Xytronix Research & Design ControlByWeb X-16s User manual

X-16s™ Users Manual
X-16s User Manual Revisions
Revision Description
1.0 Initial release
1.1 Added further information about entering slope and offset settings
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X-16s™ Users Manual Introduction
Section 1: Introduction
The X-16s™ e pansion module is used in conjunction with the X-600M™ controller. The X-16s has
eight, 0-5V, analog inputs. The X-16s employs a 24-bit A/D converter and can make both single or
differential voltage measurements. A 5.0V reference output can be used to power potentiometers or
other resistance sensing sensors. The X-16s is ideal for measuring precision analog voltages in
industrial environments. One or more X-16s e pansion modules can be connected to a X-600M control
module with a ribbon cable. The ribbon cable provides both power and communications.
The X-600M is a multifunction web-enabled industrial I/O controller. It performs control, logic, and
monitoring functions similar to that of a Programmable Logic Controller (PLC). However, unlike a PLC,
the X-600M is designed for web-based applications from the ground up. No add-on software or
hardware is required. The X-600M can be fully configured, programmed and tested using its built-in web
server. The web setup pages are intuitive and easy to use and do not require special programming skills.
The X-600M together with the X-16s provide an easy, fle ible and reliable way to monitor sensors and
devices over a network. The X-16s is suitable for use with pressure sensors, flow meters, current
transducers and position sensors – anywhere where precision analog voltage sensing is required.
The X-16s' inputs can be used to trigger email alerts based on a voltage level and can be used to control
the relay contacts of other ControlByWeb™ products (such as WebRelay™) that are located at a remote
location.
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Introduction X-16s™ Users Manual
1.1 Features
•Eight analog input channels (can be configured as eight single ended inputs, four differential inputs, or a
combination of both
•Full 0 to 5V input range (input range can be scaled by using e ternal resistors)
•24-bit, ∑∆ ADC
•10uV resolution
•4-20mA inputs (using e ternal 250-ohm resistors)
•Removable terminal connectors (included) simplify making wiring connections
•Apply a different slope and offset for each raw voltage reading (via X-600M)
•Built-in web server (via X-600M) provides simple, web based configuration and control
•Custom applications can monitor the X-16s (via X-600M) with simple XML formatted status
•Modbus/TCP protocol (via X-600M) provides interoperability with devices and software from other
manufacturers
•Set high/low alarms (via X-600M) for analog inputs which can send out alert emails and control remote
ControlByWeb devices.
1.2 The X-16s onnectors & Indicators
Analog Inputs
The X-16s has eight analog inputs. Four analog ground (Agnd) terminals provide convenient connection
points for making sensor wiring connections. The X-16s can be setup to input either eight single-ended
analog signals, four differential analog signals, or a combination both.
Reference Output
Two 5.0V reference terminals can be used to power resistance sensing sensors such as potentiometers
and bridge sensors. The reference output can provide up to 50ma (the two reference terminals are
connected together internally). When resistance sensors are e cited (powered) from the 5.0V reference
output, the measurement will be ratio-metric with the reference. With ratio-metric measurements the
absolute voltage (and error) of the reference is removed from the measurement accuracy.
Expansion Bus
The e pansion bus allows for a family of e pansion modules to be connected directly to the X-600M
without the need for an Ethernet switch. The cable can be a daisy chain with multiple connectors. The
ribbon cable e pansion bus provides both power and communications connections.
Power Supply
The e pansion bus can provide up to 1.7 Amps for powering up to 32 e pansion modules; however, the
ma imum number of e pansion modules depends on the module type and power source attached to the
X-600M.
The X-16s employs modern switch-mode power supply. With this type of power supply the current draw
decreases as the voltage increases; therefore, you can add more e pansion modules by using a 24-volt
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X-16s™ Users Manual Introduction
power supply than you can with a 12-volt power supply. See the X-600M User Manual for more details.
