGNAL INPUT/OUTPUT ............................................................................... 6 7.0 RS-485 MODBUS™ FEATURES AND SPECIFICATIONS ........................................................... 6 8.0 FAULT CIRCUIT FUNCTIONS ....................................................................................................... 7 8.1 Detector Load Bypass Jumper.......................................................................................................... 7 9.0 TEST FUNCTIONS............................................................................................................................ 8 9.1 Alarm Set Point Test........................................................................................................................ 8 9.2 Display/Alarm Test ......................................................................................................................... 9 9.3 RS-485 Address Setting Test ........................................................................................................... 9 10.0 OTHER FEATURES.......................................................................................................................... 9 10.1 Flashing Over-range ........................................................................................................................ 9 10.2 Range Configuration Jumpers........................................................................................................ 10 10.3 PolySwitch Over-current Protection............................................................................................... 10 10.4 Default Settings of Jumpers Tabs................................................................................................... 11 11.0 WARRANTY AND SERVICE POLICY ......................................................................................... 11 Revision History ....................................................................................................................................... 12 Table of Figures Figure 1 Alarm Set switches and Alarm Relay Jumpers ............................................................................................................................................................ Er ror! Bookmark not defined. List of Tables Table 1 Switch positions for setting alarm points..........................................................................................3 Table 2 Range configuration jumper locations and settings...........................................................................10 12B Control Module Instruction Manual iii Model 12B This page left intentionally blank Shipping Address 4055 Technology Forest Blvd. Suite 100,., The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com 12B Control Module Instruction Manual iv Model 12B 1.0 Description Detcon Model 12B single channel digital control modules are designed to supervise and display the status of a single remote sensor assembly. Modules are available for a variety of toxic and combustible gases. Model 12B series control modules are designed to operate on an input voltage of 24 VDC and are compatible with a complete line of Detcon enclosures and mainframe hardware assemblies. The available enclosures include designs for rack or panel mounting in non-hazardous areas (NEMA 1), for weather proof outdoor location in non-hazardous areas (NEMA 4), and for location in areas electrically classified hazardous or explosion proof (NEMA 7). Any combination of Model 12B control modules and Detcon sensor assemblies may be installed in a common mainframe assembly thereby providing monitoring for a variety of gases. Model 12B control modules are compatible with a linear 4-20 mA DC input signal. The module features a direct reading 3 digit display of the gas concentration, flashing over-range, alarm disable, RS-485 Modbus™ serial output, 4-20 mA analog signal output, and four alarm relays that are status displayed via light emitting diodes located on the front panel. Alarm functions are alarm 1, alarm 2, alarm 3, and fault. All alarms are jumper programmable for latching or non-latching operation with a common front panel reset switch. The reset is part of a common bus when installed in a mainframe, allowing for the use of an external reset switch common to all modules in the mainframe. 