Akytec PR200 User manual

akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: [phone] · www.akytec.de
PR200
Programmable relay
User guide
PR200_2019.02_0199_EN
© All rights reserved
Subject to technical changes and misprints

akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: [phone] · www.akytec.de
1
Contents
Introduction............................................................................................................................................................2
1Overview........................................................................................................................................................3
1.1 Ordering key..............................................................................................................................................4
2Specifications................................................................................................................................................5
2.1 Environmental conditions .......................................................................................................................7
3Safety .............................................................................................................................................................8
3.1 Safety precautions....................................................................................................................................8
3.2 Intended use..............................................................................................................................................8
4Functioning....................................................................................................................................................9
4.1 Operating mode........................................................................................................................................9
4.2 Fault mode.................................................................................................................................................9
4.3 RS485 network interface..........................................................................................................................9
4.4 Slave mode..............................................................................................................................................10
4.5 Master mode............................................................................................................................................11
4.6 Special modes.........................................................................................................................................14
5System menu...............................................................................................................................................16
5.1 Menu navigation .....................................................................................................................................16
5.2 Menu content ..........................................................................................................................................17
6Configuration...............................................................................................................................................20
6.1 Analog inputs AI1…AI4..........................................................................................................................20
6.2 Analog outputs AO1, AO2 .....................................................................................................................23
6.3 Display elements ....................................................................................................................................23
6.4 Auto Precision ........................................................................................................................................23
7Installation ...................................................................................................................................................24
7.1 Mounting..................................................................................................................................................24
7.2 Wiring.......................................................................................................................................................24
7.3 Quick replacement..................................................................................................................................28
8Maintenance ................................................................................................................................................29
9Transportation and storage.......................................................................................................................30
10 Scope of delivery ........................................................................................................................................31
Appendix А. Dimensions ..................................................................................................................................32
Appendix B. Terminal layouts..........................................................................................................................33
Appendix C. Galvanic isolation........................................................................................................................36
Appendix D. Circuit diagrams ..........................................................................................................................38
Appendix E. Connection to PC.........................................................................................................................39
Appendix F. Calibration ....................................................................................................................................40
F.1 General ....................................................................................................................................................40
F.2 Analog input............................................................................................................................................40
F.2 Analog output 4-20 mA ..........................................................................................................................41
Appendix G. Battery replacement....................................................................................................................42
Appendix H. Interface card installation...........................................................................................................44

Introduction
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2
Introduction
This manual describes the functions, system configuration, operating instructions,
programming and troubleshooting of the multifunctional programmable relay PR200
(hereinafter referred to as PR200, device, or relay).
Terms and abbreviations
Following terms and abbreviations are used in the guide:
HMI – Human-Machine Interface
Modbus – application layer messaging protocol for client/server communication between
devices connected on different types of buses or networks, originally published by
Modicon (now Schneider Electric), currently supported by an independent organization
Modbus-IDA (www.modbus.org).
akYtec ALP (ALP) – programming software for programming PR series relays, based on
Function Block Diagram (FBD).
Retain memory – non-volatile memory allocation for storing of retain variables
Retain variables – will not lose their values after a power-off/power-on cycle (restart)
RAM – random access memory, volatile part of system memory
ROM – read-only memory, non-volatile part of system memory
Application – user program created using ALP software
Display element – program element used for displaying information on the display

Overview
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1 Overview
The programmable relay PR200 is a small controller. User application is created as a
function plan with the programming software ‘akYtec ALP’, included on the USB stick. The
user application includes the logic programm as well as the device configuration. The PR200
enables the following functions:
−control of the outputs according to the input status and the logic of the user
application
−configuration with the function buttons or using ALP software
−comprehensive programming of LCD display
−2 programmable LEDs
−Master and / or Slave in a Modbus network
−Real-time clock
−extension modules
The device is designed in a plastic enclosure for DIN rail mounting.
The enclosure has 3-level stepped form for distributor installation. Indicators and control
elements are located on the front housing. There are mounting interlocks on the rear side.
Plug-in terminal blocks are placed on the upper and lower stepped surfaces. The blocks are
used for connecting actuators, digital and analog sensors, RS485 network lines and other
external equipment.
Plug-in terminal blocks enable quick and easy replacement of the device.
Front housing:
−2-line alphanumeric display (16 characters each)
−two LEDs: F1 (green) and F2 (red), controlled by an application
−6 function buttons for system menu and display
navigation
Under the front cover (rights):
−Connector EXT (10 pole) for extension modules
−Mini-USB socket PRG for connecting to PC. USB A-plug to micro B-plug connection
cable is included in the package.
The relay is available in several versions, for DC and AC voltage, equipped with only digital
or a combination of digital and analog inputs and outputs. The device has a 2-line 32-
character LCD display. A real-time clock and up to 2 RS485 interfaces for connection to
Modbus networks are available. The relay can be expanded with additional input and output
modules. The analog inputs can be configured as analog or as digital.
For further details see section 4 ‘Functioning’
Fig. 1.1 Front housing (front cover is open)

