AMALGAMATED INSTRUMENT PM4 Installation and operating instructions

PM4 Panel Meter
Optional Output Addendum
AMALGAMATED INSTRUMENT CO ABN: 80 619 963 692
Unit 5, 28 Leighton Place Hornsby Telephone: [phone] e-mail: [email protected]
NSW 2077 Australia Facsimile: [phone] Internet: www.aicpl.com.au

Table of Contents
1 Introduction 3
2 Analog, dual analog outputs plus relay option
(-A, -AA, -AR, -AAR and -R options) 4
3 Transmitter supply option
(-12, -R12, -A12 and -AR12 options) 7
4 Three relay output option (-RRR option) 9
5 Three relay plus analog output option (-ARRR option) 10
6 Six relay option (-R6 and -AR6 options) 12
7 Binary/BCD output option (-DN, -DNR,
-DN12, -DP, -DPR, -DP12 and -DPR12 options) 14
8 Serial and 4-20mA output option
(-A2, -A2R, -A4 and -A4R options) 18
9 Serial, second relay & transmitter supply output option
(-2, -4, -2R, -4R, -212, -412, -2R12 and -4R12 options) 20
10 Serial (RS232 and RS485) commands 22
11 Modbus communication 33
12 Analog PI control output 41
13 Guarantee and service 49
2 of 49 PM4OPTMAN-2.9-0

1 Introduction
This manual addendum contains information on the PM4 optional outputs. This manual is supplied
whenever a PM4 panel meter is supplied with an optional output fitted. Refer to the standard
manual for the PM4 model purchased for information not covered in this addendum.
Note: Not all options are available on all instruments. Check the instruction manual or brochure
for the instrument to be used to see which options are available or contact supplier.
1.1 Input Output Configuration
If you need to alter the input or output configuration link settings proceed as follows:
Remove earth screw
which passes through the
case then slide out
the printed circuit board
1. Remove the plug in terminals
from the rear of the instrument
2. Remove the 4 x self tapping screws from
the back cover then remove the back cover
by pulling it away from the instrument
3. Remove the earth screw which passes
through the underside of the case then
slide out the board or boards
4. Configure the PCB links as requred, see appropriate chapter
5. Slide PCB back into case
6. Replace the earth screw which passes through the case
7. Refit the back cover and fix with the self tapping screws
8. Plug the terminal strips back into the rear of the instrument
PM4OPTMAN-2.9-0 3 of 49

2 Analog, dual analog outputs plus relay option
(-A, -AA, -AR, -AAR and -R options)
This chapter deals with the the 12 bit single and dual isolated analog output boards. These boards
may also be optionally fitted with a relay. The relay will revert to the normally open (N/O) contact
being open when power is removed. 4-20mA outputs can be factory configured as current sinking
if required. A bipolar +/- 10V output option is also available.
Option code Options fitted to the board
-A Single isolated analog output
-AA Dual isolated analog output
-AR Single isolated analog output plus relay (form A, rated at 240VAC, 5A into
resistive load)
-AAR Dual isolated analog output plus relay (form A, rated at 240VAC, 5A into
resistive load)
-R Single extra relay
2.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual for
general information on electrical connections.
AB HC D E F J K
1 2 3 4 5 6 7 8 9 10 11
ISOLATED ANALOG
RETRANSMISSION 2
ISOLATED ANALOG
RETRANSMISSION 1
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
-
-
+
+
COM N/O
RELAY 2
SETUP
PUSHBUTTONS
F^v
4 of 49 PM4OPTMAN-2.9-0