12B Control Module Instruction Manual Rev 1.4 Page 1 of 12 Model 12B 2.0 Specification Range 0-99 ppm/% is typical but varies according to application Accuracy/Repeatability ± 2% F.S. Operating Temperature –40° F to +175° F Input Power 24 VDC standard; 12 VDC optional Power Consumption <3 watts (no alarms) 5 watts (full alarm peak load) Warranty One year Five year fixed fee service policy Outputs Analog 4-20 mA DC Serial RS-485 Modbus™ Relays Contacts include common with jumper selectable choice of normally open or normally closed for four alarms Resistive load: 5A, 250 VAC; 5A, 30 VDC Inductive load: 2A, 250 VAC; 2A, 30 VDC Max operating current: 5A 3.0 Controller models Model 12B control modules are compatible with any 4-20 mA signal input and therefore are interchangeable. This design flexibility allows a single module to be user programmed to be compatible with any of the gases or ranges listed below via rotary dip switches or jumper tabs. A change of face plate which reflects the proper labeled gas is the only other change that is required. The Model 12B control module model numbers listed below are shipped preconfigured for the gases and ranges as listed. Model CH-12B O2-12B NH-12B HC-12B PH-12B HL-12B HS-12B Gas combustible gas O2 oxygen deficiency NH3 ammonia HCN hydrogen cyanide PH3 Phosphine HCL hydrogen chloride H2S hydrogen sulfide 12B Control Module Instruction Manual Rev 1.4 Standard Range Optional Ranges 0 - 100 % LEL 0 - 25.0 % 0 - 100 ppm 0 - 10.0 ppm 0 - 100 ppm 0 - 10.0 ppm 0 - 100 ppm 0 - 1.0 0 - 10 0 - 25 0 - 50 0 - 10.0 0 - 50.0 0 - 99.9 Page 2 of 12 Model 12B CO-12B SO-12B NO-12B CL-12B CD-12B H2-12B NX-12B 4.0 CO carbon monoxide SO2 sulfur dioxide NO2 nitrogen dioxide CL2 chlorine CLO2 chlorine dioxide H2 hydrogen NO nitric oxide 0 - 100 ppm 0 - 100 ppm 0 - 100 ppm 0 - 10.0 ppm 0 - 10.0 ppm 0 - 100 ppm 0 - 100 ppm 0 - 100 0 - 200 0 – 500 0 – 999 Alarm functions and settings Model 12B control modules incorporate several user selectable alarm programming options that are accomplished via rotary dip switches or jumper tabs. These options include setting alarm points, latching of relays, contact outputs, energized/de-energized, and firing direction. See figure X for the applicable rotary switch and jumper tab locations. 4.1 Alarm set points Three alarms — alarm 1, alarm 2, and alarm 3 — can be set to fire in 1 digit increments via rotary dip switches. Each alarm features three rotary switches in which the desired alarm level is dialed by use of a jeweler’s screwdriver: one for 1’s, one for 10’s, and one for 100’s. The switch for 1’s is used to select the set point of the least significant digit - 0 through 9. The switch for 10’s is used to select the set point of the middle digit — 00 through 90. The switch for 100’s is used to select the set point of the most significant digit — 000 through 900. An alarm condition will cause the alarm relay to actuate upon reaching and/or exceeding the alarm set point. To set an alarm, follow this example: if you want the alarm to actuate at 25 ppm/% you would set the 100’s switch to 0, the 10’s switch to 2 and the 1’s switch to 5. The chart below shows which switches correspond to each alarm. Digits 1’s 10’s 100’s Alarm 1 SW2 SW3 SW4 Alarm 2 SW5 SW6 SW7 Alarm 3 SW8 SW9 SW10 Table 1 Switch positions for setting alarm points 12B Control Module Instruction Manual Rev. 1.4 Page 3 of 12 Model 12B Figure 1 Alarm Set switches and Alarm Relay Jumpers 4.2 Latching or non-Latching Relays All alarms — alarm 1, 2, 3, and fault — can be jumper programmed to operate as latching or nonlatching. If an alarm is programmed to latch, its corresponding relay and LED indicator, once activated, will stay activated until the reset button is pressed (assuming, of course, that alarm conditions have cleared). To program an alarm for latching operation: Place a jumper tab on pins 1 and 2 (left and center) of its corresponding jumper location. For non-latching operation place the tab on pins 2 and 3 (center and right) of the jumper location. The jumper locations are as follows: fault - JP12, alarm 1 - JP9, alarm 2 - JP5, and alarm 3 - JP1. 4.3 Relay Contact Output Select All alarm relays — alarm 1, 2, 3, and fault — can be jumper programmed for dry contact output as either normally open or normally closed. Refer to section 2.1 for contact ratings. To program an alarm relay for normally open contact output, place a jumper tab on pins 1 and 2 (bottom and center) of its corresponding jumper location. For normally closed contact output, place the tab on pins 2 and 3 (center and top) of the jumper location. The jumper locations are as follows: fault - JP20, alarm 1 - JP18, alarm 2 - JP16, and alarm 3 - JP14. 