Overview
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1.1 Ordering key
The relay PR200 can be ordered in various designs depending on the required supply
voltage, number and type of inputs, outputsand interfaces:
Supply voltage
230 - 230 (94…264) V AC
24 - 24 (19…30) V DC
I/O
1 - 8 DI, 6 DO
2 - 8 DI, 4 AI, 8 DO, 2 AO (4-20 mA)
4 - 8 DI, 4 AI, 8 DO, 2 AO (0-10 V)
Interfaces
0 - none
1 - RS485
2 - 2x RS485
The design of the relay enables to increase the number of RS485 interfaces by installing up
to two interface cards.
Ordering code for interface card: PR-IC485

Specifications
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2 Specifications
Table 2.1 General specification
Device PR200-230.1
PR200-230.2
PR200-230.4
PR200-24.1
PR200-24.2
PR200-24.4
Power supply
230 (94…264) V AC;
50 (47…63) Hz
24 (19…30) V DC
Power consumption, max
10 VA
17 VA
10 W
10 W
Galvanic isolation
2830 V
1780 V
Appliance class
II
III
Integrated voltage source -
24±3 V DC
100 mA
- -
Galvanic isolation
-
1780 V
-
-
Inputs
Digital
8
Analog *
-
4
-
4
Outputs
Digital (relay)
6
8
6
8
Analog
-
2
-
2
Programming
Software
akYtec ALP
Interface
Mini USB 2.0
Program cycle, min
1 ms
Function buttons
6
LEDs
F1 (green), F2 (red), programmable
LCD display
2x 16 digits, backlight adjustable
Language
English
Connection to RS485 Network
2-pole plug-in terminal block
Protocols
Modbus RTU/ASCII (Master/Slave)
Baud rate
9.6…115.2 kbit/s
Interface card
PR-IC485 (max. 2)
Galvanic isolation
1500 V
Dimensions
123 x 108 x 58 mm
Mounting
DIN rail (35 mm)
Weight
approx. 350 g
Material
Plastic
* Analog inputs AI1…AI4 can also be configured as digital inputs
Table 2.2 Digital inputs
Device PR200-230.1
PR200-230.2
PR200-230.4
PR200-24.1
PR200-24.2
PR200-24.4
Input signal Switch contact
Switch contact
PNP with open collector
Digital signals -3…+30 VDC
Input voltage
230 V AC
24 V DC
Input voltage, max
264 V AC
30 V DC
Logical 1
159…264 V (0.75…1.5 mA)
15…30 V (5 mA)
Logical 0
0…40 V (0…0.5 mA)
-3…+5 V (0…1 mA)
Pulse length, min
50 ms
2 ms
Response time, max
100 ms
30 ms
Galvanic isolation
in groups of 4 (1-4, 5-8)
Test voltage between
input groups
1780 V
Test voltage against
other circuits 2830 V

