Kimray DACC2000 User manual

DACC2000
User's Manual
ENG-015 Rev. 1

CONTENTS
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
Kimray, Inc. provides this publication “as is”, without warranty of any kind, either express or implied,
including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose.
Information in this publication is subject to change without notice. For current revision go to :
http://www.kimray.com:8100/Public/Literature/Automation
© 2005 –2006 Kimray, Inc. All rights reserved.

CONTENTS

DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
Contents
1.0 Overview of the DACC2000 1.1
1.1 Introduction 1.1
1.2 Features 1.1
2.0 Installation 2.1
2.1 Power Interconnection 2.2
2.2 Signal Connections 2.3
2.2.1 Analog Inputs 2.3
2.2.2 Digital Inputs 2.5
2.2.3 Accumulator Inputs 2.6
2.2.4 Relay Outputs 2.6
2.2.5 Analog Outputs 2.7
2.2.6 Display connection 2.7
3.0 Communications 3.1
3.1 Port Connections 3.1
3.2 RS-485 3.2
4.0 Operation 4.1
4.1 Internal 4.1
4.2 Input/Output 4.1
4.2.1 Analog Inputs 4.1
4.2.2 Status Inputs 4.2
4.2.3 Accumulator Inputs 4.2
4.2.4 Relay Outputs 4.3
4.2.5 Analog Outputs 4.4
4.2.6 Power Switching 4.4
4.2.7 Display Interface 4.5
4.2.8 Communications 4.6
5.0 Specifications 5.1

CONTENTS

1-1 OVERVIEW
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
1.0 Overview of The Kimray DACC2000 RTU
1.1 Introduction
This document describes the Kimray DACC2000, an RTU for data acquisition, supervisory
control and communications designed to handle the requirements of oil and gas field automation.
Included in this manual are the following sections:

Features

Installation

Communications

Operation

Specifications
1.2 Features

Full Production Control with PROcontrol

Multi-run Flow Computer

Store and Forward Capability

Solar Powered

Internal Temperature Compensated Charger

Dependable in Harsh Environments

Flexible and Cost Effective

RTU Initiated Communications

Integrated Telemetry

512K EPROM and 512K RAM

CMOS Ultra Low Power Design

Four Serial Communications Ports (Three RS232 & One RS485)

Display Port

Expandable using the RS485 port

DACC2000 USER'S MANUAL (ENG-015 Rev. 1)

2-1 INSTALLATION
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
2.0 Installation
This section describes configuring your DACC2000 RTU and connecting it to other devices.
EPROM
COMM1
KIMRAY DACC2000
KIMRAY
RS-485
DIGITAL INPUTS
ACCUMULATOR INPUTS
ANALOG INPUTS
DIGITAL OUT
DISPLAY
PWR
GND
485+
485-
0+
0-
1+
1-
2+
2-
3+
3-
V+
ACC0+
ACC0-
GND
ACC1+
ACC1-
V+
0+
0-
V+
1+
1-
V+
2+
2-
V+
3+
3-
0COM
0NO
0NC
1NC
1NO
1COM
2COM
2NO
2NC
3NC
3NO
3COM
ANALOG OUT0
GND VOLT CURR
VOUT
GND BATT GND
CHGR GND RAD+
GND AUX+
COMM2
PERIPH
F1
F1
F2
F3
RS-485
DIGITAL
INPUTS
ACCUMULATOR
INPUTS
ANALOG
INPUTS
DIGITAL
OUTPUTS
ANALOG
OUTPUTS
POWER
I/O
FIGURE 2.1
DACC2000 TERMINAL BLOCKS
Figure 2.1 shows the locations of the DACC2000 terminal barriers. All process wiring to the

