RC Systems ST-72 User manual

ST-72 User's Manual
Document: UM-1007 Revision Level A
0
INSTRUCTION MANUAL
R.C. SYSTEMS CO. INC.
MODEL ST-72 16,32,48 or 64 CHANNEL CONTROLLER
(Firmware 2.0 & later)
PHONE: [phone] FAX: [phone]
8621 HWY 6 HITCHCOCK, TX 77563
Website: http://www.rcsystemsco.com
Warning: Read & understand contents of this manual prior to
operation. Failure to do so could result in serious injury or death.

ST-72 User's Manual
Document: UM-1007 Revision Level A
1
SECTION 1 GENERAL DESCRIPTION.............................................................1
1.1 IMPORTANT SAFETY ISSUES.........................................................................1
1.2 GENERAL DESCRIPTION.................................................................................2
1.3 DATA DISPLAY SCREENS...............................................................................3
1.3.1 MAIN DATA SCREEN 3
1.3.2 24 HOUR TREND SCREEN 5
1.3.3 BAR GRAPHS SCREEN 6
1.3.4 COMBINATION SCREEN 7
1.3.5 ZONE SCREEN 8
1.4 SPECIFICATIONS .............................................................................................9
1.4.1 DC POWER SUPPLY REQUIREMENTS 9
1.4.1.1 600 WATT AC –24VDC POWER SUPPLY 9
1.4.1.2 150 WATT AC –24VDC POWER SUPPLY 9
1.4.1.3 RELAYS 10
1.4.2 AMBIENT TEMPERATURE RANGE 10
1.4.3 HUMIDITY RANGE 10
1.4.4 ALTITUDE 10
1.4.5 HOUSINGS 10
1.4.6 NON-INTRUSIVE MAGNETIC KEYPAD 10
1.4.7 APPROVALS 11
SECTION 2 BASIC OPERATION ....................................................................12
2.1MAIN MENU CONFIGURATION......................................................................12
2.2 CHANGING MENU VARIABLES USING THE KEYPAD.................................20
2.3 ALARM OUTPUTS ..........................................................................................20
2.3.1 STANDARD RELAY 1, 2, AND 3 22
2.3.1.1 A1 A2 & A3 VOTES REQUIRED 22
2.3.1.2 ACKNOWLEDGE 22
2.3.1.3 FAILSAFE 23
2.3.1.4 ZONE 1-8 23
2.3.1.5 OVERRIDE CHANNELS 1-8 23
2.3.2 HORN/PIEZO 23
2.3.2.1 A1 A2 & A3 24
2.3.2.2 ACKNOWLEDGE 24
2.3.2.3 FAILSAFE 24
2.3.2.4 PIEZO ALARM 24
2.3.3 DISCRETE RELAY 24
2.3.4 PROGRAMMABLE RELAY 25
2.4 CHANNEL CONFIGURATION ENTRY MENU.................................................25
2.4.1 CHANNEL CONFIGURATION MENUS 26
2.4.2 ALARM 1 / ALARM 2 / ALARM 3 MENU 27
2.4.2.1 SETPOINT 27
2.4.2.2 LATCHING 27
2.4.2.3 TRIP ON 27
2.4.2.4 ON/OFF DELAYS 27

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Document: UM-1007 Revision Level A
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2.4.2.5 HORN ON 28
2.4.2.6 COLOR 28
2.4.2.7 ENABLED 28
2.4.3 FAULT ALARM MENU 28
2.4.4 DATA FROM MENU TO SET INPUT SOURCE 28
2.4.4.1 SOURCE 29
2.4.4.2 MIN RAW & MAX RAW 29
2.4.4.3 FILTER SAMPLE COUNT 30
2.4.4.4 LOCAL CAL 30
2.4.4.5 MARKER MENU 31
2.4.4.6 REMOTE ID 32
2.4.4.7 ALIAS 33
2.4.4.8 INTERFACE 33
2.4.4.9 SLAVE BYTE ORDER 33
2.4.5 LINEARIZE 34
2.4.6 CONFIGURE MENU 34
2.4.6.1 INFO / MEASUREMENT NAME 35
2.4.6.2 ZERO / SPAN 35
2.4.6.3 DECIMAL POINTS 35
2.4.6.4 CHANNEL ON? 35
2.4.6.5 ZONE 35
2.4.6.6 DEADBAND 36
2.4.6.7 COPY TO CHANNEL 36
2.4.6.8 COPY TO GROUP 36
2.4.6.9 RESTORE CH. DEFAULTS 36
2.5 COMMUNICATION SETTINGS MENU............................................................36
2.5.1 COM 1-4 SETTINGS 38
2.5.1.1 FUNCTION 38
2.5.1.2 BAUDRATE 39
2.5.1.3 PARITY 39
2.5.1.4 TIMEOUT 39
2.5.1.5 POLL DELAY 39
2.5.1.6 SYMPATHY ENABLED 39
2.5.1.7 RADIO SETUP 40
2.5.1.8 SLAVE BYTE ORDER 40
2.5.1.9 WIRELESS TIMEOUT 40
2.5.2 MODBUS TCP SETTINGS 41
2.5.2.1 SLAVE BYTE ORDER 41
2.5.2.2 MASTER TIMEOUT 41
2.5.2.3 MASTER POLL DELAY 41
2.5.3 NETWORK SETTINGS 41
2.5.3.1 DHCP ENABLED 42
2.5.3.2 HOSTNAME 42
2.5.3.3 IP ADDRESS 42