Indicators
The green Power LED indicator is illuminated whenever the module is powered. To identify the module
during installation, the X-600M can send a blink command which will cause the power LED to blink for
three seconds.
1.3 Part Numbers and Accessories
Accessory Description Part Number
X-16s 8-channel analog input module, 0-5VDC inputs X-16s
Spare onnector 14-position, screw-terminal connector X-1803691
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Installation and Connections X-16s™ Users Manual
Section 2: Installation and onnections
Installation consists of mounting the X-16s and connecting it to an X-600M controller with a 10-conductor
ribbon cable. Programming and testing is done by using a web browser to configure the web pages,
inputs, and outputs for your specific needs.
2.1 Installation Guidelines
•This unit must be installed by qualified personnel.
•This unit must not be installed in unprotected outdoor locations.
•This unit must not be used for medical, life saving purposes, or for any purpose where its failure
could cause serious injury or the loss of life.
•This unit must not be used in any way where its function or failure could cause significant loss or
property damage.
2.2 Mounting
X-16s can be mounted to a standard (35mm by 7.55mm) DIN-Rail. Normally e pansion modules are
mounted to the left side (embossed logo side of the enclosure) of the X-600M controller so that the
ribbon cable doesn't cover the power connector. The X-16s should be located in a clean, dry location
where it is protected from the elements. Ventilation is recommend for installations where high ambient
air temperatures are e pected to be high. See Appendix D: Mechanical Information for additional
mechanical details.
2.2.1 DIN-Rail Mounting
Attach the X-16s to the DIN-Rail by hooking the top hook on the back of the enclosure to the DIN-Rail
and then snap the bottom hook into place. To remove the X-16s from the DIN-Rail, use a flat-head
screwdriver. Insert the screw driver into the notch in the release tab and pry against the enclosure to
release the bottom hook.
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X-16s™ Users Manual Installation and Connections
2.3 Making onnections
AUTION: Make sure the power is shut off before making connections.
AUTION: Miswiring or misconfiguration could cause permanent damage to the X-16s, the
equipment to which it is connected, or both.
A removable terminal connector is provided for making the power connections. The correct wiring
procedure is as follows:
1. Make sure power is turned off.
2. Remove the terminal connector from the X-16s and make wiring connections to the terminals.
This technique avoids stressing the internal components while torquing the screws.
3. Reconnect the terminal connector.
4. Apply power.
It is recommended that any load (device to be controlled) not be connected to the e pansion modules
until after the X-600M has been configured and tested. By doing this, wiring and configuration mistakes
will not cause the load device to turn on une pectedly.
Make certain the wires are properly inserted into to the terminals and that the screws are tight.
Wire Specification:
Use wire rated for 75ºC (min) for connections to the terminal blocks
Connector Specifications:
Type: 14-position, removable, 3.81 mm pitch
Connection wire: Use wire rated for 75ºC (min) for connections to the terminal blocks
Stripping Length: 7mm
Connection capacity: 1.5mm2 stranded, 1.5mm2 solid
Conductor minimum: 30AWG (UL/CUL)
Conductor ma imum: 14 AWG (UL/CUL)
Conductor Type: Copper
Tightening torque: 0.22 Nm (min), 0.25 Nm (ma )
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Installation and Connections X-16s™ Users Manual
12-Pin onnector Pinout
Terminal Description
+5Vref +5.0V reference output, 50mA ma imum
+5Vref +5.0V reference output, internally connected to above
Ain1 Analog Input 1 (0-5V) or Differential Ain1+
Ain2 Analog Input 2 (0-5V) or Differential Ain1-
Agnd Analog Ground
Ain3 Analog Input 3 (0-5V) or Differential Ain3+
Ain4 Analog Input 4 (0-5V) or Differential Ain3-
Agnd Analog Ground
Ain5 Analog Input 5 (0-5V) or Differential Ain5+
Ain6 Analog Input 6 (0-5V) or Differential Ain5-
Agnd Analog Ground
Ain7 Analog Input 7 (0-5V) or Differential Ain7+
Ain8 Analog Input 8 (0-5V) or Differential Ain7-
Agnd Analog Ground
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X-16s™ Users Manual Installation and Connections
2.4 Analog Input onnections
The analog inputs must be in the range of 0.0V to 5.0V. Analog sensors that provide an output voltage
in the range of 0 to 5 volts can be connected directly to the X-16s module. Voltages outside this range
will be clamped internally by the X-16s to 0.0 and 5.0V respectively. The inputs are internally protected
with a 1K ohm resistor and a pair of over-voltage steering diodes.
