DUALCON 6 Product Manual

DUALCON-6 USERS GUIDE
DUALCON-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.
Industrial Interface
This document may not be reproduced in any way without the prior written
permission of the company.
June 2007
IIG-010902 Page 1
CONTENTS
1. INTRODUCTION ____________________________________ 3
1.1 Hardware Features _________________________________ 3
1.1.1 Isolation Details __________________________________ 3
2. UNPACKING________________________________________ 3
3. CONNECTIONS _____________________________________ 4
4. CONFIGURING THE DUALCON ______________________ 5
4.1.1 Voltage Input: ___________________________________ 6
4.1.2 Current Input ____________________________________ 7
4.1.3 Millivolt (mV) Input ______________________________ 8
4.1.4 Potentiometer Input _______________________________ 9
4.1.5 Thermocouple Input______________________________ 10
4.1.6 RTD Input _____________________________________ 11
4.1.7 Output Configuration_____________________________ 12
5. CALIBRATING THE DUALCON ______________________ 13
6. INSTALLATION ____________________________________ 14
7. TROUBLESHOOTING_______________________________ 15
7.1 Incorrect Reading _________________________________ 15
7.2 Sensor Failure ____________________________________ 15
8. SPECIFICATIONS ( @ 25°C) _________________________ 16
Industrial Interface Ltd, Signal House, Unit 15, Alstone Lane Trading Estate
Alstone Lane, Cheltenham, Gloucestershire, GL51 8HF
Tel: 01242 251794, Fax: 01242 571683
[email protected]
www.industrialinterface.co.uk
Page 2 IIG-010902
1. INTRODUCTION
1.1 Hardware Features
The DUALCON-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 on either of 2 analogue outputs.
The unit can be powered by any DC voltage between 16 and 36Vdc or 18 and
32Vac. For mains AC voltage the DUALCON-3 is available which can be
powered from any supply from 90Vac to 264 Vac at 50 or 60Hz.
The instrument is packaged in a very compact 17.5mm wide enclosure which can
be mounted on standard TS35 DIN-rail.
1.1.1 Isolation Details
The DUALCON-6 has full 3 port isolation of 1000V between the Input Stage,
Output Stage 1, Output Stage 2 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 Dualcon-6 Isolating Signal Converter

1 Dualcon-6 User Guide
If the instrument has been factory configured 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 configuration which is 4-20mA input and 2, 4-
20mA source outputs. Please check that the details on the side label are correct,
especially the power supply voltage.
If re-configuration is required please refer to Section 4 of this manual.
IIG-010902 Page 3
3. CONNECTIONS
The DUALCON is housed in a compact DIN rail mounting enclosure, with 12

terminals, arranged in 4 rows of 3 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 together with the second analogue output, and the power supply and
first analogue output are on the top terminals.
The diagram below shows how to connect all the different input, output and
power supply types.
2 16-36Vdc / 18-32Vac
1
0V
PSU
9 +ve
2 1 x 24V Supply
7 - ve 0-10V 0(4)-20mA
4-20mA Sink
Voltage Source Current Source Current Sink
OUTPUT 1
9 7 x
125R to 1K
2 Wire RTD 2 Wire Pot
5 +ve
Input: mA, Volts, mV, T/C
4
- ve
INPUT OUT2 2-wire
transmitter
3 24V Tx Supply 4-20mA Sink

5 4 12
6 1K to 100K
3 Wire RTD 4 Wire RTD 3 Wire Pot
INPUT OUT2
1 +ve
24V Tx Supply
10 - ve 0-10V 0(4)-20mA
3 6 10 4-20mA Sink
Voltage Source Current Source Current Sink
Page 4 IIG-010902
4. CONFIGURING THE DUALCON
! WARNING !
DO NOT OPEN UNIT OR ADJUST SWITCHES WITH
! POWER SUPPLY, INPUT OR OUTPUT CONNECTED
The DUALCON is an extremely versatile device which can support many different
types of input. The unit is configured by turning the power off, selecting the
internal switch settings required and turning the power back on.
To open the DUALCON, 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.
Press here gently
There are 4 switch banks, S1, S2, S3 and S4, located inside the DUALCON as
shown below:
ON = 1
Switch S3
1 12
OFF = 0
Switch S4 10 11 12
1 12 Switch 10 is OFF
Switch S2 Switch 11 is ON
1 12 Switch S1 Switch 12 is OFF
1 12
Switch S1 and S2 configure the input type and range, and switch S3 and S4
configure the output types, ranges 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.
IIG-010902 Page 5
4.1.1 Voltage Input:
Select the range from the table below and set Switch S1 to the required values.
Voltage Switch S1
Range
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
0-4V 0 0 1 0 0
0-5V 0 1 0 0 0
0-7.5V 1 0 0 0 0
0-8V 0 0 1 1 0
0-10V 0 1 0 1 0
0-15V 1 0 0 1 0
0-20V 0 1 1 0 0
0-30V 1 0 1 0 0
0-40V 0 1 1 1 0
1-5V 0 1 0 0 1
-5 to +5V 1 1 0 0 1
-10 to +10V 1 1 0 1 0 1 0 0 1 1 0 0
Then select the required setting from the table below for switch S2
Switch S2
Voltage Range
1 2 3 4 5 6 7 8 9 10 11 12
0-30V & 0-40V