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2.5.3.4 NETMASK 42
2.5.3.5 GATEWAY 42
2.5.4 TROUBLESHOOTING 42
2.5.4.1 VIEW COMM FAILURES 43
2.5.4.2 CLEAR FAILURE COUNTS 44
2.6 SECURITY MENU............................................................................................44
2.6.1 USER NAME 44
2.6.2 LOCK CODE 44
2.6.3 MODBUS LOCK CODE 44
2.7 SYSTEM MENU...............................................................................................45
2.7.1 VERSION 47
2.7.2 CONFIGURE 47
2.7.2.1 NAME 48
2.7.2.2 CONTRAST 48
2.7.2.3 DATE & TIME 48
2.7.2.4 ENABLE CHANNEL COUNT 48
2.7.2.5 DISPLAY ALARM 48
2.7.2.6 WARMUP & CAL PURGE TIME 48
2.7.2.7 ZONE SCREEN ENABLED 48
2.7.2.8 BLOCK NEGATIVE 48
2.7.2.9 RELAY REFRESH 48
2.7.3 ZONE NAMES 49
2.7.4 MIMIC MODE 49
2.7.5 SD CARD 50
2.7.5.1 CARD STATUS 50
2.7.5.2 LOGGER ENABLED 51
2.7.5.3 SAVE CONFIGURATION FILE 51
2.7.5.4 LOAD CONFIGURATION FILE 51
2.7.5.5 VIEW LOG FILE TREND 51
2.7.6 VIEW EVENT LOG 52
2.7.7 CLEAR EVENT LOG 53
2.7.8 VIEW SENSOR LIFE 53
SECTION 3 INPUT/OUTPUT BOARDS...........................................................54
3.1 MAIN I/O INTERFACE BOARD # 10-0331 ......................................................54
3.2 INPUT / OUTPUT OPTION BOARDS..............................................................55
3.2.1 OPTIONAL ANALOG INPUT BOARD # 10-0334 56
3.2.2 OPTIONAL DISCRETE RELAY BOARD # 10-0345 58
3.2.3 OPTIONAL *BRIDGE SENSOR INPUT BOARD #10-0347 59
3.2.4 BRIDGE SENSOR INPUT BOARD INITIAL SETUP 60
3.2.5 OPTIONAL 4-20mA ANALOG OUTPUT BOARD #10-0348 61
3.2.6 OPTIONAL PROGRAMMABLE RELAY BOARD # 10-0350 62
3.2.7 OPTIONAL 24VDC 600 WATT POWER SUPPLY 64
3.2.8 OPTIONAL 24VDC 150 WATT POWER SUPPLY #10-0172 65
SECTION 4 DIAGNOSTICS.............................................................................66