12B Control Module Instruction Manual Rev 1.4 Page 4 of 12 Model 12B 4.4 Energized or De-energized All alarm relays — alarm 1, 2, 3, and fault — can be jumper programmed as normally energized or normally de-energized. The standard is de-energized. However, a relay can be programmed as energized to provide application specific features. A normally energized relay will de-energize when in alarm. A typical application of the energized configuration is to have the fault relay normally energized so that in the event of a power failure to the control module card, the fault relay will de-energize causing its relay contacts to change state, thereby creating a fault output. It must be noted that when an alarm relay is jumper programmed as normally energized, the contact outputs, normally open and normally closed, become reversed (see section 2.3.3). The normally open contact becomes the normally closed and vice versa. Reconfiguration of the contact output jumpers may be required. To program an alarm relay as normally de-energized, place a jumper tab on pins 1 and 2 (left and center) of its corresponding jumper location. For normally energized operation, place the tab on pins 2 and 3 (center and right) of the jumper location. The jumper locations are as follows: fault - JP19, alarm 1 - JP17, alarm 2 - JP15, and alarm 3 - JP13. 4.5 Ascending or Descending Alarms Three alarms — alarm 1, 2, and 3 — can be jumper programmed to operate during ascending or descending gas conditions. This feature is useful mainly for the monitoring of oxygen deficiency whereas a decrease in oxygen concentration poses a danger to personnel. However, there may be other applications where the monitoring of a specific gas concentration is desired and alarms can be programmed to operate when that concentration exceeds or drops below a predetermined range. Typically, most applications of monitoring for toxic or combustible gases will warrant that the alarm be programmed as ascending. To program an alarm for ascending gas conditions: place a jumper tab on pins 1 and 2 (left and center) of its corresponding jumper location. For descending gas conditions, place the tab on pins 2 and 3 (center and right) of the jumper location. The jumper locations are as follows: alarm 1 - JP10, alarm 2 - JP6, and alarm 3 - JP2. 4.6 Alarm Reset An alarm reset switch (SW1), located on the control module face plate is used to reset alarms that have been programmed as latching. Once alarm conditions have cleared, alarms may be reset by simply pushing the momentary switch and releasing it. Remote reset outputs are also a feature of the 12B control module. This feature is available when used in conjunction with Model 12B compatible control enclosures and mainframe motherboards. 4.7 Alarm Disable An alarm disable switch (S1), located on the control module face plate is used to disable alarm 1, 2, and 3 alarm relays. The corresponding LEDs are not affected. This feature is useful for calibration or troubleshooting. The alarm disable switch toggle is located slightly behind the face plate in order to help avoid accidental use. When the switch is in the disable position, it will cause a fault condition that will activate the fault relay and LED, and output a fault code on the RS-485 serial loop. To disable alarms, simply toggle the switch to the down position. To re-enable the alarms, toggle the switch back to the up position. 12B Control Module Instruction Manual Rev. 1.4 Page 5 of 12 Model 12B 5.0 POWER INPUT OPTIONS Standard operating input power of the Model 12B control module is 24 VDC unless 12 VDC is specified at time of order. All of the circuitry of the 12B control module, with the exception of relays, will operate on 12 or 24 VDC. A 24 VDC control module can be converted to a 12 VDC control module by changing the relays. If this is desired, it is recommended that the control modules be returned to Detcon to be converted. 6.0 ANALOG 4-20 MA SIGNAL INPUT/OUTPUT Model 12B control modules receive an analog 4-20 mA signal input corresponding to the range of detection. The signal is processed through an analog to digital converter and is calibrated so that a 4 mA input will provide display readout of “0”. This circuitry is factory set. Should adjustment become necessary, the analog to digital converter can be fine-tuned via the input zero potentiometer (PT1). Model 12B control modules feature a discreet 4-20 mA signal output corresponding to the range of detection. This feature is factory set. Should adjustment become necessary, the digital to analog converter can be calibrated via the output zero potentiometer (PT3), and the output span potentiometer (PT2). 