Bacharach GDA-1600 Instructions Manual Download

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Instruction 5700-9001

GDA-1600 16-Channel Controller

Important Safety Issues

The following symbols are used in this manual to alert the user of important instrument

operating issues.

This symbol is intended to alert the user to the presence of important

operating and maintenance / servicing instructions.

This symbol is intended to alert the user to the presence of dangerous

voltage amounts within the instrument enclosure that may be of sufficient

magnitude to constitute a risk of electric shock.

WARNINGS:

•

Read and understand the contents of this manual prior to operation.

Failure to do so could result in serious injury or death.

•

SHOCK HAZARD

- Disconnect or turn off power before servicing this

instrument.

•

NEMA 4X wall mount models should be fitted with a locking

mechanism after installation to prevent access to high voltages by

unauthorized personnel (see Figure 7.2 on page 44).

•

Only the combustible monitor portions of this instrument have been

assessed by CSA for 122.2 No. 152 performance requirements.

•

This equipment is suitable for use in Class I, Division 2, Groups A,B,C

and D or non-hazardous locations only.

•

EXPLOSION HAZARD-

Substitution of components may impair

suitability for Class I, Division 2.

•

EXPLOSION HAZARD

- Do not replace fuse unless power has been

switched off or the area is known to be non-hazardous.

•

EXPLOSION HAZARD

- Do not disconnect equipment unless power

has been switched off or the area is known to be non-hazardous.

•

Use a properly rated CERTIFIED AC power cable installed as per local

or national codes.

•

A certified AC power disconnect or circuit breaker should be mounted

near the controller and installed following applicable local and national

codes. If a switch is used instead of a circuit breaker, a properly rated

CERTIFIED fuse or current limiter is required to be installed as per

local or national codes. Markings for positions of the switch or breaker

should state (I) for on and (O) for off.

•

Clean using only a damp cloth with no solvents.

•

Equipment not used as prescribed within this manual may impair overall

safety.

Summary of Contents for GDA-1600

Page 1: ...GDA 1600 16 Channel Controller Instruction 5700 9001 Installation Operation Maintenance Rev 1 September 2012 Product Leadership Training Service Reliability ...

Page 2: ...AND ARE GIVEN AND ACCEPTED IN LIEU OF I ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND II ANY OBLIGATION LIABILITY RIGHT CLAIM OR REMEDY IN CONTRACT OR TORT WHETHER OR NOT ARISING FROM BACHARACH S NEGLIGENCE ACTUAL OR IMPLIED The remedies of the Buyer shall be limited to those provided ...

Page 3: ...ailsafe Mode 23 3 3 3 Common Horn Relay Local Piezo 23 3 3 4 Comm Port Menus 24 3 3 5 Eight Sixteen Channel Modes 25 3 3 6 Sensor Information 25 3 4 Authorization Mode 26 3 5 LCD Contrast Adjustment 26 4 DISPLAY TO DEVICE CONNECTIONS 27 4 1 Main I O Interface PCB 5700 0002 27 4 2 Input Output Optional PCBs 27 4 2 1 Optional Analog Input PCB 5700 0004 29 4 2 2 Optional Discrete Relay PCB 5700 0012 ...

Page 4: ... 3 2 Wireless Modbus Slave Mode 48 8 4 Wireless Modbus Master Mode 48 8 5 Antenna Selection 49 8 5 1 Dipole and Collinear Antennas 49 8 5 2 Yagi Antennas 49 8 5 3 Mounting Near Other Antennas 50 8 5 4 Coax Cables 50 8 6 Surge Protection and Grounding 50 8 6 1 Antenna Grounding 51 8 6 2 Connections to Other Equipment 51 9 SERVICE CENTER 52 ...

Page 5: ...of this instrument have been assessed by CSA for 122 2 No 152 performance requirements This equipment is suitable for use in Class I Division 2 Groups A B C and D or non hazardous locations only EXPLOSION HAZARD Substitution of components may impair suitability for Class I Division 2 EXPLOSION HAZARD Do not replace fuse unless power has been switched off or the area is known to be non hazardous EX...

Page 6: ...or each alarm are easily added to the addressable I2 C bus Option boards have 8 channels therefore 16 channel applications require two boards In addition to traditional analog and serial methods of providing monitored values the GDA 1600 is also capable of sending and receiving wireless data A 240 x 128 pixel graphic LCD readout displays monitored data as bar graphs trends and engineering units Sy...