2.2 Bipolar output connections
The single and dual analog output options are available in bipolar 10V output form i.e. ±10V.
The bipolar output is not user configurable and must be factory set since extra components are
required. The circuit board links should be set to 10V for this option. Connections are as shown
below.
AB HC D E F J K
1 2 3 4 5 6 7 8 9 10 11
COMMON
COMMON
+/- 10V
+/- 10V
ISOLATED ANALOG
RETRANSMISSION 1
FOR BIPOLAR OUTPUTS
ISOLATED ANALOG
RETRANSMISSION 2
FOR BIPOLAR OUTPUTS
(OPTIONAL)
(OPTIONAL)
(OPTIONAL)
COM N/O
RELAY 2
SETUP
PUSHBUTTONS
F^v
2.3 Current sinking 4-20mA output
The current sinking output is not a standard retransmission output and requires factory configured
modification to the circuit board. In this mode an external supply is required as shown in the
diagram below. This output type is sometimes required when an analog input device has a power
supply connected to the input which cannot be disconnected.
AB C
1 2 3 4 5 6 7 8 9 10 11
-
+
SETUP
PUSHBUTTONS
F^v
Load
1400 max. @ 30V
1100 max. @ 24VW
W
External DC supply
24V min.
30V max.
4-20mA output connected in current sinking mode
Links required LK1 (4-20mA), LK7 (4-20mA) & LK16 (solder link)
Components C14 and D4 removed
PM4OPTMAN-2.9-0 5 of 49

2.4 Configuring the output board
The output board has facilities for single or dual analog (4-20mA, 0-1V or 0-10V) output and an
optional relay and is factory supplied with all the necessary component for the output options
ordered. PCB links are fitted to the circuit board to provide data to the microprocessor and to
connect the electronic components for the correct output types. The 4-20mA outputs will drive
into 800Ω loads max. See the “Input Output Configuration” section 1.1 for details on dismantling
the instrument. Note: links will only activate the option if that option was ordered and fitted e.g.
fitting the “RLY2” link will only enable the second relay if this option was ordered.
Note: For single analog output boards only channel 1 links will be fitted. Bipolar 10V outputs are
only available if factory fitted and require the 10V link to be in.
LK13
LK1 LK1
LK13
LK7
LK6
LK6
LK7
4-20
4-20
4-20
4-20
4-20
4-20
4-20
4-20
1V
1V
1V
1V
1V
1V
1V
1V
10V
10V
10V
10V
10V
10V
10V
10V
RLY2 RLY2
4-20mA output selected
for both channels
4-20mA output selected
for both channels
4-20mA output selected
for channel 1,
0-10V output selected
for channel 2
4-20mA output selected
for channel 1,
0-10V output selected
for channel 2,
second relay selected
LK7
LK6
LK13
LK1
4-20
4-20
4-20
4-20
1V
10V
1V
10V
10V
1V
10V
1V
RLY2
CH1
CH1
CH1 CH1
CH1
CH2
CH2 CH2
CH2
CH1
CH2
CH2
Link setting examples
Link setting examples
Note: both sets of links
must be set e.g. to select
4-20mA for each channel
links 1, 4, 7 and 10 must
be in.
6 of 49 PM4OPTMAN-2.9-0

3 Transmitter supply option
(-12, -R12, -A12 and -AR12 options)
This chapter deals with the the transmitter supply option circuit board. The transmitter supply
may be fitted on its own or with combinations of relay and analog retransmission. The relay will
revert to the normally open (N/O) contact being open when power is removed. Note that an
internal link setting can be used to convert the transmitter supply from 24V (±12V) to 10V (±5V)
if required, see link location drawing which follows.
Option code Options fitted to the board
-12 24VDC (±12V) isolated and regulated transmitter supply rated at 25mA max.
-R12 24VDC (±12V) isolated and regulated transmitter supply rated at 25mA max.
plus extra relay
-A12 24VDC (±12V) isolated and regulated transmitter supply rated at 25mA max.
plus analog retransmission
-AR12 24VDC (±12V) isolated and regulated transmitter supply rated at 25mA max.
plus analog retransmission plus extra relay
3.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Connect across D and F for 24V or across E and F for 12V or
across D and E for -12V. Refer to “Electrical Installation” chapter in the main PM4 manual for
general information on electrical connections.
AB HC D E F J K
1 2 3 4 5 6 7 8 9 10 11
ISOLATED
RETRANSMISSION
-
+
ISOLATED DC OUTPUT
-
+
COM
COM
N/O
2nd RELAY
(Optional)
(Optional)
(Optional)
SETUP
PUSHBUTTONS
F^v
PM4OPTMAN-2.9-0 7 of 49