For some applications it may be necessary to add e ternal resistors to scale the input to a value
compatible with the X-16s. In the case of a sensor whose output levels are higher than 5 volts, a simple
voltage divider can be used to scale down the output. The following diagram shows a voltage divider
circuit for a 0-10V sensor. In the e ample resister values for R1 and R2 are chosen so that Vout will
have a 0 to 5 volt range.
Generally, you can choose a 10K Ohm resistor for R2 and then calculate the value of R1 using the
following formula.
Vout = Vin * (R2 / (R1 + R2))
To determine the proper resister value to use in the e ample above, use the ma imum output of the
sensor (10 VDC) as Vin in the equation, the ma imum input value of the X-16s (5 VDC) as Vout, and
R2=10K Ohms. Solving for R1 gives R1=10K ohms.
R1=10K, R2=10K
As another e ample, if the ma imum output voltage of the sensor is 15VDC, choose R2=10K. Solving
for R1 gives R1=20K ohms.
The input bias current of the X-16s is relatively low, such that the X-16s will work with input circuits with
an impedance of up up to 10K ohms with negligible error.
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Installation and Connections X-16s™ Users Manual
The slope and offset for the voltage divider must calculated and entered into the setup pages of the X-
600M. The general term for the Slope is:
Slope = (Y2-Y1)/(X2-X1)
For the 10V input e ample:
Slope = (10Vin – 0Vin)/(5Vout – 0Vout) = 2V/V
Once the slope is determined, calculate the offset using the Y=mX+b linear equation where b is the
offset.
0Vout = 2V/V * 0Vin + Offset
Offset = 0V – (2V/V * 0V) = 0
To configure the X-600 with the new slope and offset values, navigate to the I/O > Analog Input screen.
Click the Edit button of the desired analog input channel. Enter the new Slope, Offset and Units values.
Click Update to submit the changes.
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X-16s™ Users Manual Installation and Connections
2.4.1 urrent Sensors
Some senors generate an output current instead of an output voltage. To use these sensors, a load
resistor is connected in the current sensor loop. The load resistor generates a voltage proportional to
the sensor current which is in turn sensed by the X-16s. The following diagram shows how to connect a
4 to 20mA sensor to the X-16s.
With a 250-ohm load resistor, a 4 to 20mA sensor will generate a 1.0 to 5.0V output which can be
directly connected to the X-16s. A voltage measurement of less than 1.0V indicates the current loop is
open or that something is wrong with the sensor. Ensure the resistor wattage is appropriate to handle
the power dissipation. A 250-ohm resistor with 20mA flowing thru it will generate 0.1W. The
measurement accuracy will be no better than the resistor's accuracy. In general use a 1% or a 0.1%
resistor.
When making connections with current sensors it is very important to consider the lead dress. The
e ample above shows the voltage sense connections made with a 4-wire Kelvin connection. This
technique uses separate pairs of current-carrying and voltage-sensing wires to make accurate
measurements. The goal is to prevent current from flowing in the sense wires and terminals of the X-
16s. If current is allowed to flow in the Agnd connections of the X-16s, the current will generate a small
offset voltage due to the resistance of the wires and terminals. The offset voltage becomes a source of
error. This is especially problematic where the X-16s is used to measure multiple 4-20mA sensors.
When connecting more than one 4-20ma sensor consider using a “star” or single point ground topology.