Specifications
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Table 2.3 Analog inputs
Device
PR200-230(24).2, PR200-230(24).4
Galvanic isolation
none
Mode
Analog
Input signal
0-10 V, 4-20 mA, 0-4000 ohm
Input voltage *
-36…+36 V
Input resistance (0-10 V)
61 kohm
Input resistance (4-20 mA)
121 ohm
Basic error
±0.5%
Temperature influence
±0.05%/10°C
Resolution
2.7 mV / 6 µA
Resolution ADC
12 bit
Sampling time for 4 inputs, max
10 ms
Mode
Digital
Logic 1 **
0…10 V, adjustable
Logic 0 **
0…10 V, adjustable
Current at input voltage 15…30 V, max
5 mA
* If the voltage at one input is below -0.5 V, the accuracy for all inputs cannot be guaranteed.
** Parameter can be set in ALP Property Box using the option ‘Input mode’ = ‘digital’.
Table 2.4 Digital outputs
Type
relay (NO)
Switching capacity AC
5 A, 250 V (resistive load)
Switching capacity DC
3 A, 30 V
Minimum load current
10 mA (at 5 V DC)
Service life, electrical
3 A, 30 V DC
200,000 switching cycles
5 A, 250 V AC (resistive load)
100,000 switching cycles
Galvanic isolation
in groups of 2 (1-2, 3-4, 5-6, 7-8)
Test voltage between output groups
1780 V
Test voltage against other circuits
2830 V
Table 2.5 Analog outputs
Table 2.6 Memory
ROM memory
128 kB
RAM memory
32 kB
Retain memory
1016 Byte
Network variable memory *
128 Byte
* The limitation applies only to the slave mode, in which all network variables are
automatically declared as retain.
Device
PR200-230(24).2
PR200-230(24).4
Auxiliary voltage
12…30 V DC
12…30 V DC
Quantity
2
Output signal
4-20 mA
0-10 V
Output load, max
1 kohm
2 kohm
Basic error, max
±0.5%
Temperature influence
±0.05%/10°C
Inductive load, max
50 µH
-
Signal conversion time
100 ms
DAC resolution
10 bit
Galvanic isolation
2830 V, individual
2830 V, in group

Specifications
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Table 2.7 Real-time clock
Accuracy
±3 s/day (25°C)
Correction
-2.75…+5.5 min/month
Backup, min
8 years
Backup battery
CR2032
2.1 Environmental conditions
The relay is designed for natural convection cooling. It should be taken into account when
choosing the installation site.
The following environment conditions must be observed:
−clean, dry and controlled environment, low dust level
−closed non-hazardous areas, free of corrosive or flammable gases
Table 2.1
Conditions
Permissible range
Ambient operating temperature
-20…+55°C
Storage temperature
-25…+55°C
Relative humidity
up to 80% (at +25°C, non-condensing)
IP Code
IP20
Altitude
up to 2000 m above see level
EMC immunity
conforms to IEC 61000-6-2
EMC emission
conforms to IEC 61000-6-4

Safety
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3 Safety
Explanation of the symbols and keywords used:
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could
result in minor or moderate injury.
►
NOTICE NOTICE indicates a potentially harmful situation which, if not avoided, may result in
damage of the product itself or of adjacent objects.
3.1 Safety precautions
WARNING
Ensure that the mains voltage matches the voltage marked on the nameplate!
Ensure that the device is provided with its own power supply line and electric fuse!
Do not feed any external devices from the power contacts of the device.
►
NOTICE
It is necessary to observe the polarity while connecting 24V power sources. Improper
connection can damage the device.
►
NOTICE The device must be powered off before connecting to PC.
►
NOTICE
Removing of the terminal blocks may be performed only after powering off the device
and all connected equipment.
3.2 Intended use
Programmable relays of PR200 series has been designed and built solely for the intended
use described in this manual, and may only be used accordingly. The technical
specifications contained in this manual must be observed. Only by akYtec GmbH
recommended extension modules may be connected to the relay.
The relay may be operated only in properly installed condition.
Improper use
Any other use is considered improper. Especially to note:
– This device should not be used for medical devices which receive, control or
otherwise affect human life or physical health.
– The device should not be used in an explosive environment.
– The device should not be used in an atmosphere with chemically active substance.