3.2 Configuring the output board
The 4-20mA output will drive into 800Ω load max. PCB links are fitted to the circuit board
to provide data to the microprocessor and to connect the electronic components for the correct
output types. It may be necessary to alter the PCB links to change the analog output or DC
voltage output (see link settings below). See the “Input Output Configuration” section 1.1 for
details on dismantling the instrument.
LK13
LK1 LK1
LK13
LK7
LK6
LK6
LK7
4-20 4-20
4-20
4-20
1V 1V
1V
1V
10V 10V
10V
10V
RLY2 RLY2
4-20mA output selected
4-20mA output selected
0-10V output selected
4-20mA output and
second relay selected
LK7
LK6
LK14
10VEX
LK13
LK1
4-20
4-20
1V
10V
10V
1V
RLY2
CH1
CH1
CH1 CH1
CH1
CH1
Link setting examples
Link setting examples
Note: both sets of analog links
must be set e.g. to select
4-20mA links 1 and 7 must
be in.
LK14 transmitter supply link.
Link out for 24V (+/-12V)
Link in for 10V (+/-5V)
8 of 49 PM4OPTMAN-2.9-0

4 Three relay output option (-RRR option)
This chapter deals with the the three relay output option.
Components are factory fitted for the three relay operation. No links are required for the selection
of the relay outputs. Relays are form C, rated at 240VAC, 5A resistive load. All relays will revert
to the normally open (N/O) contacts being open circuit when power is removed.
4.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual
for general information on electrical connections.
PM4OPTMAN-2.9-0 9 of 49

5 Three relay plus analog output option (-ARRR option)
This chapter deals with the the three relay plus isolated analog output option circuit board. Com-
ponents are factory fitted for the option. Relays are form A, rated at 240VAC 5A resistive load.
Links for selection of analog output type are as shown below. No link settings are required for
the relays. All relays will revert to the normally open (N/O) contacts being open when power is
removed.
5.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual
for general information on electrical connections.
10 of 49 PM4OPTMAN-2.9-0

5.2 Configuring the output board
The output board for the -ARRR option has facilities for 4-20mA, 0-1V and 0-10V output and is
factory supplied with all the necessary component for the output options required. The 4-20mA
output will drive into 600Ω load max. PCB links are fitted to the circuit board to provide data to
the microprocessor and to connect the electronic components for the correct output types. It may
be necessary to alter the PCB links to change the output type (see link settings below). See the
“Input Output Configuration” section 1.1 for details on dismantling the instrument.
LK1
LK3
LK1
LK3
LK1
LK3
10V
10V 10V
1V
1V 1V
4-20 4-20
4-20
1V 1V
1V
10V 10V
10V
VOLTS VOLTS VOLTS
0 to 10V output
4-20mA output 0 to 1V output 4-20mA output
0 to 1V output 0-10V output
Analog Links
Both analog and digital links need to be set
Digital Links
LK1
LK3
LK5
LK7
LK6
LK5 LK5 LK5
LK6 LK6 LK6
LK7 LK7 LK7
4-20
1V
1V
10V
4-20
4-20 4-20 4-20
mA mA mA
10V
PM4OPTMAN-2.9-0 11 of 49

6 Six relay option (-R6 and -AR6 options)
The optional output board is factory supplied with the necessary components for the output options
required. The last digits in the model number, which can be found at the bottom of the label on
the instrument case, indicate the options fitted, option combinations available with this board are
show in the table below. Relays are form A, rated 240VAC, 5A resistive load. All relays will revert
to the normally open (N/O) contacts being open when power is removed.
Option code Options fitted to the board
-R6 Six extra relays
-AR6 Six extra relays plus isolated analog retransmission, link selectable 4-20mA,
0-1VDC or 0-10VDC
6.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual
for general information on electrical connections.
AB HC D E F J K L M P
NR
1 2 3 4 5 6 7 8 9 10 11
COM
COM COM
COM
COM
COM
RELAY 6
RELAY 5 RELAY 7
RELAY 4
RELAY 3
RELAY 2
N/O
N/O N/O
N/O
N/O
N/O
ISOLATED
RETRANSMISSION
-
+
(Optional)
F^v
12 of 49 PM4OPTMAN-2.9-0