If the output current from one sensor changes or affects the measurements of other sensors (crosstalk),
you will need to re-consider your connections.
Loop powered current transmitters normally require 7 to 8 Volts across their terminals in order to work
properly. With a 250-ohm resistor the load resistor will drop an additional 5-Volts. Allow 2-volts or so for
voltage drops across the wiring, especially if the wires are small or long. In this e ample make certain
your loop power source is at least 15-Volts (8+5+2).
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Installation and Connections X-16s™ Users Manual
2.4.2 Differential Inputs
The differential input mode can be used with sensors that have two analog outputs that are referenced
to each other instead of ground. When making differential voltage measurements, the X-16s is
programmed to use a pair of inputs (2) to make a single differential measurement. With differential
inputs you must make certain both inputs are within the common mode range (0-5V) of the input
amplifiers. Normally this means you must provide some sort of input bias. If no input bias is provided,
even though the differential voltage is correct the absolute voltages may drift into or beyond the 0-5V
power rails of the amplifiers and will produce erratic measurements.
The illustration below shows the connections for a Wheatstone bridge sensor with two output signals.
The outputs are connected to Ain1 and Ain2. The X-16s must be programmed for differential mode on
“Ain1”. The analog measurement will be made by the voltage difference between the two inputs (Ain1-
Ain2). For differential measurements the measurement range is ±5V. For e ample, if Ain1 is 2.0V and
Ain2 is 3.0V, the differential measurement will be -1.0V. Note however, the absolute voltage of both
inputs must be in the range of 0-5V for the input amplifiers to work. For e ample:
Ain1 Ain2 Measurement
+5V 0V +5.0V
0V +5V -5.0V
When the differential input mode is selected for a pair of inputs, the differential data is output on both
channels. For the e ample above, Ain1 = Ain2.
In the illustration below the bridge is e cited (driven) by the 5.0V reference output. Notice also that the
bridge provides the necessary input bias.
The low input bias and high resolution inputs of the X-16s together with the reference output make the
X-16s workable with many bridge sensors without using a preamplifier or other circuitry.
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X-16s™ Users Manual E ample Applications
Section 3: Example Applications
3.1 Monitor Height, Position, etc. over an IP network
The illustration below shows an e ample of using the X-16s with a potentiometer position sensor.
Potentiometers are in essence a variable resistor with three connections. Typically the +5Vref reference
from the X-16s is used to apply power across the potentiometer. The wiper terminal of the potentiometer
is connected to any of the eight analog inputs.
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E ample Applications X-16s™ Users Manual
3.2 Monitor Flow, Distance, or Speed with a 4-20mA Sensor
Signal conditioners are available for measuring flow, distance, speed and many other industrial
processes. Many popular signal conditioners employ a 4-20mA analog output. With a simple shunt
resistor these transducers can be connected directly to the X-16s as described in Section 2.4.1 above.
Once the components are properly wired, the X-600M must be configured with the proper Slope and
Offset to convert the voltage measurement into engineering units such as CFS (flow), Meters (distance)
or Meters per Second (speed). For linear transducers this is normally done with a Y=mX+b equation.
Engineering Value = (Measured Value * Slope) + Offset
The documentation for the sensor must be consulted for the calculations. For e ample, if the range of a
laser rangefinder is 1Meters to 100Meters the transducer will output 4mA at 1M and 20mA at 100M. By
default the X-16s makes measurements in units of Volts. To convert this measurement to engineering
units the voltage measurement must be processed with a Slope setting. The general term for the Slope
is:
Slope = (Y2-Y1)/(X2-X1)
To determine the slope, first determine the minimum and ma imum voltage range that will be applied to
the X-16s. In this e ample the transducer will output 4mA at 1M and 20mA at 100M. This can be
converted to voltage using Ohms Law V=IR.
Vmin = 4mA * 250 Ohms = 1V
Vma = 20mA * 250 Ohms = 5V
To calculate the slope:
Slope = (100M – 1M)/(5V – 1V) = 24.75 Meters/Volt
Once the slope is determined, calculate the offset using the Y=mX+b linear equation where b is the
offset.