Functioning
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4 Functioning
Once the application has been transferred to the non-volatile memory, the relay restarts. On
startup the relay runs a self-test. If unsuccessful, the relay switches to the fault mode (see
4.2). Otherwise the application runs (Fig. 4.1)
WARNING
Before transferring the application to PR200 ensure that all devices connected to
the relay outputs are disconnected. It is recommended to transfer the application
before wiring the relay.
►
NOTICE
Before starting
Before switching on, make sure that the device was stored at the specified ambient
temperature (-20 ... +55 °C) for at least 30 minutes.
4.1 Operating mode
Operating mode of the device is cycle oriented:
−Start (testing of operational readiness)
−Update of the input process image
−Running the application
−Update of the output process image
−Back to Start.
Fig. 4.1 Operating sequence
4.2 Fault mode
Table 4.1 – Error messages
Indication
Cause
Remedy
LOGIC Program
INVALID
Invalid application
Repare application with ALP
LOGIC Program
MEMORY ERROR
Retain variables cannnot be
read
LOGIC Program
BLOCKED
RUN-STOP jumper is set,
application stopped (see 4.6)
Remove the RUN-STOP jumper
and restart the device
LED F2 lit
Firmware is damaged
Update firmware or contact the
service center
LED F2 blinks
LOGIC Program
STOPPED
Application stopped
Start the application using
system menu and restart the
device
4.3 RS485 network interface
PR200 can have up to two RS485 interface cards (depends on modification) for
communication via Modbus RTU / ASCII protocol as a Master or a Slave.
The interface card PR-IC485 is set to Slave by default. To use the interface as a Master,
jumpers XP4 and XP5 on the card must be set in accordance with the Fig. 4.2:
−set jumpers on the interface card to the ‘M’ position
−configure the interface using the ALP software (Menu>Device>Configuration)

Functioning
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For detailed information about network interface configuration see ‘akYtec ALP Help’.
Network parameters can also be changed using system menu.
Fig. 4.2PR-IC485 jumper positions: Master (a), Slave (b)
4.4 Slave mode
Functions:
−read digital I/O status
−read analog I/O value
−read / write network variables
−read / write Real-Time Clock data
Modbus registers are listed in Tab. 4.2.
In the slave mode the Modbus RTU and Modbus ASCII protocols are supported, with
automatic protocol detection.
To add an interface click RMB on the node ‘Interfaces’ in the configuration tree and select
‘Add interface’ (Fig. 4.3). Click RMB on this interface and add a master device to it (Fig 4.4).
See ALP Help for further instructions.
Following parameters can be set:
−Name – device name in the configuration tree
−Address – device address in a Modbus network.
To create a variable for polling click the ‘+’ icon (see Fig. 4.4).
To delete the selected variable click the ‘-’ icon.
Fig. 4.3 Slave configuration in slave mode

Functioning
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Fig. 4.4Master configuration in slave mode
4.5 Master mode
There can be only one Master in a Modbus network.
To use the interface as a Master follow the instruction given in section 4.3 ‘RS485 network
interface’.
PR200 as a Master can control up to 16 slave devices over each RS485 interface. Each
slave device can use up to 256 variables. It is allowed to use the same name and the same
address for different slave devices.
To add an interface click RMB on the node ‘Interfaces’ in the configuration tree and select
‘Add interface’ (Fig. 4.5). Set the interface to Master, click RMB on it and add the slave
device (Fig 4.6).
See ALP Help for further instructions.