Ranges 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
! WARNING !
Please note that PC Software is available to provide information on

switch settings for your input and output requirements.
Page 6 IIG-010902
4.1.2 Current Input
Switch S1
mA Range
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
0-4mA 0 0 1 0 0
0-5mA 0 1 0 0 0
0-8mA 0 0 1 1 0
0-10mA 0 1 0 1 0
0-15mA 1 0 0 1 0
0-20mA 0 1 1 0 0
0-30mA 1 0 1 0 0
4-20mA 0 1 1 0 1
4-40mA 0 1 1 1 1
4-30mA 1 0 1 0 1
-5 to +5mA 1 1 0 0 1
-10 to +10mA 1 1 0 1 0 0 0 0 1 1 1 0
Switch S2
mA Range
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
! WARNING !

IIG-010902 Page 7
4.1.3 Millivolt (mV) Input
Switch S1
mV Range
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
0-100mV 0 0 1 0
0-125mV 0 1 0 0
0-150mV 1 0 0 0
0-200mV 0 0 1 1
0-250mV 0 1 0 1
0-300mV 1 0 0 1
0-500mV 0 1 1 0
0-600mV 1 0 1 0
0-1000mV 0 1 1 1
0-1200mV 1 0 1 1
-125 to +125mV 1 1 0 0
-125 to +1000mV 1 1 1 1 0 0 0 1 1 1 0 0
And then select the required setting from the table below for switch S2
Switch S2
mV Range
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
Bipolar Ranges
(e.g.
-125 to +125mV) 0 1 0 0 1 0 1 0 0 0 0 0
! WARNING !

Page 8 IIG-010902
4.1.4 Potentiometer Input
Potentiometer Switch S1
Input
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
2 Wire 0-500R 0 0 1 0
2 Wire 0-625R 0 1 0 0
2 Wire 0-750R 1 0 0 0
2 Wire 0-1K 0 0 1 1 0 0 0 1 1 1 0 1
3 Wire from
0-1K to 0-100K 0 0 0 0 0 1 0 1 1 1 1 0
Potentiometer Switch S2
Input
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
! WARNING !

IIG-010902 Page 9
4.1.5 Thermocouple Input
Switch S1 for Thermocouple Input

Temperature Range in °C Switch
KJRSNE 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 to 200 400 to 600 0 to 100 0 0 0 1
0 to 400 400 to 800 0 to 200 0 0 1 0 T/C
0 to 800 400 to 1200 0 to 400 0 0 1 1 Type
0 to 125 400 to 525 -50 to 50 0 1 0 0 0 0 0 K
0 to 250 400 to 650 -50 to 100 0 1 0 1 0 0 1 J
0 to 500 400 to 900 -50 to 200 0 1 1 0 0 1 0 R
0 to 1000 400 to 1400 -50 to 400 0 1 1 1 0 1 1 S
0 to 150 400 to 550 -100 to 50 1 0 0 0 1 0 0 N
0 to 300 400 to 700 -100 to 100 1 0 0 1 1 0 1 E
0 to 600 400 to 1000 -100 to 200 1 0 1 0 1 1 0 B
0 to 1200* 400 to 1600 -100 to 400 1 0 1 1 1 1 1 T
0 to 175 400 to 575 -200 to 50 1 1 0 0
0 to 350 400 to 750 -200 to 100 1 1 0 1
0 to 700 400 to 1100 -200 to 200 1 1 1 0
0 to 1400** 400 to 1800 -200 to 400 1 1 1 1 0 0 0
Linearisation ON 0
Linearisation off 1
* n/a for types N and E CJC ON 0

** n/a for types K, J, N and E CJC off 1
Switch S2
Thermocouple
1 2 3 4 5 6 7 8 9 10 11 12
All Ranges 0 1 0 0 1 1 1 0 0 0 0 0
! WARNING !

Page 10 IIG-010902
4.1.6 RTD Input
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 to 400 0 0 1 0
0 to 800 0 0 1 1
-50 to 50 0 1 0 0
-50 to 150 0 1 0 1
-50 to 250 0 1 1 0
-50 to 350 0 1 1 1
-100 to 50 1 0 0 0
-100 to 100 1 0 0 1
-100 to 200 1 0 1 0
-100 to 400 1 0 1 1
-200 to 200 1 1 0 0
-200 to 400 1 1 0 1
-200 to 600 1 1 1 0
-200 to 800 1 1 1 1 0 0 1 0 0
RTD linearisation ON 0 PT100 0

RTD linearisation off 1 PT1000 1
RTD 2 or 4 wire 0
RTD 3 wire 1
And then select the required setting from the table below for switch S2
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
4 Wire RTD 0 1 0 0 0 0 0 1 0 1 0 0
! WARNING !

