i-MO ISOCON-6 User manual

ISOCON-6 USERS GUIDE
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
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.
ISOCON-6_Users_Guide

ISOCON-6 USERS GUIDE
CONTENTS
1. INTRODUCTION
1.1 Hardware Features
1.1.1 Isolation Detail
2. UNPACKING
3. CONNECTIONS
4. CONFIGURING THE ISOCON
4.1.1 Voltage Input:
4.1.2 Current Input
4.1.3 Millivolt (mV) Input
4.1.4 Potentiometer Input
4.1.5 Thermocouple Input
4.1.6 RTD Input
4.1.7 Output Conguration
5. CALIBRATING THE ISOCON
6. INSTALLATION
7. TROUBLESHOOTING
7.1 Incorrect Reading
7.2 Sensor Failure
8. SPECIFICATIONS ( @ 25°C)
IMO Precision Controls Limited
1000 North Circular Road
Staples Corner, London NW2 7JP
Telephone: [phone]
Fax: [phone]
Web: www.imopc.com
Email: [email protected]
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
1. INTRODUCTION:
1.1 Hardware Features:
The ISOCON-6 is a universal input Isolating Signal Converter. It can accept virtually every type of analogue input signal from
millivolts to 40Vdc, mA, thermocouples, RTD’s etc. It also produces 3 types of analogue output; voltage, mA source, or mA sink.
The unit can be powered by any DC voltage between 12 and 36Vdc or 12 and 32Vac. For mains AC voltage the ISOCON-3 is
available which can be powered from any supply from 90Vac to 264Vac at 50 or 60Hz.
The instrument is packaged in a very compact 12.5mm wide enclosure which can be mounted on standard TS35 DIN-rail.
The unit can also be equipped with 1 digital output which can be either a relay or an open collector output, or a second analogue
output (see DUALCON-6). Note, units with above options are housed in a 17.5mm wide box.
1.1.1 Isolation Details
The ISOCON-6 has full 3 port isolation of 1000V between the Input Stage, Output Stage and Power Supply for functional reasons.
2. UNPACKING:
The instrument should be carefully inspected for signs of damage which may have occurred in transit. In the unlikely case that
damage has been sustained, DO NOT use the instrument, but please retain all packaging for our inspection and contact your
supplier immediately.
The instrument comes with the following items as standard:
1 Isocon-6 Isolating Signal Converter
1 Isocon-6 User Guide
If the instrument has been factory congured the input and output details will be listed on the Serial number label on the side of
the unit. If this label is blank then the unit will be set to its default conguration which is 4-20mA input and 4-20mA source output.
Please check that the details on the side label are correct, especially the power supply voltage.
If re-conguration is required please refer to Section 4 of this manual.
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
3.CONNECTIONS:
The ISOCON is housed in a compact DIN rail mounting enclosure, with 8 terminals, arranged in 4 rows of 2 terminals. Two rows
are at the top of the front panel and 2 rows are at the bottom. All the sensor input terminals are on the bottom rows and the power
supply and analogue outputs are on the top terminals.
The diagram below shows how to connect all the different input, output and power supply types.
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
4. CONFIGURING THE ISOCON:
The ISOCON is an extremely versatile device which can support many different types of input. The unit is congured by turning the
power off, selecting the internal switch settings required and turning the power back on.
To open the Isocon, 2 catches just below the outer terminal blocks must be pushed in gently, one at a time. The front of the case
can then be pulled and the unit will come out of the box.
There are 3 switch banks, S1, S2, and S3, located inside the ISOCON as shown below:
Switch S1 and S2 congure the input type and range, and switch S3 congures the output type, range and a few additional
functions. The switch settings are explained in the next few pages. The diagrams refer to switch positions 0 and 1, with 0 being OFF
and 1 being ON. This is illustrated in the picture above.
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
4.1.1 Voltage Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
Voltage
Range Switch S1
1 2 3 4 5 6 7 8 9 10 11 12
0-1V 0 0 0 0 0 1 0 0 1 1 0 0
0-2V 0 0 0 1 0 1 0 0 1 1 0 0
0-4V 0 0 1 0 0 1 0 0 1 1 0 0
0-5V 0 1 0 0 0 1 0 0 1 1 0 0
0-7.5V 1 0 0 0 0 1 0 0 1 1 0 0
0-8V 0 0 1 1 0 1 0 0 1 1 0 0
0-10V 0 1 0 1 0 1 0 0 1 1 0 0
0-15V 1 0 0 1 0 1 0 0 1 1 0 0
0-20V 0 1 1 0 0 1 0 0 1 1 0 0
0-30V 1 0 1 0 0 1 0 0 1 1 0 0
0-40V 0 1 1 1 0 1 0 0 1 1 0 0
1-5V 0 1 0 0 0 1 0 0 1 1 0 1
-5 to +5V 1 1 0 0 0 1 0 0 1 1 0 1
-10 to +10V 1 1 0 1 0 1 0 0 1 1 0 0
Voltage
Range Switch S2
1 2 3 4 5 6 7 8 9 10 11 12
0-30V & 0-40V 0 0 1 1 0 0 1 1 0 0 0 0
All other Ranges
Listed Above 0 0 1 0 1 0 1 0 0 0 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