7.0 RS-485 MODBUS™ FEATURES AND SPECIFICATIONS Model 12B control modules feature Modbus™ compatible communications protocol and are addressable via rotary dip switches for multi-point communications. Communication is two-wire, half duplex, with the 12B control module set up as a slave device. The communications is Modbus RS-485 with 19200 Baud, 8 data bits, no parity, and 1 stop bit. A master controller up to 4000 feet away can theoretically poll up to 256 different 12B control module cards. This number may not be realistic in harsh environments where noise and/or wiring conditions would make it impractical to place so many devices on the same pair of wires. If a multipoint system is being utilized, each 12B control module should be set for a different address. Typical address settings are: 01, 02, 03, 04, 05, 06, 07, 08, 09, 0A, 0B, 0C, 0D, 0E, 0F, 10, 11, etc. Model 12B control module ID numbers are set via SW11 and SW12. For example, to set the ID number to 01, set the most-significant-bit rotary dip switch (SW11) to 0, and the least-significant-bit rotary dip switch (SW12) to 1. The following register list describes the parameters available from the 12B control module: 40000 40001 40002 40003 40004 Range Reading Alarm 1 Set Point Alarm 2 Set Point Alarm 3 Set Point 12B Control Module Instruction Manual Rev 1.4 Page 6 of 12 Model 12B 8.0 FAULT CIRCUIT FUNCTIONS Model 12B control modules feature fail safe supervisory circuits designed to assure maximum reliability in system performance. A fault condition will cause the fault LED to illuminate and the fault relay to actuate. The exception to this is if the fault relay is jumper-programmed as normally energized, a loss of external 24 VDC power or the internal 5 VDC supply will cause the relay to de-energize but the LED will not illuminate. Below is a list of conditions that will cause a fault alarm. 1) Placing the alarm disable switch in the disable position 2) Loss of 24 VDC power to the 12B control module (only if relay is jumper programmed as normally energized). 3) Open power loop from the control module to the sensor. 4) Open signal loop from the control module to the sensor. 5) When used with a Detcon TP series solid state H2S sensor — an open heater on the sensor chip 6) When used with a Detcon FP series combustible sensor — an open catalytic bead or bridge. 7) Loss of the internal 5 VDC supply (only if relay is jumper programmed as normally energized). 8) Signal level drift below 2.4 mA from the sensor. 8.1 Detector Load Bypass Jumper When a sensor other than the Detcon TP series H2S, or FP series LEL is used with the 12B control module, a load bypass jumper must be placed in the appropriate location to prevent a false fault alarm. This jumper’s purpose is to bypass the heater/bridge fault detection circuitry which is not needed when used with Detcon oxygen or toxic gas sensors. Another application that will require the load bypass jumper is if the sensor is being powered by a power supply other than the supply that is coming from the 12B control module. In this instance, the load bypass jumper will prevent a false fault condition that would be caused by the 12B control module’s monitoring of the power loop. An example of this type of application is a sensor that is part of a sample draw system. In this instance, the sensor is an integral part of the sample draw system and is typically powered by that system. If desired, gas conditions at the sensor can be monitored by simply terminating the 4-20 mA signal output from the sensor to the 12B control module. Since the control module is not powering the sensor, it will detect a power loop fault and will require that the load bypass feature be used. 12B Control Module Instruction Manual Rev. 1.4 Page 7 of 12 Model 12B To program the load bypass circuit for either of the conditions described above: place a jumper tab on pins 2 and 3 (center and right) of the jumper location labeled JP-21. When the 12B control module is used in conjunction with a Detcon TP or FP series sensor, and is being powered by the 12B control module, the jumper tab should be placed on pins 1 and 2 (left and center) of the jumper location. 