INSTALLATION 2-2
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
DACC2000 terminates in the modern version of terminal strip called a "compression screw
solderless connector". This form of connector requires no soldering or lug to be placed on the
end of the wire, but instead uses a "bare wire" termination technique. "Bare wire" terminations
have been shown to be generally superior to the use of ring or spade lugs hand compressed to the
ends of signal wires and terminated with screw terminals. The bare wire termination usually
results in corrosion resistant "cold flow gas-tight seals", whereas the hand compression lug
terminations usually do not. Bare wire terminations are also much faster to install.
The recommended technique for bare wire terminations is very simple: strip 1/4" of insulation
from the end of the wire, insert into an open termination slot, and turn the compression screw
tight with hand pressure using a pocket screwdriver.
2.1 Power Interconnection
This section describes connecting your DACC2000 to the Battery, Radio, Charging Source and
other power devices. The power terminal barrier is on a plug in card on the bottom right of the
DACC2000 (refer to Figure 2.1). Figure 2.2 illustrates the connections and fuse locations.
KIMRAY
ANALOG OUT0
GND VOLT CURR
VOLT
GND BATT GND
CHGR GND RAD+
GND AUX+
F1
F2
F3
AUXILLARY +
DEVICES -
RADIO +
-
- BATTERY
+
- SOLAR PANEL OR
+ DC SUPPLY
3A. AUXILLIARY OUT
3A. RADIO POWER
5A. BATTERY INPUT
20V.OUTPUT
Optional Extension
to top of Card
FIGURE 2.2
DACC2000 POWER INTERCONNECTIONS AND FUSING
Solar Input
A 12 volt solar panel is normally used as the charging source for the battery. The positive output
of the panel connects to the CHGR terminal and the minus to the GND terminal as shown. The
Battery is automatically charged with no external charger controller required. The maximum
current for the charger on the DACC2000 is 4 Amp. This limits the maximum size of the solar
panel controlled by the DACC2000 to 70 watts. If a larger solar panel is required, an external
battery charging regulator must be used.

2-3 INSTALLATION
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
Direct Current power from an AC power supply can also be used to charge the battery. The
positive output voltage is connected to the CHGR terminal and the minus output to the GND
terminal. When using a voltage source for charging the battery, the voltage must be high enough
to adequately charge the battery. A voltage of 15 to 16 Volts should be satisfactory for a 12 Volt
battery. The power supply output must be current limited to less than 4 A.
Battery Input
The positive terminal of the battery connects to BATT and the minus to GND. For proper
operation the battery voltage must be greater than the cutoff threshold (11.5V).
Radio Output
The radio connection provides software switched power from the battery for a 12 volt radio.
Switching provides for the radio to be electrically disconnected under program control when the
battery voltage is low. The RAD+ terminal connects to the plus terminal of the radio and GND
to the minus terminal.
Auxiliary Output
The Auxiliary Output provides battery voltage that is switched off along with the DACC2000
because of low (<10.5 Volts) battery voltage. AUX+ is positive and GND is minus.
20V. Output
An optional extended version of the plug-in power card provides a terminal strip with two 20V
outputs on the top of the card. This can be used to provide power for 4-20mA sensors.
2.2 Signal Connections
2.2.1 Analog Inputs
Analog input signals are typically subject to the effects of induced electrical noise. Proper wire
routing and shielding can reduce this noise by orders of magnitude. A recommended noise
reduction technique is using shielded twisted pair wiring between the signal source and the
DACC2000 termination. Twisted pair wire with a minimum of 6 twists per inch will cancel
noise induced by 60 Hz AC current by introducing equal and opposite currents in both wires.
The shield should be a 100% coverage metallized plastic with a copper drain wire. Any currents
carried or induced in the shield are conducted to the bare drain wire which is to be connected at
one end only to a ground. The end to be grounded is normally considered to be the end closest to
the source of power. The shield on signal wires coming from self-powered transmitters should
be grounded close to the transmitter itself. The shield on signal wires to unpowered field
transmitters which draw DC power from the DACC2000 should be grounded at the DACC2000.
If there is more than one grounding point of the shield, local conditions will occur in which
substantial currents flow in the shield due to small differences in ground potential. Not only will
this induce process noise, but it can cause heating of the shield and drain wire, and even burn-out
of the cable. The shield and drain wire at the ungrounded end should be stripped back and cut
cleanly at the edge of the overall cable jacket.
If the analog signals must pass within the electromagnetic fields of large motors, the twisted
shielded pairs should be inside metal conduit for the section exposed to the field. This will
provide protection from large induced voltages. Analog signal wires should not be run in the
same conduit with AC electrical power wiring which can also produce large magnetic fields.
Figure 2.1 shows the location of the terminal blocks and Figure 2.3 illustrates the input
connections.