ISOCON-6 USERS GUIDE
4.1.2 Current Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
mA
Range Switch S1
1 2 3 4 5 6 7 8 9 10 11 12
0-1mA 0 0 0 0 0 0 0 0 1 1 1 0
0-2mA 0 0 0 1 0 0 0 0 1 1 1 0
0-4mA 0 0 1 0 0 0 0 0 1 1 1 0
0-5mA 0 1 0 0 0 0 0 0 1 1 1 0
0-8mA 0 0 1 1 0 0 0 0 1 1 1 0
0-10mA 0 1 0 1 0 0 0 0 1 1 1 0
0-15mA 1 0 0 1 0 0 0 0 1 1 1 0
0-20mA 0 1 1 0 0 0 0 0 1 1 1 0
0-30mA 1 0 1 0 0 0 0 0 1 1 1 0
4-20mA 0 1 1 0 0 0 0 0 1 1 1 1
4-40mA 0 1 1 1 0 0 0 0 1 1 1 1
4-30mA 1 0 1 0 0 0 0 0 1 1 1 1
-5 to +5mA 1 1 0 0 0 0 0 0 1 1 1 1
-10 to +10mA 1 1 0 1 0 0 0 0 1 1 1 0
mA Range Switch S2
1 2 3 4 5 6 7 8 9 10 11 12
Using Internal 24V Tx
Supply for 4 to 20mA 1 1 0 1 0 0 1 1 0 0 1 0
Unipolar Ranges (e.g.
0-20mA, 4-20mA) 1 1 0 0 0 0 1 1 0 0 0 0
Bipolar Ranges (e.g. -10
to +10mA) 1 1 0 0 1 0 1 0 0 0 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

ISOCON-6 USERS GUIDE
4.1.3 Millivolt (mV) Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
mV
Range Switch S1
1 2 3 4 5 6 7 8 9 10 11 12
0-25mV 0 0 0 0 0 0 0 1 1 1 0 0
0-50mV 0 0 0 1 0 0 0 1 1 1 0 0
0-100mV 0 0 1 0 0 0 0 1 1 1 0 0
0-125mV 0 1 0 0 0 0 0 1 1 1 0 0
0-150mV 1 0 0 0 0 0 0 1 1 1 0 0
0-200mV 0 0 1 1 0 0 0 1 1 1 0 0
0-250mV 0 1 0 1 0 0 0 1 1 1 0 0
0-300mV 1 0 0 1 0 0 0 1 1 1 0 0
0-500mV 0 1 1 0 0 0 0 1 1 1 0 0
0-600mV 1 0 1 0 0 0 0 1 1 1 0 1
0-1000mV 0 1 1 1 0 0 0 1 1 1 0 1
0-1200mV 1 0 1 1 0 0 0 1 1 1 0 1
-125 to +125mV 1 1 0 0 0 0 0 1 1 1 0 1
-125 to +1000mV 1 1 1 1 0 0 0 1 1 1 0 0
mV Range Switch S2
1 2 3 4 5 6 7 8 9 10 11 12
All Unipolar Ranges (e.g.
0-500mV) 0 1 0 0 0 0 1 1 0 0 0 0
S2Bipolar Ranges (e.g.
-125 to +125mV) 0 1 0 0 1 0 1 0 0 0 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