9.0 TEST FUNCTIONS Model 12B control modules feature microprocessor supervised test functions that allow the user to verify various control module settings and performance without having to remove the control module card from the control enclosure. The test functions are activated by the alarm reset switch located on the control module face plate and all applicable data is then displayed via the seven-segment LED displays and alarm LEDs. There are three test features: 1) Display of alarm set points for alarm 1, alarm 2, and alarm 3 2) A simulation of applying a full scale gas sample that will take the display through an incremental count up to the top of the range and back down, activating alarms at the programmed set points and allowing verification of alarm outputs, as well as the over-range flashing feature. 3) Display of the RS-485 Modbus™ address setting. Entering the test mode is performed by pressing and holding the alarm reset button for about 5 seconds. This will cause the fault LED to illuminate, indicating that you have entered the test mode. After the fault LED illuminates, you will have 5 seconds to select a test function. This is done by pressing and releasing the alarm reset button. Pressing once will select test one. Pressing twice will select test two. Pressing three times will select test three. If the button is not pressed within the 5 second time limit, the 12B control module will automatically return to the normal operating mode. NOTE: The fault LED will remain illuminated during testing. However, the fault relay will not activate during testing unless there is a fault condition. An example of this would be the disabling of alarms during testing via the alarm disable switch. Below is a description of how to perform each test and what will occur during the test. 9.1 Alarm Set Point Test To perform the alarm set point test, press and hold the alarm reset button for about five seconds until the fault LED illuminates. Next, press and release the alarm reset button once. The alarm 1 LED will illuminate indicating that this test has been selected. The test will begin automatically within five seconds. The test will begin by displaying the alarm 1 set point with the alarm 1 LED illuminated. After about 3 seconds, the alarm 2 set point will be displayed and the alarm 2 LED will illuminate. After an additional 3 seconds, the alarm 3 set point will be displayed and the alarm 3 LED will illuminate. As the display cycles through the three alarm set points, only the corresponding alarm LED will be illuminated, indicating which alarm is being displayed. Alarm relays are not activated during this test. Normal operation resumes when the cycle is complete. 12B Control Module Instruction Manual Rev 1.4 Page 8 of 12 Model 12B 9.2 Display/Alarm Test To perform the display/alarm test, press and hold the alarm reset button for about five seconds until the fault LED illuminates. Next, press and release the alarm reset button twice. The alarm 2 LED will illuminate indicating that this test has been selected. The test will begin automatically within five seconds. Normal operation resumes when the test is complete. The test will begin by displaying an incremental count up from the bottom of the range (0) to the top of the range with the count changing approximately three times each second. The exception to this is oxygen monitoring which will begin its count at the top of the range and go down. As the count reaches an alarm set point, that alarm will activate both LED and relay. When the count reaches the top of the range it will hold there briefly to allow verification of the flashing over-range feature before it begins the count back down to zero. As the test counts down below an alarm set point, that alarm will de-activate. If the alarm is programmed for latching operation it will remain active. After the test is complete and the control module returns to normal operation, the alarm reset button can be pressed to de-activate latching alarms. If the actuating of alarm relays during this test is problematic, alarm relays can be disabled by toggling the alarm disable switch into the disable (down) position. 9.3 RS-485 Address Setting Test To perform the RS-485 address setting test, press and hold the alarm reset button for about five seconds until the fault LED illuminates. Next, press and release the alarm reset button three times. The alarm 3 LED will illuminate indicating that this test has been selected. The test will begin automatically within five seconds and will terminate automatically when completed. The test will simply display the RS-485 address setting for approximately four seconds and then return the control module to normal operating mode. 10.0 OTHER FEATURES Model 12B control modules include other features which are discussed below. 