Page 7: ...iod The SI field on the top right indicates number of seconds remaining in the current 6 minute subinterval 2 1 2 Bar Graphs Screen The GDA 1600 Bar Graphs screen shown in Figure 3 0 on page 10 allows all active channels to be viewed simultaneously Both engineering unit values and bar graph values are indicated in real time Lines across the bars indicate the alarm trip points making it easy to ide...

Page 8: ...Common relays are standard and menus provide voting logic for ALARM 1 ALARM 2 FAULT and HORN Discrete relays are optional All relays are rated at 5 Amp for 28 VDC and 250 VAC RESISTIVE loads IMPORTANT Appropriate diode DC load or MOV AC load snubber devices must be installed with inductive loads to prevent RFI noise spikes Relay wiring should be kept separate from low level signal wiring Temperatu...

Page 9: ...I O PCB Ribbon Cable 5700 0023 10 inch I O PCB Ribbon Cable 5700 0034 2 4GHz single port wireless kit w collinear antenna 5700 0035 2 4GHz dual port wireless kit w collinear antenna 5700 0036 900MHz single port wireless kit w collinear antenna 5700 0037 900MHz dual port wireless kit w collinear antenna 5700 0038 900MHz NEMA 4x radio modem kit includes 5700 0036 5700 0039 2 4GHz NEMA 4x radio modem...

Page 10: ...re entered by pressing EDIT from any data screen and scrolling to the desired menu using the UP DOWN keys Pressing EDIT again enters the selected menu s tree of variables This Setup mode may be exited manually by pressing NEXT or automatically when no keys are pressed for 5 minutes Alarm relays and front panel alarm LED indicators remain active during the Setup mode An AUTHORIZE menu offers a pass...

Page 11: ...rough each allowed entry The NEXT key moves the cursor to the next position within a field When the field is complete EDIT clears the cursor and loads it into non volatile memory where it is retained indefinitely With no cursor present NEXT closes open menus in reverse order and returns the LCD to the most recent data display 3 2 Channel Configuration Menus Figure 3 1 illustrates the menu tree for...

Page 12: ...GDA 1600 16 Channel Controller Instruction 5700 9001 12 Figure 3 1 Channel Configuration Menus ...

Page 13: ...r falling below the setpoint On Off Delay Allow ON and OFF time delays affecting how long the setpoint must be surpassed before an alarm event transition occurs ON delays are limited to 10 seconds while OFF delays may be as long as 120 minutes Delays are useful in many applications to prevent nuisance alarms and unwanted cycling into and out of alarm conditions Horn On Used to link this alarm to t...

Page 14: ...ull scale and the discrete alarms trip as the input exceeds a level then the 10 Fault setpoint must be entered first Toggle the TYPE menu entry to FAULT and enter 10 00 into the setpoint entry Next toggle the menu back to LEVEL and enter the desired Alarm 3 level setpoint The 10 Fault value is retained in memory even though it no longer appears on the menu Figure 3 3 Alarm Fault Menus 3 2 4 Data F...

Page 15: ...represent a range value In the GDX 350 this value is 12 bit and is ranged in a 4 20 mA style signal where 4mA sends a value or counts of 800 min raw and 20mA sends a value or counts of 4000 max raw A slave with a 10 bit output would send 200 for 4mA and 1000 for 20mA The Modbus Master RS 485 port supports most integer types resolutions and formats MODBUS 16 BIT menu indicates that 16 bit is the ma...

Page 16: ...splays the actual raw A D counts currently being read by this channel This reading may be used to test the input device for what A D counts are provided for zero and 100 if these values are unknown Forcing the input device to read zero should provide the A D counts value needed to make this channel s display also read zero Likewise forcing the input device to read 100 should provide the A D counts...

Page 17: ...ws user entry of the 6 digit ASCII message to be displayed when the marker is detected 3 2 4 3 Sensor Life Detection Sensor Life should only be activated when the Marker event is Calibration and when a sensor life value is transmitted after each calibration NOTE This feature is provided primarily for use when interfacing with the GDA 1600 to Bacharach s GDX 350 Sensor Transmitters which may be con...