INSTALLATION 2-4
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
ANALOG INPUTS
V+
0+
0-
V+
1+
1-
V+
2+
2-
V+
3+
3-
V
C
C
20 V. POWER
SUPPLY
JP4
JP5
JP6
JP7
F1
JP1
½ A. fuse for internally
provided power for Analog,
Status and Accumulator inputs
Jumper for Internal +12v to be
used for Analog V+ power
Jumpers to connect 250 Ohm
resistors for current loop inputs
FIGURE 2.3
DACC2000 ANALOG INPUT CONNECTIONS
The voltage output pins of the terminal block are connected to the internal fused battery voltage
by jumper JP1, shown in Figure 2.3. The fuse for this power is F1, also shown in Figure 2.3.
Jumpers are provided for each analog channel of the DACC2000, as illustrated in Figure 2.3, to
configure shunt resistors for each channel. JP4 through JP7 are used to connect 250

shunt
resistors to each channel for using 4 to 20 mA input signals. The resistors are enabled by closing
the jumper. As long as the jumper is open the resistor is not used and the input is set up for a 1
to 5V input signal.
The following table describes the current loop resistor corresponding to each Jumper.
Analog Input
Current Loop
Jumpers
AI 0
JP4
AI 1
JP5
AI 2
JP6
AI 3
JP7
Current Inputs
Most 4 to 20 mA process transmitters are unpowered, meaning that the signal line carries both
power and the signal. They are used by connecting a common DC power source in series with
the transmitters. When a voltage of 20 Volts is required for the sensors, it must be supplied by
an external supply. Figure 2.3. shows current transmitters connected to channels 1 and 2 using
an external 24 volt power supply. The minus terminal of the supply can be connected to ground

2-5 INSTALLATION
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
as shown (the minus input of a channel) if the Normally Closed solder jumper for that channel is
closed. If all sensors are powered from the same supply, Jumper JP2 (Figure 2.4) can be
removed and the external supply connected to one of the V+ terminals. This provides the
external voltage to all of the other V+ terminals on the analog input terminal blocks. The
internal voltage may be used instead of an external power supply if 12 volts is sufficient to drive
the transmitter. 12 volts is usually not adequate because the voltage available for the transmitter
is 12 volts minus the 5 volts for the 250 ohm resistor minus the voltage drop in the signal lines.
Thus the available voltage is less than 7 volts which is not usually sufficient.
Each external high level channel is provided with a 250

resistor for use with the 4 to 20 mA signals to
convert the current to a 1 to 5 volt signal. The resistor is enabled by closing the jumper (shown in Figure
2.3) for the channel.
Voltage Inputs
1 to 5 volt transmitter signals are connected as shown in Figure 2.3 when the DACC2000 is
providing the power for the transmitter. The shunt resistor jumpers remain open, keeping the
250 ohm resistors out of the circuit.
2.2.2 Digital Inputs
Each digital input is terminated in two compression screws in the terminal barrier located on the
left edge of the DACC2000 (refer to Figure 2.4). Open inputs are read as a 1 and closed inputs
as a 0. Each closed input causes a corresponding LED to light.
Physical status conditions are commonly detected by the closure of a switch or by an open
collector transistor output (illustrated in Figure 2.4). Manual inputs are often a pushbutton
depression. These result in the closure of a physical electrical contact.
DIGITAL INPUTS
ACCUMULATOR INPUTS
0+
0-
1+
1-
2+
2-
3+
3-
V+
ACC0+
ACC0-
GND
ACC1+
ACC1-
Turbine Meter
JP2
JP3
FIGURE 2.4
DACC2000 DIGITAL AND ACCUMULATOR INPUT CONNECTIONS
2.2.3 Accumulator Inputs
One accumulator input (Accumulator 0) terminates in the four compression screws of the
Accumulator 0 terminal strip (refer to Figure 2.4). The terminals are: V+, ACC0+, ACC0- and