Functioning
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Table 4.2 Modbus registers
Device Parameter Data type
Address
ModBus
function
Inputs
All Digital input status DI1...DI8
BOOL
0x1000 – 0x1007
0x01, 0x02
INT16
0x0100
0x03, 0x04
PR200-
230(24).2
PR200-
230(24).4
Measured value AI1 analog
REAL32
0x0B00, 0х0B01
0x03, 0x04
Measured value AI2 analog
REAL32
0x0B02, 0х0B03
0x03, 0x04
Measured value AI3 analog
REAL32
0x0B04, 0х0B05
0x03, 0x04
Measured value AI4 analog
REAL32
0x0B06, 0х0B07
0x03, 0x04
Measured value AI1 analog *
INT16
0x0B80
0x03, 0x04
Measured value AI2 analog *
INT16
0x0B81
0x03, 0x04
Measured value AI3 analog *
INT16
0x0B82
0x03, 0x04
Measured value AI4 analog *
INT16
0x0B83
0x03, 0x04
Decimal point (dp) AI1 analog
INT16
0x0BC0
0x03, 0x04
Decimal point (dp) AI2 analog
INT16
0x0BC1
0x03, 0x04
Decimal point (dp) AI3 analog
INT16
0x0BC2
0x03, 0x04
Decimal point (dp) AI4 analog
INT16
0x0BC3
0x03, 0x04
Analog input status AI1 digital
BOOL
0xB800
0x01, 0x02
Analog input status AI2 digital
BOOL
0xB810
0x01, 0x02
Analog input status AI3 digital
BOOL
0xB820
0x01, 0x02
Analog input status AI4 digital
BOOL
0xB830
0x01, 0x02
Outputs
PR200-
230(24).2
PR200-
230(24).4
Digital output status
(DO1...DO8, F1, F2)
BOOL
0x0000 – 0x0009
0x01, 0x02
INT16 0x0000 0x03, 0x04
PR200-
230(24).1
Digital output status
(DO1...DO6, F1, F2)
BOOL
0x0000 – 0x0007
0x01, 0x02
INT16
0x0000
0x03, 0x04
PR200-
230(24).2
PR200-
230(24).4
Output value AO1 analog (0…1)
REAL32
0х0A00, 0х0A01
0x03, 0x04
Output value AO2 analog (0…1)
REAL32
0х0A02, 0х0A03
0x03, 0x04
Output value AO1 analog (0…10000)
INT16
0x0A80
0x03, 0x04
Output value AO4 analog (0…10000)
INT16
0x0A81
0x03, 0x04
All Network variables BOOL 0x2000 – 0x23F0
0x01, 0x02,
0x05, 0x0F
INT16 0x0200 – 0x023F
0x03, 0x04,
0x06, 0x10
Real-time clock
All
Seconds INT16 0x0400
0x03, 0x04,
0x06, 0x10
Minutes INT16 0x0401
0x03, 0x04,
0x06, 0x10
Hours INT16 0x0402
0x03, 0x04,
0x06, 0x10
Day INT16 0x0403
0x03, 0x04,
0x06, 0x10
Month INT16 0x0404
0x03, 0x04,
0x06, 0x10
Year INT16 0x0405
0x03, 0x04,
0x06, 0x10
Weekday
INT16
0x0406
0x03, 0x04
Week of month
INT16
0x0407
0x03, 0x04
Calendar week
INT16
0x0408
0x03, 0x04
* To calculate the INT16 value, the value of type REAL32 is multiplied by 10dp, where ‘dp’ is
a decimal point position and is set as configuration parameter (see 6.1.1).
For outputs dp = 4 is fixed.

Functioning
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Read request is trigged by the Polling cycle. Optionaly it can be triggered by event, i.e. a
variable of type BOOL.
Write request is triggered by change of parameter value. Optionaly it can be triggererd by
event, i.e. a variable of type BOOL.
Following parameters can be set:
−Name – device name in the configuration tree
−Address – device address in a Modbus network.
−Polling cycle – time between requests (0…65535 ms)
−Timeout – maximum time to wait for reply (0…65535 ms)
−Retries – number of request retries if no reply (0…255)
−Status – status of slave device (BOOL variable)
−Polling – enable / disable polling (BOOL variable)
−Time between frames – the time span the master waits between the last response
(or timeout) and the next request (Fig. 4.5).
When constructing a Modbus network with the PR200 as a master it is necessary to observe
the following rules to speed up the process of receiving data from all devices:
−If one or more Slave are not connected or not accessible, it is recommended to
block the polling of these devices in the application using the parameter Polling' or to
minimize the parameter 'Timeout' for these devices. Otherwise, the response time
will significantly increase with the number of unavailable devices and the sum of
time-outs.
−When setting the parameter ‘Time between frames’ the number of Slaves and the
total number of requests must be taken into account. This parameter will be ignored
if the total polling time takes longer than the set value.
Fig. 4.5 Master configuration in master mode

Functioning
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Fig. 4.6Slave configuration in master mode
To create a variable to be requested click the ‘+’ icon (see Fig. 4.6).
To delete the selected variable click the ‘-’ icon.
Variable properties:
−Name
−Type – data type BOOL, INT16, REAL32
−Register – register address
−Bit – bit number in register (0…15), only for BOOL varables
−Number of registers –variable length
−Read function – Modbus read function
−Write function – Modbus write function
−Start reading – BOOL variable event to start the reading request
−Start writing – BOOL variable event to start the writing request
−Status – INT variable to store the error code
−Comment
4.6 Special modes
The connectors XP2 and XP3 under the device cover (Fig. 4.5) are used to set special
device modes.
►
NOTICE
Don’t set the jumpers on connectors XP2 and XP3 at the same time, otherwise the
device can be damaged.
Fig. 4.5