Page 18: ...4 0 0 0 5 0 0 0 6 0 0 0 7 0 0 0 8 0 0 0 9 0 0 0 10 0 0 2 0 0 0 3 0 0 0 4 0 0 0 5 0 0 0 6 0 0 0 7 0 0 0 8 0 0 0 9 0 0 0 A l a r m 1 A l a r m 2 A l a r m 3 Da t a F r o m Ca l i b r a t e L i n e a r i z e C o n f i g u r e Figure 3 7 Linearization Menus 3 2 6 Configure Menu The CONFIGURE menu may be entered from the entry level setup menu in Figure 3 8 This is used for setting variables which defi...

Page 19: ...t is extremely stable If decimal points are limited to one the 0ppm reading becomes 0 0 and the 100ppm reading remains 100 0 Resolution may be limited further by setting Decimal Points to 0 In the above example this would cause 0ppm to display 0 and 100ppm to display 100 Channel On Turning Off Unused Channels The Channel On entry determines if this channel is to be utilized Turning it off will cau...

Page 20: ...zero calibration apply the ZERO calibration value to the sensor and observe the live reading If the zero reading differs from the zero setpoint a calibration is necessary To calibrate zero move the pointer to Set Zero and press EDIT A warning message explains that pressing EDIT again will change the zero calibration and any other key will exit The procedure for span calibration is identical For ex...

Page 21: ...Instruction 5700 9001 GDA 1600 16 Channel Controller 21 Figure 3 10 Configuration Menus ...

Page 22: ...channels 9 16 trip relays on an optional discrete relay PCB configured for Alarm 1 see section 4 2 2 on page 30 Failsafe Failsafe controls relay activation for this common relay Failsafe ON causes the relay to de energize during alarm conditions and energize when there is no alarm Thereby a power failure forces the relay contact to the alarm position Note the common Fault relay is always failsafe ...

Page 23: ...menu shown in Figure 3 12 Entering YES causes these discrete relays to have energized coils when no alarm condition exists for the associated channel and de energized coils when the alarm occurs Failsafe is useful for indicating failed relay coils and loss of power conditions IMPORTANT Zoning jumpers P N 5700 0012 as seen in Figure 4 4 should not be used when Discrete Relays menus are set for fail...

Page 24: ... the comm2 slave Modbus serial port comm1 master port ID settings are per channel as described in section 3 2 4 This slave port may be used to transfer GDA 1600 data to a host device such as a PC PLC DCS or even another GDA 1600 The slave port is addressable allowing many GDA 1600 controllers to be connected to a single RS 485 cable Slave Baud Parity UART Timer The UART Timer setting is disabled w...

Page 25: ...ost is kept low is Input Output option PCBs are arranged into groups of 8 channels Therefore users with less than 9 channels require only 1 PCB and do not pay for I O hardware for 16 channels If more than 8 channels are needed a second I O option PCB may be required Figure 3 15 Channel Configuration 3 3 6 Sensor Information Sensor Info is available when at least one channel has Sensor Life activat...

Page 26: ...ecord the 4 digit code However if lost it may be displayed briefly at power up using the following procedure Remove power from the controller Reapply power and as the alarm LEDs begin scrolling down hold the following keys simultaneously UP DOWN NEXT EDIT The 4 digit authorization code appears briefly at bottom left of the screen IMPORTANT DO NOT hold the keys before applying power since this caus...

Page 27: ... TX lines simplifying 2 wire daisy chains by providing additional terminals for incoming and outgoing cables For example installing the 2 COM 1 jumpers connects screw terminals 1 5 and terminals 3 7 Socketed RS 485 terminating resistors R6 COMM 1 and R12 COMM 2 are located on the MAIN I O board These resistors should be removed if communication wire lengths are very short less than 25 feet or if t...

Page 28: ...GDA 1600 16 Channel Controller Instruction 5700 9001 28 Figure 4 2 Main PCB ...

Page 29: ...nd IN HI terminals are socketed termination resistors for 4 20mA inputs These may be removed if voltage inputs are to be applied EXC and IN LO terminals are bussed together internally EXC terminals are tied directly to TB2 1 and IN LO terminals are tied to TB2 2 Bussing allows transmitter power to be brought into the system at a single point TB2 and distributed back out at each channel s EXC IN LO...

Page 30: ...2 or ALARM 3 FAULT for channels 1 8 or 9 16 A 1 minute time delay after power up is provided to inhibit relay actuation until the system has had time to stabilize Alarm groups or zones may be created by connecting adjacent channels together using JP4 as shown This creates a wire OR function with selected channels causing any alarm included within the zone to actuate ALL zone relays Failsafe operat...