INSTALLATION 2-6
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
GND. The other input is terminated in 2 compression screws in the other barrier strip (ACC1+
AND ACC1-). Two LEDs, one per channel monitor the input states.
The frequency response of Accumulator 0 is jumper selectable with Jumpers JP2
and JP3. When no jumpers are used there is no filtering of the input. Jumper JP3
enables filtering. With the other jumper out the channel will have a response of
approximately 30 Hz. If the other jumper for is used (JP2) the frequency response
increases to 1 kHz. The DACC2000 is normally set for 30 Hz filtering.
Some devices generate or switch ON a voltage when they change state (voltage input
devices). Some devices only close a contact when the state is changed. The state of
both types of devices are sensed with the Accumulator 0 input interface.
Contact Input Devices
Contact closure inputs are powered from the DACC2000. V+ will be connected to ACC0+ and
the switch (or open collector transistor) will be between ACC0- and GND. This is illustrated in
Figure 2.4 where the input is connected between ACC0- and GND.
Voltage Input Devices
The most common type of voltage input device is the relay or switch. When open, there is no
power on the switched side of the device. When the relay is energized or the switch is closed,
there is power on the switched side of the device. Wiring from the switched side of the device
and a power return provides the required sensing signal. For this case the input is connected
between ACC0+ and ACC0- and the V+ terminal is not used.
Turbine Meter Input
The DACC2000 can be connected directly to a turbine meter. The low level signal from the
turbine meter should be connected directly to the terminals of ACC1. This is illustrated in Figure
2.4 where the input is connected between ACC1- and ACC1-.
2.2.4 Relay Outputs
The DACC2000 has 4 relay (digital) output channels, each a set of form C contacts (SPDT). The
DIGITAL OUT
0COM
0NO
0NC
1NC
1NO
1COM
2COM
2NO
2NC
3NC
3NO
3COM
RELAY
RELAY
RELAY
RELAY
FIGURE 2.5
DACC2000 RELAY OUTPUT CONNECTIONS
outputs of the relays are available on the terminal barrier along the bottom left of the DACC2000
card (refer to Figure 2.5). Each channel has three screw terminals: COM, NO and NC. The
JP2
JP3
No Filtering
JP2
JP3
1 KHz Filtering
JP2
JP3
30 Hz Filtering

2-7 INSTALLATION
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
COM terminal is the pole of the relay, NO is the normally open contact and NC the normally
closed contact. Each channel has an LED to indicate when the channel is energized.
2.2.5 Analog Outputs
The two optional Analog outputs of the DACC2000 each generate a 4 to 20 mA DC output
(which is normally required for process actuators) or a 1 to 5 volt output. The outputs are
normally powered by the DACC2000 but can be powered from an external source. The analog
output terminations are located along the bottom right edge of the DACC2000 card on TB7 and
TB8 (refer to Figure 2.6). Each channel has four screw terminations labeled +VOUT, CURR,
VOLT and GND.
Current Sinking Outputs
For connecting the current sinking output to a device with the DACC2000 supplying the power,
connect as shown for channel 1 in Figure 2.6. The CURR terminal connects to the minus
terminal of a device and the VOUT connects to the plus terminal. Jumper JP8 must be installed
to power the outputs internally.
ANALOG OUT0
JP8
GND
VOLT
CURR
VOUT
TB7
TB8
ANALOG OUT1
GND
VOLT
CURR
VOUT
+ -
DEVICE
+ -
DEVICE
EXT. +
POWER -
FIGURE 2.6
DACC2000 ANALOG OUTPUT CONNECTIONS
When external power is used, the device's plus terminal is connected to the external power
source and the minus terminal is connected to the CURR terminal of the DACC2000 as
illustrated for Channel 0 in Figure 2.6. The external power source common is connected to the
GND terminal.
Voltage Outputs
For a voltage output with internally supplied power, connect the minus terminal of the device to
GND, the plus terminal to VOLT and jumper +VOUT to CURR as shown in Figure 2.7.
When using externally supplied power, connect as shown for Channel 0 in Figure 2.7. The
minus output of the power source connects to GND and the plus output connects to CURR. The
device is connected for internally supplied power with minus to GND and plus to VOLT.

