40B96

1 40B96 POSITION, FORCE and PRESSURE INDICATOR-INTERCEPTOR with INPUTfor STRAIN-GAUGE and POTENTIOMETERS oftware Version 81652D/ Edit. 04 -04/05 INSTRUCTIONS FOR USE AND WARNINGSGENERAL INDEX30pageGraphic symbol used311 Preliminary instructions31 General description31 Alarm unit in basic version31 Options32 Operator interface32 Electrical interface32 Preliminary warnings322 Installation and connection33 Electrical power supply33 Notes concerning electrical safety and Electromagnetic compatibility33 Advice for correct installationfor EMC34 Instrument power supply34 Inputs and outputs connection34 Dimensions and cut-out35 Installation with panel mounting35 Warnings and instructions formounting to the panel35 Nominal ambient conditions35 Electrical connections36 Example of connection with input fromMelt Sensor383 Functions39 Operator interface39 General operating notes40 Navigating through the instrument menu 41page4 Configuration and programming42 Configuration/Programming 42 Application notes50Eb function 50 HOLD function50 FLASH function50

2 Alarms50 Filter51 UCAL strain-gauge calibration51 Virtual Instrument525 Technical specifications536 Maintenance54 Cleaning the instrument 54 Repairs 54 Checking the jumpers 54 Troubleshooting Guide557 Technical-Commercial information55 Order code 55 Accessories RS232/TTL interface for GefranInstrument configuration 56 Appendix56 The contents of each section are summarizedimmediately following the section headingGraphic symbols usedTo distinguish between the type and importance of the information provided in these instructions for use, graphicsymbols have been used as a reference to make interpreting the information the contents of the various manual sections,the general warnings, notes, and other points towhich the reader's attention should be a particularly delicate situation thatcould affect the safety and correct workingoperation of the instrument, or a rule that mustbe strictly observed to avoid dangerous situa-tionsIndicates a condition of risk for the safety of theuser, due to the presence of dangerous voltagesat the points shownIndicates a suggestion based on the expe-rience of the GEFRAN Technical Staff,which could prove especially useful undergiven circumstancesIndicates a reference to Detailed TechnicalDocuments available on the GEFRAN website the programming and configuration flowsfor the controller, indicates allthe parame-ters that can be set in the PRELIMINARY INSTRUCTIONSThis section contains information and warningsof a general nature which should be read befo-re proceeding with instrument installation,configuration and DescriptionGEFRAN series 40B96 digital controllers have beendesigned for temperature control in any applicationsinvolving heating or cooling processes.

3 They representan exclusive combination of performance, reliability andapplicational flexibility. In particular, this new line ofGefran temperature controllers is the ideal solution forapplication in sectors where performance and servicecontinuity are important, including: extrusion lines presses for rubber test benches honing machines processing plant for the food industry weighing manostat positioner motopotentiometer 40B96 series interceptors are made on an extremelyversatile hardware and software platform, that allows themost suitable I/O composition for the plant to be chosenfrom a series of options, up to a maximum of:- variable input - digital input - transmitter power supply - analog retransmission output - a maximum of 4 outputs - RS485 interfaceAlarm unit in basic version- 1 inputthat allows connection of most popular sensortypes potentiometer with 100 ohm minimum resistance load cells with autoranging sensitivity from to strain-gauge pressure probesaccuracy better than output for sensor or transmitter power supply Vdc for potentiometer 5 Vdc, 10 Vdc max 120 mA for strain-gauge 15 Vdc, 24 Vdc max 50 mA for transmitter- 2 standard outputs: one relay type and the otherrelay/logic, or1 triac output- display functions with setting of engineering scaleand possible linearization, settable decimal pointposition, sampling time from 30 to 120 msec - trip pointvalues can be set in a range differing fromscale limits, different modalities, hysteresis settable inscale points or time, with or without latch.

4 - serviceserial line for configuration via PC (Winstrum)31 Options- 3rd relay output - 4th relay output (alternative to analog retransmissionoutput)- 1 digital input - 1 analog retransmission outputin current0 or voltage (alternative to 4th relayoutput)- RS485 optically isolated serial interface Operator InterfaceAll the operator interface devices are concentrated onthe controller faceplate, suitably protected by amembrane in Lexan that guarantees IP65 levelprotection. 3 buttons to be used for manual configuration/selection 1 red five-digit displays (Process Variable) 4 red LEDs for status indication of same number of relay/logic outputsElectrical InterfaceAll connection terminals (power supply, inputs, outputs,options) are grouped together on the back of the technical specifications and performance detailsrefer to Section 5 "Technical Specifications .Preliminary WarningsThe following preliminary warnings should beread before installing and using the series 40B96 interceptor.

5 This will allow the controller tobe put into service more quickly and will avoidcertain problems which may mistakenly be inter-preted as malfunctions or limitations of the inter-ceptor. Immediately after unpacking the controller, make a note of the order code and the other identification datagiven on the label affixed to the outside of the containerand copy them to the table details must always be kept close at hand and referred to the personnel involved in the event of help from Gefran Customer Service Assistance. Check also that the controller is complete and has not been damaged at all during transit, and that the package contains not only the instrument and these Instructions for Use, but also the two brackets for fixing to the panel and the dust protection seal - see:Installation with Panel Fixing in Section inconsistencies, omissions or evident signs of damage should be reported immediately to your Gefran sales agent. Check that the order code corresponds with the configuration requested for the application the controller is needed for, referring to Section 7: Technical - Commercial Information.