Page 31: ... to prevent RFI noise spikes Relay wiring should be kept separate from low level signal wiring 4 2 3 Optional Bridge Sensor Input Board 5700 0011 An optional 8 channel 12 bit Bridge Sensor Input board allows these popular gas detectors to be connected directly to the GDA 1600 without additional signal conditioning or transmitters Fault supervision circuitry forces the GDA 1600 into a FAULT conditi...

Page 32: ...m the Main I O board s TB2 terminal 10 12 see Figure 4 2 Measure the voltage between each channel s A and R terminals and set the Voltage Adjust potentiometers for the correct sensor excitation voltage This may range from 1 5 volts to 7 5 volts depending upon sensor specifications WARNING Sensors may be damaged by accidental over voltage conditions It is recommended the Voltage Adjust potentiomete...

Page 33: ...e Two volts 100 input to the A D Converter and 0 4 volts 0 therefore 1 2 volts 50 Place the 3 position Coarse LEL Gain jumper into the position which reads between 0 8 volts and 1 2 volts on the test point with 50 LEL gas on the sensor Gain settings for each jumper position are as follows No jumper 1 LOW 7 MED 21 HI 41 Multiple jumpers have an additive affect upon gain so the LOW and MED jumpers t...

Page 34: ...Figure 4 6 allows these popular temperature sensors to be connected directly to the GDA 1600 without additional signal conditioning or transmitters A 3 position range jumper allows setting the gain of the input bridge amplifier for the three popular ranges of 0 100 C 0 200 C or 0 400 C Other ranges are available by special order Figure 4 6 RTD Sensor Input Board ...

Page 35: ...are best simulated with an RTD calibrator Since RTDs are stable and repeatable of over long time periods calibrations normally only need to be performed upon initial installation Since the PCB has 8 channels two are required for 16 channel applications JP25 configures inputs for channel groups 1 8 or 9 16 4 2 6 Optional 4 20mA Analog Output Board 5700 0005 An optional 10 bit 4 20mA analog output b...

Page 36: ...GDA 1600 16 Channel Controller Instruction 5700 9001 36 Figure 4 7 Analog Output Board ...

Page 37: ...l ports and analog I O It is exited manually by pressing NEXT and automatically if no keys are pressed for 5 minutes IMPORTANT CHANNEL INPUT DATA IS NOT PROCESSED DURING THE DIAGNOSTICS MODE It is possible to miss important input values while utilizing this mode and appropriate safeguards should be in place However the Diagnostics Mode can prove invaluable when testing I O since relays and analog ...

Page 38: ...GDA 1600 16 Channel Controller Instruction 5700 9001 38 Figure 5 2 System Diagnostic Options ...

Page 39: ...characters per register Channel Tag 12 40489 40496 3 n a 2 characters per register Channel Tag 13 40497 40504 3 n a 2 characters per register Channel Tag 14 40505 40512 3 n a 2 characters per register Channel Tag 15 40513 40520 3 n a 2 characters per register Channel Tag 16 40521 40528 3 n a 2 characters per register Six character Eunits Tag Type Channel First Last Read FC Write FC Notes EUNITS 1 ...

Page 40: ... 3 n a 2 characters per register 3 registers per channel Memory Floating Point Notes Returned as 15 bit 2s complement with 5 over under range applied Therefore this must be considered when scaling values to be displayed at the Modbus master The following equation may be used to determine a value for display Display Value MODBUS Value Span Value Zero Value 1 1 32767 Zero Value Span Value Zero Value...

Page 41: ...t integer Common LED Status 1 16 31052 n a 4 n a packed 16bit integer LCD Display Screen Displayed Integer Type Channel First Last Read FC Write FC Notes LCD Screen n a 31053 n a 4 n a 8bit integer Sensor Life Type Channel First Last Read FC Write FC Notes Sensor Life 1 31065 n a 4 n a Signed 16bit integer Sensor Life 2 31066 n a 4 n a Signed 16bit integer Sensor Life 3 31067 n a 4 n a Signed 16bi...