Functioning
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‘RUN-STOP’ mode
Setting a jumper on the XP2 connector activates ‘RUN-STOP’ mode. In this mode the user
application is interrupted. It can be usefull if the system menu is unavailable, e.g. the
application is corrupted and leads to improper operation of the device.
While PR200 is in RUN-STOP mode, a new application can be uploaded to the device. In
this mode the device can be used as a Slave. The input values can be read and the output
values can be written, only network variables are disabled.
‘Down.Mode’ mode
Setting the jumper on XP3 connector activates ‘Down.Mode’. This mode is necessary for
troubleshooting if a firmware update was unsuccessful (power outage, communication errors
etc.). In this mode the firmware update can be forced. See ALP Help for further details about
firmware update.

System menu
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5 System menu
System menu enables to view the information about
– device modification
– firmware version
– cycle time
– I/O status
and other device parameters.
The application can be interrupted by using the menu item Device>Program>Run/Stop.
When the setting is changed it requires a reboot to take effect. When the application is
interrupted all parameters exept network variables are available via Modbus in slave mode
and via system menu. The menu is password protected, with can be set or changed in ALP
or using the menu. If the password is lost, it can be changed by loading a new application.
Press the button for 3 seconds to access the menu.
Press the button for 3 seconds to exit the menu.
5.1 Menu navigation
There are editable and not editable display elements thus the display can be used in view or
edit mode.
View mode
To move between lines use and buttons.
To enter the selected level use and to exit.
Edit mode
Press button to enter the edit mode from the current display. The first editable element
starts flashing. Use buttons and to change the parameter. Use following button
combinations to move between characters:
−+ – one character to the left
−+ – one character to the right.
To save the new value and exit Edit mode use .
To reset a parameter to its original value and exit Edit mode use .
To save the new value staying in the Edit mode use . The next editable parameter will be
displayed selected.
The last changed parameter will be shown next time when the edit mode is entered.

System menu
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5.2 Menu content
The menu structure is shown in Fig. 5.1
Fig. 5.1 System menu
Inputs
−Digital
Status of digital inputs is displayed as a bitmask: 0 for OFF state, 1 for ON state.
The first bit in the mask corresponds to input 1.
Use the menu item Inputs>Digital>Filter to set the time constant for the debouncing
filter in the range of 0…255 ms.
ALT
OK OK
OK
OK
OK
OK
ESC
OK
OK OK OK
OK
OK OK OK
OK
OK
OK OK
OK
OK
OK
OK

System menu
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−Analog
Status of each analog input is displayed as a scaled measured value of REAL32
type. The lower and the upper limits can be set in the menu item
Inputs>Analog>Scale.
The type of input signal can be selected in the menu item Inputs>Analog>Sensor.
The menu item Inputs>Analog>Filter enables to set the time constant for the filter
within the range of 0.01…60 s with the increment of 0.001 s.
Outputs
−Digital
Status of digital outputs is displayed as a bitmask: 0 for OFF state, 1 for ON state.
The first bit in the mask corresponds to output 1.
−Analog
Status of each analog output is displayed as a REAL32 value within the range of
0…1.
Interfaces
Inteface configuration depends on the interface mode, Master or Slave.To set interface
parameters use the menu item Interfaces and select the interface.
−Slave mode
oSettings
Baud rate
Data bits
Parity
Stop bits
oProtocol
Address
−Master mode
oSettings
Baud rate
Data bits
Parity
Stop bits
oProtocol
List of configured devices (see 4.5 ‘Master mode’)
•Address
•Polling cycle (ms)
•Time-out (ms)
•Retries, max.
Time between frames (see 4.5 ‘Master mode’)

System menu
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19
Modules
Information about connected extention modules. If there are no connected modules, the
menu item is hidden.
Fig. 5.2 Extension module connection
Password
Password can be set or changed.