1M = 24.75M/V * 1V + Offset
Offset = 1M – (24.75M/V * 1V) = -23.75M
Configure the X-600M with the new settings as shown in Section 2.4.
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X-16s™ Users Manual E ample Applications
3.3 Monitor Motor Load urrent
The illustration below shows an e ample of using the X-16s in conjunction with a current transducer to
measure the current draw of a motor.
This e ample uses a current sensor that will measure current up to 20 Amps AC. The sensor produces
a linear 0-5VDC output that it can be connected directly to one input of the X-16s analog module. The
slope is calculated and entered into the setup pages of the X-600M. The slope calculation is given
below:
Slope = (Y2-Y1)/(X2-X1)
Slope = (20Amps – 0 Amps)/(5 VDC – 0 VDC) = 4 Amps/V
Configure the X-600M with the new settings as shown in Section 2.4.
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E ample Applications X-16s™ Users Manual
3.4 Level Alarm at a Remote Location
The illustration below shows an e ample of using the X-16s to sense water (or other) liquid level and to
sound an alarm at a remote location using a WebRelay module. This e ample is similar to the
potentiometer e ample above e cept that the X-600M is configured to control a remote device. Each
analog input can be configured to send messages to a remote ControlByWeb device when a high or low
threshold is reached. In this e ample the X-600M is configured to send a remote message to sound an
alarm when a certain level is e ceeded.
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X-16s™ Users Manual E ample Applications
3.5 Dry ontact Switch
The illustration below shows an e ample of using the X-16s to monitor the status of a gate or door over
an IP network. The status of the device is detected with a simple switch. These type of sensors are
called “dry contacts” in that the device output is a bare switch with no power source. In this e ample a
voltage source for the switch is provided by the +5Vref output. A pull-down resistor must be provided to
drive the input to a known state (0V) when the switch is open. In this e ample the measurement voltage
will be 5.0V when the switch is closed and 0-V when the switch is open. A conditional event can be
defined to detect whether the input voltage is above or below a 2.5-V threshold to detect the state of the
switch.
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Configuration and Setup X-16s™ Users Manual
Section 4: onfiguration and Setup
4.1 Setup Example
The Quick Start Demo
After making the power and Ethernet connections, the X-600M can automatically scan for the presence
of any ControlByWeb™ Ethernet devices (on the same sub-net) and also for any e pansion modules
connected to the X-600M via the ribbon-cable connector. It also automatically creates a dashboard web
page and populates it with all of the resources (components) supported by the Ethernet devices and
e pansion modules. This makes it easy to start e perimenting with the web page's user interface and to
try out the relays and sensors.
To quickly add a device do the following:
1. Click on the Devices menu tab to pull up the De ices O er iew page. Then click on the Find New
Devices button to scan the e pansion bus and the local network for ControlByWeb devices and
e pansion modules.
2. In this e ample we are going to add an X-16s analog expansion module. Click the Add button for the
X-16s.
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X-16s™ Users Manual Configuration and Setup
3. In the Select column, click the checkbo es of the I/O components you would like to configure and
select the reate Device Widget checkbo (This will display the status of the I/O on the Dashboard).
Click Add hecked I/O to submit these changes.
4. Click ommit hanges - Once clicked, the X-600M begins to monitor the newly added device.
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Configuration and Setup X-16s™ Users Manual
5. On the main menu, click the View Dashboards menu tab. The View Dashboards page shows a
display similar to what users will see when accessing the X-600M's control page. The measurement data
for all eight analog inputs should be shown. Use this page to test and debug the dashboards, panels,
widgets and components in real time. A pull-down menu allows access to other dashboards. Within
minutes you can e perience the power and fle ibility of the dashboard's user interface and
e periment/test the buttons, sliders, and data entry bo es to meet your needs for your specific
application.
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