6 No. and Type of Inputs/Outputs available Presence of the necessary options and accessories Mains voltage supplyEx: 40B 24 RR 00 1 2 1 Model 40B96 alarm unit 24 V output for transmitter power supply Output 1 - Relay; Output 2 - Relay, Output 3 - noneDigital Input - no analog retransmissionRS485 Digital CommunicationPower supply Before installing the series 40B96 instrument on the control panel of the machine or host system, referto the paragraph "Dimensions and Cut-out" in Section 2 "Installation and Connection . Where configuration by PC is provided for, make surethe interface RS232 cable is available and the CD- ROM containing the WINSTRUM software. For the order code refer to Section 7 "Technical - Commercial Information ..Users and/or system integrators who wish toknow more about the concepts of serial commu-nication between standard PC and/or GefranIndustrial PC and Gefran ProgrammableInstruments , can access the various technicalreference Documents in Adobe Acrobat formatavailable in the Download section of the GefranWeb Site : Serial Communication MODBus ProtocolIn the same Download section of the Gefran Web Site referencemanual is available in Adobe Acrobat the event of presumed instrument malfunction, before contacting Gefran Technical Service Assistance, refer to the Troubleshooting Guidegiven in Section 6 "Maintenance", and if necessary refer to the Section (FrequentlyAsked Questions) on the Gefran Web.

7 (Serial no.)CODE:.. (Finished product code)TYPE:.. (Order Code)SUPPLY: .. (Type of electrical power supply)VERS:.. (Software version)2 INSTALLATION AND CONNECTIONThis section contains the instructions necessaryfor correct installation of the 40B96 instrumentinto the machine control panel or the hostsystem and for correct connection of the inter-ceptor power supply, inputs, outputs and proceeding with installation read thefollowing warnings carefully! Remember that lack of observation of thesewarnings could lead to problems of electricalsafety and electromagnetic compatibility, aswell as invalidating the power supply the instrument is NOT equipped with an On/Off switch:the user must provide a two-phase disconnecting switchthat conforms to the required safety standards (CE mar-king), to cut off the power supply upstream of the switch must be located in the immediate vicinity ofthe instrument and must be within easy reach of the switch may control more than one instrument.

8 If the instrument is connected to NOT isolated electri-cal equipment ( thermocouples), the earth connec-tion must be made with a specific conductor to preventthe connection itself from coming directly through themachine structure. if the instrument is used in applications with risk ofdamage to persons, machinery or materials, it is essen-tial to connect it up to auxiliary alarm is advisable to make sure that alarm signals are alsotriggered during normal instrument must NOT be installed in flammable orexplosive environments; it may be connected to equip-ment operating in such atmospheres only by means ofappropriate and adequate types of interface, conformingto the applicable safety Concerning Electrical Safety andElectromagnetic Compatibility:CE MARKING: EMC Conformity (electromagneticcompatibility) in accordance with EEC Directive 89/336/CEE modifiedby Directive 93 40B96 interceptor are mainly designed to opera-te in industrial environments, installed on the switch-boards or control panels of productive process machi-nes or regards electromagnetic compatibility, the strictestgeneric standards have been adopted, as indicated inthe table Conformity (low tension)

9 In accordance withDirective 73/23/CEE modified by Directive 93 conformity has been tested with the typeLengthPower supply cable1mm21mRelay output connection wire0, standards, emission standard for residential commer-cial and light industrial environmentsEmission enclosureEmission AC mainsRadiated emissionCEI EN 61000-6-3 CEI EN 61000-6-3 CEI EN 61000-6-3 CEI EN 61326 CISPR 16-2 Gruppo1 Classe BGruppo1 Classe BClasse BEMC EmissionEMC ImmunityGeneric standards, immunity standard for industrial environ-mentsImmunity ESDI mmunity RF interferenceImmunity conducted disturbanceImmunity burstImmunity pulseImmunity Magnetic fieldsVoltage dips, short interruptions and voltage immunity testsCEI EN 61000-6-2 CEI EN 61000-4-2 CEI EN 61000-4-3 /A1 CEI EN 61000-4-6 CEI EN 61000-4-4 CEI EN 61000-4-5 CEI EN 61000-4-8 CEI EN 61000-4-114 kV contact discharge level 28 kV air discharge level 310 V/m amplitude modulated80 MHz-1 GHz10 V/m amplitude GHz-2 GHz10 V/m amplitude MHz-80 MHz (level 3)2 kV power line (level 3)2 kV I/O signal line (level 4)Power line-line 1 kV (level 2)Power line-earth 2 kV (level 3)Signal line-earth 1 kV (level 2)100 A/m (level 5)100%U, 70%U, 40%U,LVD SafetySafety requirements for electrical equipment for measurement,control and laboratory useCEI EN 61010-1 Advice for Correct Installation for EMCI nstrument power supply The power supply to the electronic equipment on the switchboards must always come directly from an isolation device with a fuse for the instrument part.

10 The electronic instruments and electromechanical power devices such as relays, contactors, solenoid valves, etc., must always be powered by separate lines. When the electronic instrument power supply is strongly disturbed by the commutation of transistor orpower units or motors, an isolation transformer should be used for the controllers only, earthing the screen. It is essential that the plant has a good earth connection:- the voltage between neutral and earth must not be <1V- the Ohmic resistance must be <6 ; If the mains voltage fluctuates strongly, use a voltage stabilizer. In the proximity of high frequency generators or arc welders, use adequate mains filters. The power supply lines must be separate from the instrument input and output and outputs connection The externally connected circuits must be doubly isolated. To connect the analogue inputs the following isnecessary:- physically separate the input cables from those of thepower supply, the outputs and the power use woven and screened cables, with the screen earthed in one point only To connect the regulating and alarm outputs (contactors, solenoid valves, motors, fans, etc.)