6.2 Configuring the output board
The 4-20mA output will drive into 600Ω load max. PCB links are fitted to the circuit board
to provide data to the microprocessor and to connect the electronic components for the correct
output types. It may be necessary to alter the PCB links to change the analog output or DC
voltage output (see link settings below). See the “Input Output Configuration” section 1.1 for
details on dismantling the instrument.
LK1
LK3 LK9 LK4
4-20
0-1
0-1V
0-10
4-20mA VOLTS
OUTPUT 0-1V 0-10V 4-20mA 6 RELAY
SERIAL No.
4-20 4-20
4-20
4-20mA
4-20mA
4-20mA
0-1V 0-1V 0-1V
0-1
0-1 0-1
0-10
0-10 0-10
VOLTS
VOLTS
VOLTS
LK1
LK1 LK1
LK4 LK4 LK4
LK3
LK3 LK3
LK9 LK9 LK9
DIGITAL LINKS ANALOG LINKS
4-20mA Selected
0-10V Selected
0-1V Selected
PM4OPTMAN-2.9-0 13 of 49

7 Binary/BCD output option (-DN, -DNR,
-DN12, -DP, -DPR, -DP12 and -DPR12 options)
The optional output board is factory supplied with the necessary components for the output options
required. The option board will be factory configured as either NPN or PNP output versions. The
last digits in the model number which can be found at the bottom of the label on the instrument
case indicate the options fitted, option combinations available with this board are show in the table
below. Relays are form A, rated 240VAC 5A resistive. The relay will revert to the normally open
(N/O) contact being open when power is removed.
Option code Options fitted to the board
-DN Digital retransmission NPN, 16 bit user selectable as binary or BCD
-DNR Digital retransmission NPN plus second relay
-DN12 Digital retransmission NPN plus isolated DC supply 24VDC (12V) rated at
25mA max.
-DNR12 Digital retransmission NPN plus second relay plus isolated DC supply.
-DP Digital retransmission PNP, 16 bit user selectable as binary or BCD
-DPR Digital retransmission PNP plus second relay
-DP12 Digital retransmission PNP plus isolated DC supply 24VDC (12V) rated at
25mA max.
-DPR12 Digital retransmission PNP plus second relay plus isolated DC supply.
7.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2for relay and transmitter supply option wiring. An IDC connector
is used for the NPN or PNP digital output. Refer to “Electrical Installation” chapter in the main
PM4 manual for general information on electrical connections.
AB HC D E F J
1 2 3 4 5 6 7 8 9 10 11
ISOLATED DC OUTPUT
-
+
COM
COM
N/O
2nd RELAY
(Optional)
(Optional)
DIGITAL OUTPUT
IDC CONNECTOR
VIEWED FROM
REAR OF INSTRUMENT
SETUP
PUSHBUTTONS
F^v
1
2 4
3
6
5
8
7
10
9
12
11
14
13
16
15
18
17
20
19
Pin number Function
1 D0
2 D1
3 D2
4 D3
5 D4
6 D5
7 D6
8 D7
9 D8
10 D9
11 D10
12 D11
13 D12
14 D13
15 D14
16 D15
17 V IN
18 OUTPUT
ENABLE
19 GND
20 GND
14 of 49 PM4OPTMAN-2.9-0