Page 42: ...3 real divisor Fault Real 1 16 41161 76 n a 3 n a alarm 3 real w o decimal point Fault DP 1 16 41177 92 n a 3 n a alarm 3 real divisor 24 Hour Trend Database The 24 hour MAX MIN and AVERAGE trend data may be retrieved over the Modbus serial interface Each channel consists of 240 MAX MIN and AVERAGE values or one value for every 1 10 hour 6 minutes Since there are 16 channels this database equals 3...

Page 43: ...codes RACK PANEL MOUNT 19 RACK SPREADER PLATES PANEL MOUNT BEZAL NOT SHOWN 10 60 9 10 FRONT VIEW 5 22 SIDE VIEW 9 60 Note Panel cut out 5 25 X 9 20 Figure 7 1 Mounted Enclosure 7 2 Wall Mount Fiberglass Enclosure The GDA 1600 shown in Figure 7 2 is a fiberglass NEMA 4X wall mount enclosure Seven 8 channel I O option PCBs such as analog input or discrete relay may be mounted inside this enclosure I...

Page 44: ...GDA 1600 16 Channel Controller Instruction 5700 9001 44 Figure 7 2 Wall Mount Enclosure Figure 7 3 Grounding Illustrations ...

Page 45: ...m Note 5700 0036 Has One Radio Module Installed 5700 0037 Has Two Radio Modules Installed Figure 8 1 The dual port radio modems have two radio modules installed and can be used to receive and transmit data simultaneously The radio kit options allow three separate modes of wireless operation These are Wireless Receiver accepting data from GDX 350 RF sensor transmitters Wireless Modbus Slave providi...

Page 46: ... be centrally located since all Clients must receive the beacon in order to communicate 8 2 Radio Setup Menu Radio modules must be connected to the master port for RADIO SETUP Pressing the EDIT key with the arrow pointing to the Radio Setup menu brings the RADIO CONFIG menus to the screen right side of Figure 8 2 Entries Description Hop Channel Hop Channel may be set from 1 32 using the keypad Sys...

Page 47: ...he channel to display and alarm from battery voltage levels at this GDX 350 RF Voltage level of the 3 6 volt lithium battery in this GDX 350 RF is also displayed on this screen Figure 8 3 8 3 1 Radio Status Alarms Wireless Receiver Mode When an GDA 1600 channel s INPUT DATA FROM menu is set for WIRELESS RF900 in addition to processing the GDX 350 RF s 10 bit counts value it also receives status bi...

Page 48: ...a standard Modbus network However radios must have the same Hop Channel and System ID settings to communicate Radio modules may only be configured when connected to the GDA 1600 s master port If it is necessary to modify Hop Channel and System ID settings the radio module may be temporarily connected to the GDA 1600 s master port for configuration then moved back to the slave port for operation 8 ...

Page 49: ...ency Wavelength in meters 300 frequency in MHz Wavelength in feet 1000 frequency in MHz Therefore 900 MHZ antennas require at least 2 3 meter 2 feet and 2 4GHz 15 cm 6 inches Antennas may be mounted with less clearance but radiation will be reduced It is important for the antenna mounting bracket to be well connected to earth or ground for good lightning surge protection 8 5 2 Yagi Antennas Yagi a...

Page 50: ... weatherproofing tape with a final layer of electrical PVC tape Allowing a drip U loop of cable before the connection is also a good idea The loop allows water to drip off the bottom of the U instead of into the connection reduces installation strain and provides spare cable length in case later the original connectors need to be removed the cable cut back and new connectors fitted Avoid installin...

Page 51: ... path causes damage unless the other two paths provide a better earth connection allowing surge energy to bypass the electronics Coax surge diverters have gas discharge element which breaks down in the presence of high surge voltage and diverts any current directly to a ground connection A surge diverter is not normally required when the antenna is within a plant or factory environment as the plan...

Page 52: ...GDA 1600 16 Channel Controller Instruction 5700 9001 52 9 Service Center United States 8621 Highway 6 Hitchcock TX 77563 Ph 724 334 5051 Fax 724 334 5723 Email help MyBacharach com ...

Page 53: ...Instruction 5700 9001 GDA 1600 16 Channel Controller 53 ...

Page 54: ...00 9001 54 Headquarters 621 Hunt Valley Circle New Kensington PA 15068 7074 Toll Free 800 736 4666 Tel 1 724 334 5000 FAX 1 724 334 5001 Website www MyBacharach com E mail help MyBacharach com Printed in U S A Registered Trademark of Bacharach Inc ...

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