ISOCON-6 USERS GUIDE
4.1.4 Potentiometer Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
Potentiometer
Input Switch S1
1 2 3 4 5 6 7 8 9 10 11 12
2 Wire 0-125R 0 0 0 0 0 0 0 1 1 1 0 1
2 Wire 0-250R 0 0 0 1 0 0 0 1 1 1 0 1
2 Wire 0-500R 0 0 1 0 0 0 0 1 1 1 0 1
2 Wire 0-625R 0 1 0 0 0 0 0 1 1 1 0 1
2 Wire 0-750R 1 0 0 0 0 0 0 1 1 1 0 1
2 Wire 0-1K 0 0 1 1 0 0 0 1 1 1 0 1
3 Wire from0-1K to
0-100K 0 0 0 0 0 1 0 1 1 1 1 0
Potentiometer Input Switch S2
1 2 3 4 5 6 7 8 9 10 11 12
2 Wire Potentiometer 0 1 0 0 1 0 0 1 0 0 0 1
3 Wire Potentiometer 0 0 1 1 0 0 1 1 0 0 1 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED

ISOCON-6 USERS GUIDE
4.1.5 Thermocouple Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
Switch S1 for Thermocouple Input T/C
Type
Temperature Range in °C Switch
K J R S N E B T 1 2 3 4 5 6 7 8 9 10 11 12
0 to 100 400 to 500 0 to 50 0 0 0 0 0 0 0 0 0 0 K
0 to 200 400 to 600 0 to 100 0 0 0 1 0 0 0 0 0 1 J
0 to 400 400 to 800 0 to 200 0 0 1 0 0 0 0 0 1 0 R
0 to 800 400 to 1200 0 to 400 0 0 1 1 0 0 0 0 1 1 S
0 to 125 400 to 525 -50 to 50 0 1 0 0 0 0 0 1 0 0 N
0 to 250 400 to 650 -50 to 100 0 1 0 1 0 0 0 1 0 1 E
0 to 500 400 to 900 -50 to 200 0 1 1 0 0 0 0 1 1 0 B
0 to 1000 400 to 1400 -50 to 400 0 1 1 1 0 0 0 1 1 1 T
0 to 150 400 to 550 -100 to 50 1 0 0 0 0 0 0
0 to 300 400 to 700 -100 to 100 1 0 0 1 0 0 0
0 to 600 400 to 1000 -100 to 200 1 0 1 0 0 0 0
0 to 1200* 400 to 1600 -100 to 400 1 0 1 1 0 0 0
0 to 175 400 to 575 -200 to 50 1 1 0 0 0 0 0
0 to 350 400 to 750 -200 to 100 1 1 0 1 0 0 0
0 to 700 400 to 1100 -200 to 200 1 1 1 0 0 0 0
0 to 1400** 400 t0 1800 -200 to 400 1 1 1 1 0 0 0
*n/a for types N and E
**n/a for types K, J, N and E
Thermocouple Switch S2
All Ranges 1 2 3 4 5 6 7 8 9 10 11 12
0 1 0 0 1 1 1 0 0 0 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED
Linearisation ON 0
Linearisation off 1 CJC ON 0
CJC off 1

ISOCON-6 USERS GUIDE
4.1.6 RTD Input:
Select the range from the table below and set Switch S1 to the required values.
Then select the required setting from the table below for switch S2
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
RTD Switch S2
1 2 3 4 5 6 7 8 9 10 11 12
2 Wire RTD 0 1 0 0 1 0 0 1 0 0 0 1
3 Wire RTD 0 1 0 0 0 0 0 0 1 0 0 1
4Wire RTD 1 0 0 0 0 0 1 0 1 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED
Range in °C Switch S1
1 2 3 4 5 6 7 8 9 10 11 12
0 to 100 0 0 0 0 0 0 1 0 0
0 to 200 0 0 0 1 0 0 1 0 0
0 to 400 0 0 1 0 0 0 1 0 0
0 to 800 0 0 1 1 0 0 1 0 0
-50 to 50 0 1 0 0 0 0 1 0 0
-50 to 150 0 1 0 1 0 0 1 0 0
-50 to 250 0 1 1 0 0 0 1 0 0
-50 to 350 0 1 1 1 0 0 1 0 0
-100 to 50 1 0 0 0 0 0 1 0 0
-100 to 100 1 0 0 1 0 0 1 0 0
-100 to 200 1 0 1 0 0 0 1 0 0
-100 to 400 1 0 1 1 0 0 1 0 0
-200 to 200 1 1 0 0 0 0 1 0 0
-200 to 400 1 1 0 1 0 0 1 0 0
-200 to 600 1 1 1 0 0 0 1 0 0
-200 to 800 1 1 1 1 0 0 1 0 0
RTD linearisation ON 0
RTD linearisation off 1 RTD 2 or 4 wire 0
RTD 3 wire 1 PT1000 0
PT1000 1

