Sensata 2002-ALM-HL Configurable Dual Trip Amplifier User Manual

CONFIGURABLE DUAL TRIP AMPLIFIER 2002-ALM-HL
USER MANUAL

2002-ALM-HL Configurable Dual Trip Amplifier

Whilst every effort has been taken to ensure the accuracy of this document, we accept no responsibility for damage, injury, loss, or expense resulting from errors or omissions, and reserve the right of amendment without notice.
This document may not be reproduced in any way without the prior written permission of the company.
AUG 2022

INTRODUCTION

The 2002-ALM-HL is a configurable trip amplifier capable of accepting a wide variety of electrical input types and providing two trip action relay outputs.
The input signal, trip configuration, and power supply information are required to define any unit exactly. This information, together with a unique serial number is printed on the side label of each unit; records of the exact configuration of every product shipped are maintained at the factory.
1.1 Input Types And Ranges:
1.1.1 2002-ALM-HL
Accepts either DC voltage or current (i.e. high level) inputs.
In general, the limits on signals that can be handled with the accuracy specified in section 8 are:

10M ohm
Use 2002-TC FOR Vin<100mV

All the standard process ranges such as 0-10 mA, 4-20 mA, 0-20 mA, 1-5V, and 0-10V are of course covered.
1.1.1.1 Reconfigurable input option
The user-reconfigurable inputs are as follows: 0-10V, 0-5V, 0-20 mA, 4-20 mA and 0-10 mA. Other input ranges can be factory configured, please call with your requirements.

Description of operation

The input stage of the 2002-ALM-HL produces an internal process signal of 0 – 10V DC corresponding to the input span.
The trip set point potentiometers produce set point signals of 0 – 10V DC corresponding to the input span. These signals can be measured between terminal 7 (-ve) and terminal 9 for Setpoint 1 and terminal 12 for Setpoint 2. This enables set points to be accurately set without the need for an input simulator. 0-10 V corresponds to 0-100% of the input range.
Internal circuitry compares the processed signal with each of the set point levels and changes the state of the output relays and indicator LEDs as the signal passes through the set point, the exact action being factory or user configurable (see section 4).
A hysteresis band (typically 1% of span unless specifically requested) below each set point ensures chatter-free trip operation.
A block schematic diagram of the 2002-ALM-HL is shown in Figure 1.

FIG. 1 – BLOCK SCHEMATIC DIAGRAM FOR THE 2002-ALM-HL TRIP AMPLIFIER

UNPACKING

Please inspect the instrument carefully for signs of shipping damage. The unit is packaged to give maximum protection but we can not guarantee that undue mishandling will not have damaged the instrument. In the case of this unlikely event, please contact your supplier immediately and retain the packaging for our subsequent inspection.
2.1 Checking the Unit Type
Each unit has a unique serial number label on which full details of the configuration are given (see Figure 2 for example). These details should be checked to ensure conformance with your requirement.

CONNECTIONS

This section details the instrument connection information. These details are also shown on the connections side label on each unit (see figure 2 above).
3.1 Power Supply
The power supply is connected to terminals 10 (negative) and 11 (positive). The supply voltage is indicated on the serial number label (Figure 2)
APPLICATION OF VOLTAGES HIGHER THAN THAT STATED FOR THE SUPPLY MAY CAUSE DAMAGE TO THE INSTRUMENT.
3.2 Sensor Connections
All sensor connections are made to terminals numbered 7 and 8 on the instrument.
The inputs are connected as described below.
3.2.1 DC Voltage Inputs
The signal should be connected between pins 7 (negative) and 8 (positive).
3.2.2 DC Current Inputs
The signal should be connected between pins 7 (negative) and 8 (positive).

TRIP CONFIGURATION

4.1 Standard (non-latching) operation
The action of each trip can be simply described by considering the state of the relevant relay and LED indicator with process signal on either side of the trip set point. The options for each trip are as follows:

a) Relay energized for process signal above-set point
b) Relay energized for process signal above-set point
c) Relay energized for process signal below-set point
d) Relay energized for process signal below-set point| LED on for process signal above-set point
LED off for process signal above-set point
LED on for process signal below the set point
LED off for process signal below-set point
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Thus any combination of fail-safe or non-fail-safe options can be catered for.
4.1.2 Factory Pre-Configured Units
Where the unit is required for a preset trip configuration this can be requested at the time of order and will be carried out free of charge at the factory. In this case, the following convention, which corresponds to options a to d above is used for specifying operation:

a)
b)
c)
d)| RLY x > SP x < LED x
RLY x > SP x > LED x
RLY x < SP x > LED x
RLY x < SP x < LED x| Where
x = 1 for trip 1
x = 2 for trip 2
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This information will appear on the serial number side label on pre-configured units (figure 2). It is helpful if this convention is used by the customer when specifying units.
4.1.3 Default Configuration
In the event that pre-configuration information is not available, units will be shipped by the default configuration as follows:

RLY 1 > SP 1 < LED 1
RLY 2 < SP 2 > LED 2| (case a, section 4.1)
(case c, section 4.1)
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4.1.4 User configuration
If it is necessary to change the trip action of the instrument must be removed from the plastic enclosure. This is achieved by gently pressing on both lugs on the side of the black plastic box beneath the connection terminals, and withdrawing the circuit board from the enclosure.
The units may then be configured by changing the switch settings with reference to the diagrams in Figure 3 (see Section 5)
4.2 Latching Operation
Latching operation of relay 1 can be achieved by connecting link 1. Note that, where the latching operation is specified, trip set point 2 is used to set the unlatch threshold such that Relay 2 is not independent. Latching operation is not possible with relay 2.
With Link 1 fitted, Relay 1 can be set to energize when the processed signal rises above or falls below trip set point 1, in the normal fashion. At the same time LED, 1 can be set to be above or below set point 1. Once relay 1 has become energized it will remain energized so long as either the initial condition which caused the trip is sustained, whilst relay 2 is de-energized or both. i.e., relay 1 can only be latched whilst relay 2 is de-energized and can only be unlatched whilst relay 2 is energized. (Note that LED 1 denotes whether the processed signal is above or below trip set point 1, not whether relay 1 is energized.)
By way of example the latching mode of operation is likely to be used to maintain the processed signal between an upper and a lower limit (for instance tank level control) as shown in Figure 4:

Trip 1 is set to option d) (section 4.1)
Trip 2 is set to option b) (section 4.1)
Trip set point 1 is set to the lower allowable limit
Trip set point 2 is set to the upper allowable limit
When the processed signal is below set point 1 relay 1 is energized (latched) and will remain energized until the signal reaches set point 2. At this point relay, 1 is unlatched (by relay 2 energizing). As the processed signal reduces relay 2 de-energizes. As the signal falls below set point 1 relay 1 is energized (latched) again and the cycle repeats.
The LEDs can be used to indicate the status as follows:

LED1
OFF
OFF
ON
ON| LED2
OFF
ON
OFF
ON| STATUS
Power Fail
At or below the bottom unit
At or above the top limit
Within limits
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INPUT RECONFIGURATION AND CALIBRATION

The 2002-ALM-HL has a reconfigurable input. Reconfiguration can be carried out by changing the position of individual switches on the PCB and, for the greatest accuracy, recalibrating the 0-10V internal process signal.
5.1 2002-ALM-HL Reconfiguration and Calibration
(i) Referring to the 2002-ALM-HL switch setting diagram (figure 3), set switches 1 through 8 on switches S1, S2 and S3 as required
(ii) Connect the voltmeter between connector terminals 7 (-ve) and the Voltage Adjust point shown in Figure 3.
iii) Connect a current or voltage source as appropriate to input terminals 7 (-ve) and 8 (+ve)
(iv) Adjust Zero pot to give 0.00V on the voltmeter at zero scales for 4-20mA range only – zero is automatic for other ranges
(v) Adjust the Span pot to give 10.00V on the voltmeter at full scale
(vi) Repeat (iv) and (v) as necessary.

SETTING TRIP POINTS

The trip points can be measured between connection terminal 7 and terminal 9 for Setpoint 1 and terminal 12 for Setpoint 2. The measured signal is a voltage between 0 and 10V corresponding to 0-100% of the input range of the unit.
6.1 2002-ALM-HL Trip Points
Since the 0-10V process signal is linear for this device the trip point is equal to 100% of the span multiplied by the set point voltage
e.g.  4-20m in input
trip at 16mA input = 75% of span
therefore trip set point = 7.50V

INSTALLATION

Fig. 5 – Installation Data & Terminal Positions For 2002-ALM
Installation Data

7.1 Installation onto Rails
The instrument is designed to mount directly onto the “Top hat” TS35 standard assembly rail to
DIN46277 part 3/EN 50022/BS5584.
7.2 Mounting Arrangements
Ideally, the unit should be mounted in a vertical position, i.e. on a horizontal rail. This is the optimum orientation to minimize temperature rise within the unit. However successful operation is possible in any orientation.
Ensure the maximum ambient temperature is less than 55°C.
Good airflow around the unit will maximize reliability.
7.3 Wiring Precautions

These units can accept a variety of sensor inputs, some of which produce very small voltages. Therefore it is advisable to adhere to the following rules of good installation practice:
(i) Do not install close-to switchgear, electromagnetic starters, connectors, power units or motors.
(ii) Do not have power or control wiring in the same loom as sensor wires.
(iii) Use screened cable for sensor wiring with the screen earthed at one end only.
(iv) Take care not to allow cut pieces of wire to fall onto the unit as they might enter via the ventilation holes and cause electrical short circuits. If in doubt, remove the units from the rail until the wiring is complete.
(v) Use bootlace ferrules on all bare wires.

IMPORTANT:
The connection terminals are designed for a maximum torque of 0.4Nm. Exceeding this figure is unnecessary and will result in unwarrantable damage to the unit.

SPECIFICATIONS

All specifications are at 20 °C operating ambient unless otherwise stated.
8.1.1 2002-ALM-HL

8.2 Power Supply Isolation and Operating Ambient

8.3 EMC

EMC
LVD Standards| BS EN61326
EN61010-1
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