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4.1 STANDARD RELAYS......................................................................................66
4.2 DISCRETE RELAYS........................................................................................67
4.3 PROGRAMMABLE RELAYS...........................................................................67
4.4 ANALOG INPUTS............................................................................................68
4.4.1 VIEW INPUTS 68
4.4.2 CALIBRATE BOARD 68
4.5 ANALOG OUTPUTS........................................................................................69
4.6 PIEZO ..............................................................................................................69
4.7 LEDS ...............................................................................................................70
4.8 SERIAL PORTS...............................................................................................71
4.9 I/O BOARD CONFIGURATION........................................................................72
SECTION 5 MODBUS......................................................................................73
5.1 MODBUS TCP.................................................................................................73
5.2 MODBUS SLAVE WRITES..............................................................................73
5.3 MODBUS SLAVE REGISTER LOCATION......................................................73
5.3.1 COILS 74
5.3.2 DISCRETE INPUTS 74
5.3.3 INPUT REGISTERS 76
5.3.4 HOLDING REGISTERS 80
5.3.5 STANDARD RELAY 1 81
5.3.6 STANDARD RELAY 2 84
5.3.7 STANDARD RELAY 3 87
5.3.8 DISCRETE RELAYS 89
5.3.9 HORN/PIEZO 90
5.3.10 CHANNEL CONFIGURATION 90
5.3.11 PROGRAMMABLE RELAYS 94
SECTION 6 ENCLOSURE OPTIONS..............................................................98
6.1 ST-72PM PANEL / RACK MOUNT ENCLOSURE...........................................98
6.2 ST-72N4 NEMA 4X LARGE WALL MOUNT FIBERGLASS ENCLOSURE.....99
6.3 ST-72CP NEMA 4X COMPACT WALL MOUNT FIBERGLASS ENCLOSURE
100
6.4 ST-72XP NEMA 7 WALL MOUNT ALUMINUM ENCLOSURE......................102
6.5 ST-72 MAIN I/O & OPTION PCB FOOTPRINT DIMENSIONS AND
ENCLOSURE CAPACITIES.......................................................................................103
SECTION 7 WIRELESS OPTION ..................................................................105
7.1 RADIO SETUP MENU ...................................................................................106
7.1.1 HOP CHANNEL 107
7.1.2 SYSTEM ID 107
7.1.3 MODE 107
7.2 WIRELESS MONITOR MODE .......................................................................107
7.2.1 RADIO STATUS ALARMS - WIRELESS MONITOR MODE 108
7.2.1.1 COMMUNICATIONS ERROR 108
7.2.1.2 LOW BATTERY 109
7.2.1.3 CALIBRATIONS 109
7.3 WIRELESS MODBUS SLAVE MODE............................................................109
7.4 WIRELESS MODBUS MASTER MODE ........................................................109

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7.5 ANTENNA SELECTION ................................................................................110
7.5.1 DIPOLE AND COLLINEAR ANTENNAS 110
7.5.2 YAGI ANTENNAS 110
7.5.3 MOUNTING NEAR OTHER ANTENNAS 111
7.5.4 COAX CABLES 111
7.6 SURGE PROTECTION & GROUNDING........................................................112
7.6.1 ANTENNA GROUNDING 112
SECTION 8 WEBPAGE.................................................................................114
8.1 SYSTEM SCREEN.........................................................................................115
8.2 ZONE SCREEN .............................................................................................116
8.3 CHANNEL SCREEN......................................................................................117
8.4 EVENT LOG SCREEN...................................................................................118
8.5 CONFIGURE..................................................................................................119
8.5.1 ALARM OUTPUTS 119
8.5.2 CHANNEL CONFIGURATION 120
8.5.3 COPY CHANNELS 121
8.5.4 PROGRAMMABLE RELAYS 122
8.5.5 SYSTEM CONFIGURATION 123
8.5.6 CONFIGURATION UPLOAD/DOWNLOAD 124
SECTION 9 TROUBLESHOOTING ...............................................................125
9.1CHANNEL ERRORS......................................................................................125
9.1.1 COMM ERROR 125
9.1.2 CONFIG ERROR 125
9.1.3 I/O ERROR 125
9.2 RESET TO FACTORY DEFAULTS ...............................................................126
SECTION 10 NETWORK CONNECTION........................................................127
10.1 DIRECT CONNECTION WITH CROSSOVER CABLE OR HUB/SWITCH.....127
10.2 CONNECTING THE ST-72 TO AN EXISTING LAN.......................................128
10.3 CONNECTING THE ST-72 ON AN ISOLATED NETWORK..........................129
10.4 STATIC IP CONFIGURATION.......................................................................130
10.4.1 ST-72 STATIC IP CONFIGURATIION 130
10.4.2 WINDOWS XP STATIC IP CONFIGURATION 130
10.4.3 DYNAMIC IP CONFIGURATION 133
10.5 TESTING CONNECTIONS.............................................................................134

ST-72 User's Manual
Document: UM-1007 Revision Level A
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SECTION 1 GENERAL DESCRIPTION
1.1IMPORTANT SAFETY ISSUES
The following symbols are used in this manual to alert the user of important instrument
operating issues:
WARNINGS:
Shock Hazard - Disconnect or turn off power before servicing this instrument.
WARNING- EXPLOSION HAZARD- DO NOT REPLACE FUSE UNLESS POWER HAS
BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
WARNING- EXPLOSION HAZARD- DO NOT DISCONNECT EQUIPMENT UNLESS
POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-
HAZARDOUS.
Use a properly rated CERTIFIED AC power (mains) cable installed as per local or
national codes
A certified AC power (mains) disconnect or circuit breaker should be mounted
near the controller and installed following applicable local and national codes. If
a switch is used instead of a circuit breaker, a properly rate CERTIFIED fuse or
current limiter is required to be installed as per local or national codes. Markings
for positions of the switch or breaker should state (I) for on and (O) for off.
Clean only with a damp cloth without solvents.
Equipment not used as prescribed within this manual may impair overall safety.
!
!
This symbol is intended to alert the user to the presence of important
operating and maintenance (servicing) instructions.
This symbol is intended to alert the user to the presence of
dangerous voltage within the instrument enclosure that may be
sufficient magnitude to constitute a risk of electric shock.
!
!