10.1 Flashing Over-range The flashing over-range feature will cause the display to flash on and off, at approximately one second intervals once the top of the range has been exceeded. After the signal drops back into the normal range, the display will cease flashing and operate normally. 12B Control Module Instruction Manual Rev. 1.4 Page 9 of 12 Model 12B 10.2 Range Configuration Jumpers The applicable range of the 12B control module is factory set according to its corresponding sensor. However, the control module range of detection can be changed if a particular application should warrant it. Range selection is accomplished via configuration jumpers. Use the table below to determine the proper con figuration. See Figure 1 for applicable jumper locations. Range 0 - 1.0 0 – 10 0 - 25 (O2) 0 – 25 0 – 50 0 - 10.0 0 - 25.0 (O2) 0 - 25.0 0 - 50.0 0 – 100 0 – 200 0 – 500 0 – 999 0 - 99.9 CFG1 (JP11) 2 to 3 2 to 3 1 to 2 2 to 3 1 to 2 1 to 2 2 to 3 1 to 2 2 to 3 1 to 2 2 to 3 1 to 2 2 to 3 1 to 2 CFG2 (JP7) 2 to 3 1 to 2 1 to 2 2 to 3 2 to 3 1 to 2 2 to 3 2 to 3 1 to 2 1 to 2 2 to 3 2 to 3 1 to 2 1 to 2 CFG3 (JP8) 2 to 3 2 to 3 2 to 3 1 to 2 1 to 2 1 to 2 2 to 3 2 to 3 2 to 3 2 to 3 1 to 2 1 to 2 1 to 2 1 to 2 CFG4 (JP3) 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 CFG5 (JP4) 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 2 to 3 Table 2 Range configuration jumper locations and settings 10.3 PolySwitch Over-current Protection Model 12B control modules incorporate PolySwitch over-current protection components that act as resettable fuses. The PolySwitch circuit protector is a positive temperature coefficient resistor that undergoes a large, abrupt change in resistance when an over-current or high temperature heats it above a specific point. Normally just tens of milliohms, the resistance of the PolySwitch protector increases orders of magnitude when switched. This increase limits current to several milliamps. When the current or temperature fault that caused the device to switch has been substantially reduced, the PolySwitch device resets, allowing normal circuit operation to resume. The protector requires no manual resetting or replacement. Four separate PolySwitches monitor and protect the following circuitry: the 4-20 mA signal input loop, the 4-20 mA output signal loop, the 24 VDC input power loop, and the 24 VDC output power loop to the sensor. 12B Control Module Instruction Manual Rev 1.4 Page 10 of 12 Model 12B 10.4 Jumper JP1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 JP9 JP10 JP11 JP12 JP13 JP14 JP15 JP16 JP17 JP18 JP19 JP20 JP21 Default Settings of Jumpers Tabs Default 1 to 2 none none none 1 to 2 none none none 1 to 2 none none 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 1 to 2 2 to 3 2 to 3 none Function Alarm 3 (latched) Alarm 3 Firing Direction Configuration 4 Configuration 5 Alarm 2 (latched) Alarm 2 Firing Direction Configuration 2 Configuration 3 Alarm 1 (latched) Alarm 1 Firing Direction Configuration 1 Fault Alarm (latched) Alarm 3 (de-energized) Alarm 3 (normally open contacts) Alarm 2 (de-energized) Alarm 2 (normally open contacts) Alarm 1 (de-energized) Alarm 1 (normally open contacts) Fault Alarm (energized) Fault Alarm (normally open contacts when energized) Detector Load Bypass 11.0 WARRANTY AND SERVICE POLICY Detcon, Inc., as manufacturer, warrants each new Model 12B series digital electronic control module to be free from defects in material and workmanship under intended normal use for a period of one year from date of shipment to the original purchaser. Detcon, Inc, additionally provides for a fixed fee repair/replace service policy which covers Model 12B series digital control modules for a period of five years after expiration of the warranty. The fixed policy rate is $75.00 per control module, per transaction, during the period of the policy. The policy is FOB Detcon, Inc., The Woodlands, Texas. 12B Control Module Instruction Manual Rev. 1.4 Page 11 of 12 Model 12B Appendix C Revision History Revision 1.3 1.4 Date 10/18/10 04/25/12 Changes made Prior release Converted to MS Word format from Quark Removed notation of customer replaceable relays. Corrected Modbus specifications. 12B Control Module Instruction Manual Rev 1.4 Page 12 of 12