7.2 NPN digital isolated output
The NPN output board is provided with internal PCB links for selecting internal 5V or external
V+ (5 to 50VDC) signal voltages and output continuously enabled or externally controlled. If the
optional pull up resistors are not fitted the output requires an externally supplied 5VDC signal
voltage on each of the output terminals used (D0 to D15). The signal voltages will be switched
between 5V (or V+ via Link 5) and 0V by the output transistors Q0 to Q15. Unless otherwise
ordered the links are factory set as follows:
Link 4 OUT (when in Link 4 provides +5V output level via optional pull up resistors).
Link 5 OUT (when in Link 5 connects external V+ to the output via the optional pull up resistors).
Link 6 OUT (when in link 6 connects circuit for external control). Note: this input OUTPUT
ENABLE is initiated by a TTL level, active low input. The chip has internal pull-up resistor
fitted.
Link 7 IN (when in Link 7 sets circuit to continuous enable).
Notes: the maximum allowable V+ voltage is 50 volts, note this is dependant on the input resistance
of the connected device. Link 4 or 5 is only required when the optional pull up resistors are fitted.
Only one of these links should be fitted. The value of the pull up resistors depends on the voltage
being switched and the input resistance of the connected device. Link 6 or Link 7 must be fitted,
do not fit links to both Link 6 and Link 7.
LINK 4 LINK 5
+5V
OPTIONAL
PULL-UP
RESISTORS
V IN (17)
D0 (1)
D15 (16)
GND
(19 or 20)
Q0 to Q15
OUTPUT
ENABLE
(18)
LINK 6
LINK 7
PM4OPTMAN-2.9-0 15 of 49

7.3 Configuring the NPN output board
The digital output board is factory supplied with the necessary components for the output options
required. PCB links are fitted to the circuit board to provide data to the microprocessor and
to connect the electronic components for the correct output types. It may be necessary to alter
the PCB links to configure to you requirements (see drawing below). See the “Input Output
Configuration” section 1.1 for details on dismantling the instrument. Optional plug-in pull-up
resistors are available - these are factory fitted only if specified when ordered.
7.4 PNP digital isolated output
The PNP output board is provided with an internal PCB link selecting the output as continually
enabled or externally controlled. Optional plug-in pull-down resistors are available - these are
factory fitted only if specified when ordered. Unless otherwise ordered the links are factory set
with Link 4 set between “OE” and “INT” (ground) i.e. set to continuous enable. To select for
external control move the link to between “OE” and “EXT”. Note: This input OUTPUT ENABLE
is initiated by a TTL level - active low input. Note: External supply VBB required, 5VDC minimum
to 50VDC maximum, note this is dependant on the input resistance of the connected device.
16 of 49 PM4OPTMAN-2.9-0

OPTIONAL
PULL-DOWN
RESISTORS
VBB (17)
D0 (1)
D15 (16)
GND
(19 or 20)
Q0 to Q15
OUTPUT
ENABLE
(18)
LINK 4
EXT
OE
INT
7.5 Configuring the PNP output board
The digital output board is factory supplied with the necessary components for the output options
required. PCB links are fitted to the circuit board to provide data to the microprocessor and
to connect the electronic components for the correct output types. It may be necessary to alter
the PCB links to configure to you requirements (see drawing below). See the “Input Output
Configuration” section 1.1 for details on dismantling the instrument. Optional plug-in pull-down
resistors are available - these are factory fitted only if specified when ordered.
LK4
EXT DE INT
LK2 LK1
Digital links (factory fitted)
LK1 IN for binary/BCD output
LK2 IN for second relay
Optional pull up
resistor packs
Setup links (fit link for required function)
LK4 (EXT) IN for external enable or OUT for Continuous enable
LK4 (INT) OUT for external enable or IN for Continuous enable
PM4OPTMAN-2.9-0 17 of 49