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Document: UM-1007 Revision Level A
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1.2GENERAL DESCRIPTION
The R. C. Systems Co. Inc. ST-72 64 channel Controller is designed to display and control
alarm event switching for up to 64 sensor data points. It may also be set as a 16, 32 or
48 channel controller for applications needing fewer inputs. Three programmable
standard alarms with features such as ON and OFF delays, Alarm Acknowledge, along
with dedicated horn and fault relays make the ST-72 well suited for many multi-point
monitoring applications. Data may be input to the ST-72 by optional analog inputs or via
the multiple communication ports. These communication ports are programmable so
the controller can be configured with multiple Master or Slave configurations. With a
Modbus RTU slave RS-485 port configured, sending data to PCs, PLCs, DCSs, or even
other ST-72 Controllers is available. The Ethernet port allows the unit to be a
ModbusTCP Master and Slave and also provides access to the embedded webpage.
Options such as analog I/O and discrete relays for each alarm are easily added to the
addressable I2C bus. Option boards have 16 channels and therefore require multiple
boards for 64 channel applications.
In addition to traditional analog and serial methods of providing monitored values, the
ST-72 is also capable of sending and receiving wireless data.
A color 320 x 240 pixel graphic LCD readout displays monitored data as bar graphs,
trends and engineering units. System configuration is through user friendly menus or
via the internal webpage that can be accessed through the Ethernet connection built
into the main I/O Board. All configuration data is retained in non-volatile memory
during power interruptions and can also be backed up and loaded using the SD card
located to the left of the display. The ST-72 front panel is shown below in Figure1-1
displaying the Combination screen. Additional data screens are shown in section 1.

ST-72 User's Manual
Document: UM-1007 Revision Level A
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16, 32, 48, 64 Channel
Graphic Display & Alarm Controller
SD Card
Ch07
PCTLEL
Measurement Name
50
Min:0 Avg:32Max:95
Zero:0 Span:100
27 24 21 18 15 12 9 6 3m
100
80
60
40
20
0
Standard
Relay 1 Standard Relay 2 Standard Relay 3 Fault Relay Horn Relay
!
*DO NOT REMOVE
WHEN LED IS ON
Alarm
Reset
Next Edit
Menu
72-1020
Serial No.
2400 Counts
Figure1-1
1.3DATA DISPLAY SCREENS
The ST-72 Controller offers five distinct graphic displays for depicting the monitored
data. These are Main Data, 24 Hour Trend, Bar Graphs, Zone and Combination Screens.
Pressing
Menu
from any of these display screens will bring you to the Main Menu.
Pressing
Edit
from the Main Data, 24 Hour Trend or Combination Screens will skip the
Main Menu and bring you directly to the Channel Configuration Menu for the channel
that is selected.
1.3.1 MAIN DATA SCREEN
The ST-72 Main Data screen shown below (Figure1-1) displays all active channels at
once. It is capable of displaying 16, 32, 48 or 64 channels depending on the controller’s
configuration. This screen displays measurement name and uses a bar graph and
colored cells that flash with new alarms to indicate alarm conditions. Once the alarms

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have been acknowledged by an operator the cell will remain the appropriate color but
will stop flashing, showing the alarm has been acknowledged. Utilizing the Display
Alarm feature in the Systems Configuration menu allows new alarms to always force the
LCD to the Main Data screen. This is useful for applications requiring channels with new
alarms to be displayed.
While in the Main Data screen, use ///to highlight any cell and press
Edit
to go directly to that channel’s configuration menu or press
Next
twice to scroll
through that channel’s individual data screens. The exploded channel 38 in the example
below (Figure 1-2) indicates it is the channel selected and unused channels are grayed
out when turned off.
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
% Oxygen
Measurement
Measurement
ppm H2S
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Ppm H2S
Measurement
% Oxygen
Measurement
Measurement
Ch. 32 off
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
% Oxygen
Measurement
Measurement
Measurement
Measurement
Ch. 48 off
% Oxygen
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
% Oxygen
% Oxygen
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement Name
46PCTLEL 38
Figure 1-2
Main Data Screen (64 Ch. Mode)