INSTALLATION 2-8
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
ANALOG OUT0
JP8
GND
VOLT
CURR
VOUT
TB7
TB8
ANALOG OUT1
GND
VOLT
CURR
VOUT
+ -
DEVICE
+ -
DEVICE
EXT. +
POWER -
FIGURE 2.7
DACC2000 VOLTAGE OUTPUT CONNECTIONS
2.2.6 Display connection
Figure 2.8 shows the connection of the display to the Processor Card. The display interface
connector is on the top center of the card. The Potentiometer by the connector controls the
contrast of the display.
DISPLAY
CONNECTOR
COMM1
KIMRAY DACC2000
DISPLAY
COMM2
PERIPH
CONTRAST
ADJUSTMENT
FIGURE 2.8
DACC2000 DISPLAY

3-1 COMMUNICATIONS
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
3.0 Communications
This section describes connecting the DACC2000 to communications devices and configuring
the DACC2000's communications ports.
3.1 Port Connections
The communications connectors are located along the top of the DACC2000 (Figure 3.1).
XMIT
XMIT
RECEIVE
COMM1
KIMRAY DACC2000
RS-485
DIGITAL INPUTS
DISPLAY
PWR
GND
485+
485-
0+
0-
1+
1-
2+
2-
3+
3-
COMM2
PERIPH
FIGURE 3.1
DACC2000 COMMUNICATIONS PORTS
Table 3.1 shows the pinout of the three 9-pin DB-9 connectors. The PERIPH port (top of the
card) is normally used for setup with the Local Operator Station (LOS) or equivalent.
DB9 Pin#
Direction
PERIPH
COMM1
COMM2
2
IN
RXD
RXD
RXD
3
OUT
TXD
TXD
TXD
4
OUT
DTR(+6V)
DTR(+6V)
DTR(+6V)
5
GND
GND
GND
6
-5.5V
-5.5V
7
OUT
RTS
RTS
8
IN
CTS
CTS
9
SLEEP
TABLE 3.1

COMMUNICATIONS 3-2
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
The COMM 1 port is used to communicate to the central computer via radio, wire line, etc. while
the COMM2 port is typically used for a radio store and forward function or to connect to another
field device.. Both COMM ports have an LED beside the connector. The LED is on whenever
data is transmitted out of that port. In addition, there is one receive LED (refer to Figure 3.1)
which is turned on whenever data is received from any port.
3.2 RS-485
The RS-485 port is on the top left of the DACC2000. RS-485 is an enhanced version of the RS-
422 balanced line standard. It allows multiple drivers and receivers (up to 32) on a two wire
system. This allows you to put together large systems with many drop points. RS-485 is used as
a 2-wire half duplex medium. The half duplex wiring of RS-485 requires only a single wire pair
to interconnect all stations. Termination resistors should be placed at the opposite ends of the
system. The DACC2000 has an internal termination resister connecting to the transmission line.
A second termination resistor (120 ohm) should be placed at one of the devices on the RS-485
line. Refer to Figure 3.3 for an illustration of a typical RS-485 system. Notice the wiring goes
from one device to another in a “daisy chain” configuration.
The 2 wires for the RS-485 connection as well as the power and ground wires are connected as
shown in Figure 3.4. This figure illustrates the connection of the Kimray Multivariable CIM and
the Kimray I/O CIM to the DACC2000. Both of the CIMs have a termination resistor which can
be installed with a jumper. Only one of the devices should have the termination resistor enabled.
RS485
DEVICE
RS485
DEVICE
RS485
DEVICE
RS485
DEVICE
DACC2000
FIGURE 3.3
DACC2000 RS-485 SYSTEM CONFIGURATION

3-3 COMMUNICATIONS
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)
KIMRAY DACC2000
PWR
GND
485+
485-
TB1
KIMRAY I/O CIM
KIMRAY MULTIVARIABLE CIM
FIGURE 3.4
DACC2000 AND KIMRAY CIM CONNECTION

COMMUNICATIONS 3-4
DACC2000 USER'S MANUAL (ENG-015 Rev. 1)