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
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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
akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: [phone] · www.akytec.de
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
akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany Tel.: [phone] · www.akytec.de
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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
akYtec GmbH · Vahrenwalder Str. 269 A · 30179 Hannover · Germany · Tel.: [phone] · www.akytec.de
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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)