8 Serial and 4-20mA output option
(-A2, -A2R, -A4 and -A4R options)
This addendum covers instruments with the isolated serial/isolated analog output board. This
board allows output of either RS232 or RS485 plus 4 - 20mA plus a second relay. See “Configuring
the output board” section which follows for link selection details. The last digits in the model
number, which can be found at the bottom of the label on the instrument case, indicate the
options fitted, option combinations available with this board are show in the table below. Note:
Voltage output is not available with this board. Relays are form A, rated 240VAC, 5A resistive
load. The relay will revert to the normally open (N/O) contact being open when power is removed.
Option code Options fitted to the board
-A2 Isolated 4-20mA output plus isolated RS232 serial communication
-A2R Isolated 4-20mA output plus isolated RS232 serial communication plus second
relay
-A4 Isolated 4-20mA output plus isolated RS485 serial communication
-A4R Isolated 4-20mA output plus isolated RS485 serial communication plus second
relay
8.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual
for general information on electrical connections.
AB HC D E F J K
1 2 3 4 5 6 7 8 9 10 11
ISOLATED ANALOG
4-20mA RETRANSMISSION
-
+
SERIAL RETRANSMISSION
RS232 Tx OR
RS485 B
RS232 Rx OR
RS485 A
SERIAL GND
COM
N/O
2nd RELAY
(Optional)
(Optional)
(Optional)
SETUP
PUSHBUTTONS
F^v
18 of 49 PM4OPTMAN-2.9-0

8.2 Configuring the output board
The PM4IS output board has facilities for RS232 or RS485 and 4-20mA output and a second relay
and is factory supplied with all the necessary component for the output options ordered. PCB links
are fitted to the circuit board to provide data to the microprocessor and to connect the electronic
components for the correct output types. The 4-20mA output will drive into 800Ω load max. See
the “Input Output Configuration” section 1.1 for details on dismantling the instrument. Note:
links will only activate the option if that option was ordered and fitted e.g. fitting the “RLY2”
link will only enable the second relay if this option was ordered and fitting the “RS485” link will
not change the output from RS232 to RS485 unless the RS485 components are fitted and RS232
components removed.
LK7
LK5
RS232
RS485
RLY2
LK7
LK5
RS232
RS485
RLY2
LK7
LK5
RS232
RS485
RLY2
Link out
RS232
chip
Note: only one of these chips
should be fitted.
RS485
chip
Link in
RS485
selected
RS232
selected
RS232 and
second relay
selected
RS485 and
second relay
selected
LK7
LK5
RS232
RS485
RLY2
LK7
LK5
RS232
RS485
RLY2
LK1
TERM
Note: LK1 should
only be placed in
if the unit is the
final one in an
RS485 link when
long cable runs
are used.
LK1
TERM
LK1
TERM
U14
U15
PM4OPTMAN-2.9-0 19 of 49

9 Serial, second relay & transmitter supply output option
(-2, -4, -2R, -4R, -212, -412, -2R12 and -4R12 options)
The information provided in this section relates to PM4 panel meters with isolated RS232 or
isolated RS485 outputs using the optional serial output/relay/transmitter supply board. Note: If
the serial and 4-20mA output board has been fitted then the connection details below do not apply.
Refer to the “Serial and 4-20mA output option” section 8for connection details. Relays are form
A, rated 240VAC, 5A resistive load. The relay will revert to the normally open (N/O) contact
being open when power is removed.
Option code Options fitted to the board
-2 Isolated RS232 serial communication
-4 Isolated RS485 serial communication
-2R Isolated RS232 serial communication and second relay
-4R Isolated RS485 serial communication and second relay
-212 Isolated RS232 serial communication and isolated transmitter supply
-412 Isolated RS485 serial communication and isolated transmitter supply
-2R12 Isolated RS232 serial communication and second relay and isolated transmitter
supply
-4R12 Isolated RS485 serial communication and second relay and isolated transmitter
supply
9.1 Electrical Connections
All electrical connections are at the rear of the instrument. The plug in screw connectors used
allow for wire of up to 2.5mm2. Refer to “Electrical Installation” chapter in the main PM4 manual
for general information on electrical connections.
SETUP
PUSHBUTTONS
AB HC D E F J K
1 2 3 4 5 6 7 8 9 10 11 F^v
RS232 Tx / RS485 B
RS232 / RS485 GND
N/O
RS232 RX / RS485 A COM +
-
ISOLATED DC OUTPUT
(Optional)
COM 2nd RELAY
(Optional)
20 of 49 PM4OPTMAN-2.9-0