ISOCON-6 USERS GUIDE
4.1.7 Output Conguration:
Select the range from the table below and set Switch S3 to the required values.
Examples:
Please note that PC Software is available to provide information on switch settings for your input and output requirements.
Switch S3 Examples
1 2 3 4 5 6 7 8 9 10 11 12
4-20mA Source 1 0 1 0 1 0 0 0 0 0 0 0
0-20mA Source 1 0 1 0 1 0 0 0 0 0 0 1
0-10V 1 0 1 0 1 1 0 0 0 0 0 1
4-20mA Sink 1 1 0 1 0 0 0 0 0 0 0 0
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
Warning: DO NOT OPEN UNIT OR ADJUST SWITCHES WITH POWER SUPPLY, INPUT OR OUTPUT CONNECTED
Switch S3
1 2 3 4 5 6 7 8 9 10 11 12
0 Buttons Disabled
1Buttons Enabled
Output value if fault on input signal
Front panel buttons can be disabled to allow
tamper-proof operation of unit
0Normal
1 Inverted o/p
High Burnout 0
Low Burnout 1
Normal 0
Square Root 1
00 1 0 1 0 mA Source
1 0 1 0 0 mA Sink
0 1 0 1 1 Voltage
4-20mA / 2-10V 0 0
0-20mA /0-10V 0 1
0-10mA / 0-5V 1 0
2-10mA / 1-5V 1 1

ISOCON-6 USERS GUIDE
5. CALIBRATING THE ISOCON:
When the unit is shipped the ISOCON will be calibrated for the input and output types and ranges noted on the side label. If this label
is blank then the unit will be calibrated for 4-20mA input and 4-20mA source output.
If the unit is re-ranged by the user it is necessary to re-calibrate the unit to obtain the maximum accuracy. The calibration is
achieved by using both switches on the front panel to select the zero or span input and then using the switches as raise/lower
buttons to adjust the output to the value required.
The mode the unit is in is indicated by the colour of the LED:
Green - Normal Operation
Red - Span Adjust
Yellow - Zero Adjust
Setting of the zero and span points is non-interactive, so each point need only be set once. A typical calibration sequence would be
as follows:
The unit is now calibrated and ready for use.
Note: The unit will retain the new settings on power down.
LED Colour Mode Action
Green Normal Apply full scale input. Press and release both buttons together to enter span mode
RED Span Adjust Press raise / lower buttons to adjust output value Press and release both buttons
together to return to normal mode
Green Normal Apply zero scale input Press and release both buttons together to enter zero mode
YELLOW Zero Adjust Press raise / lower buttons to adjust output value Press and release both buttons
together to return to normal mode
Green Normal Use product
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
6. INSTALLATION:
The ISOCON’s input and output circuits are classed as Separated Extra Low Voltage (SELV). This means that they must not be
externally connected to voltages exceeding 30V ac or 60V dc, nor do they generate voltages above these limits internally. Where a
higher voltage input is required a specially designed DIVIDER unit can be used to condition the input signal prior to connection to the
process input terminals.
The ISOCON unit clips directly onto ‘Top Hat’ (TS35) symmetrical DIN rail. Ideally, mounting orientation should be vertical, with the
power supply situated on the top face to minimise temperature rise. Good airow around the unit will maximise reliability of the
instrument.
The use of bootlace ferrules is recommended on wiring terminations.
Do not exceed terminal torque rating of 0.4 Nm – use an appropriate screwdriver. The unit can be removed from the DIN rail by
sliding a small screwdriver into the slot at the rear of the enclosure on the lower face and gently levering the metal clip, whilst lifting
the unit from the rail.
When the unit is used to convert a thermocouple input it is important when calibrating to ensure that the thermocouple simulator
employed is switched to automatic cold junction compensation and is at the same ambient temperature as the ISOCON. Note that
this is not always easy to achieve, especially if the ISOCON is mounted in a warm cabinet. An altenative method is to use an ice-
point reference and a mV source.
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER

ISOCON-6 USERS GUIDE
7. TROUBLESHOOTING:
The ISOCON has some built in self diagnostic functions. If the LED on the front panel is ashing then the fault mode can be found by
counting the number of ashes between gaps and using the table below to locate the problem.
7.1 Incorrect Reading:
• Check that Unit is congured for the correct Sensor
• Check that Input Scaling is as required.
• Check that Linearisation has not been set incorrectly.
• Check that Thermocouples have correct compensation cables, and polarity.
• Check that RTD is set for correct option 2, 3 or 4 Wire.
• Check that RTD leads are connected to appropriate terminal pins.
7.1 Incorrect Reading:
• Check that sensor wiring is correct.
• Check Thermocouple polarity.
• Check that all RTD leads are connected to correct terminals.
• Check that the ISOCON is congured for correct sensor.
• Check that applied voltage is not out of range.
• Check that applied current is not out of range.
• Check that applied millivoltage is out of range.
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER
No of Flashes Nature of Fault Corrective Action
0
(Green On) Unit Working – no suspected fault Check Wiring and switch settings
2,3,4,5,6,8,9,
10,11,12 Green
Hardware Error, extreme noise,
poor supply
Switch off unit, check switch settings, and wiring, and retry. If
still faulty please contact supplier
7 Green RTD / Thermocouple burnout Repair RTD, T/C or wiring
3 or 4 Red Span point is too close to zero
point Change input span value and retry
3 or 4 Yellow Zero point is too close to span
point Change input zero value and retry
No LED Power Failure Check supply lines and voltage

ISOCON-6 USERS GUIDE
8. SPECIFICATIONS ( @ 25°C):
Operating Temperature: 0 to 55 °C
Operating Altitude: Sea Level to 2000m
Humidity: 0-90% RH
Power Requirements:
DC Supply: 12 to 36Vdc
AC Supply: 12 to 32Vac
Current Consumption: 55mA @ 24Vdc (20mA in & out)
85mA @ 24Vdc (maximum load, tx supply)
200mA @ 12Vdc (maximum load, tx supply)
260mA for 50ms on 24Vdc power up
Transmitter Power Supply: 22V to 29V @ up to 24mA
Dependant on supply voltage and load
Calibration accuracy: ±0.05% full scale
Linearity: ±0.05% full scale
Temperature Stability: 50ppm / °C
Input Impedance:
Current Input: 15 ohms
Voltage Input: 1 Mohm
Millivolt Input: Greater Than 10 Mohm
Thermocouple Burn Out Current: 500nA Nominal
Cold junction compensation accuracy: ±0.5°C over operating range
Maximum Voltage Output: 11.5 V into a minimum of 7Kohm
Maximum Current Output: 23.0 mA into a maximum of 1Kohm
Time Response: (90% of step change): 50ms ± 10ms
Unit has full 3 port Isolation to 1kV between Power Supply, Input and Output.
The unit can also withstand transients of 2.5kV for 50 μsecs.
Dimensions: 114.5 mm x 99mm x 12.5mm (H x D x W)
Mounting: DIN Rail TS35
Connections: Screw Clamp with pressure plate
Conductor Size: 0.5 to 4.0 mm
Insulation Stripping: 12 mm
Maximum Terminal Torque: 0.4 Nm
Weight Approx. 95g
EMC Emissions:
EN50081-1:1992
EN50081-2:1993
EMC Immunity: EN50082-1:1997
LVD Standards: EN61010-1:1993
Installation Category (IEC 664): II
Pollution Degree (EN61010-1:1993): 2
Equipment Class (IEC 536): II
ISOCON-6
24V AC or DC POWERED ISOLATING SIGNAL CONVERTER