IIG-010902 Page 11
4.1.7 Output Configuration
Select the range for Output 1 from the table below and set Switch S3 to the
required values.
Switch S3 - Output Configuration
1 2 3 4 5 6 7 8 9 10 11 12
0 1 0 1 0 mA Source 0 Normal 0 1
1 0 1 0 0 mA Sink 1 Inverted o/p
0 1 0 1 1 Voltage
0 Buttons Disabled High Burnout 0

1 Buttons Enabled Low Burnout 1
4-20mA / 2-10V 0 0
Output value if fault on input signal 0-20mA / 0-10V 0 1
0-10mA / 0-5V 1 0
Front panel buttons can be disabled to allow 2-10mA / 1-5V 1 1
tamper-proof operation of the unit
Examples:
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 1 0 0
0-20mA Source 1 0 1 0 1 0 0 0 0 1 0 1
0-10V 1 0 1 0 1 1 0 0 0 1 0 1
4-20mA Sink 1 1 0 1 0 0 0 0 0 1 0 0
Repeat the process for Output 2 using the table below for switch S4:
Switch S4 - Output 2 Configuration
1 2 3 4 5 6 7 8 9 10 11 12
1 0 1 0 1 0 mA Source 0 Normal 1
1 0 1 0 0 mA Sink 1 Inverted o/p
0 1 0 1 1 Voltage
Normal 0
High Burnout 0 Square Root 1
Low Burnout 1
4-20mA / 2-10V 0 0
Output value if fault on input signal 0-20mA / 0-10V 0 1
0-10mA / 0-5V 1 0
2-10mA / 1-5V 1 1
! WARNING !

Page 12 IIG-010902
5. CALIBRATING THE DUALCON
When the unit is shipped the DUALCON 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 2 x 4-20mA source outputs.
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 adjust mode 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’s for both channels:
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:
LED CH1 LED CH2 Mode Action

Apply full scale input.
Green Green Normal Press and release both buttons together to
enter output 1 span mode
Output 1 Press raise / lower buttons to adjust
RED Green Span output 1 value. Press and release both
Adjust buttons together to return to normal mode
Apply zero scale input
enter output 1 zero mode
YELLOW Green Zero output value. Press and release both
Apply full scale input.
enter output 2 span mode
Green RED Span output 2 value. Press and release both
Apply zero scale input
enter output 2 zero mode
Green YELLOW Output 2 Press raise / lower buttons to adjust
IIG-010902 Page 13
Zero output 2 value. Press and release both

Green Green Normal Use product
The unit is now calibrated and ready for use.
Note: The unit will retain the new settings on power down.
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 DUALCON. Note that this is not always easy to achieve, especially if the
DUALCON is mounted in a warm cabinet. An altenative method is to use an ice-
point reference and a mV source.
6. INSTALLATION
The DUALCON’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 DUALCON 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 airflow 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.
Page 14 IIG-010902
7. TROUBLESHOOTING
The DUALCON has some built in self diagnostic functions. If the LED’s on the
front panel are flashing then the fault mode can be found by counting the number
of flashes between gaps and using the table below to locate the problem.
No of Nature of Fault Corrective Action

Flashes
0 Unit Working – no suspected Check Wiring and switch
(Green On) fault settings
2,3,4,5,6,8,9, Hardware Error, extreme Switch off unit, check switch
10,11,12 noise, poor supply settings, and wiring, and retry.
Green If still faulty please contact
supplier
7 Green RTD / Thermocouple Repair RTD, T/C or wiring
burnout
3 or 4 Red Span point is too close to Change input span value and
zero point retry
3 or 4 Zero point is too close to Change input zero value and
Yellow span point retry
No LED Power Failure Check supply lines and voltage
7.1 Incorrect Reading
• Check that Unit is configured 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.
7.2 Sensor Failure
• Check that sensor wiring is correct.

• Check Thermocouple polarity.
• Check that all RTD leads are connected to correct terminals.
• Check that the DUALCON is configured 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 not out of range.
IIG-010902 Page 15
8. SPECIFICATIONS ( @ 25°C)
Operating Temperature 0 to 55 °C
Operating Altitude Sea Level to 2000m
Humidity 0-90% RH
Power Requirements
DC Supply 16 to 36Vdc
AC Supply 18 to 32Vac
Current Consumption 95mA ±5% @ 24Vdc (20mA in & out)
120mA ±5% @ 24Vdc (maximum load)
200mA ±5% @ 16Vdc (maximum load)
280mA for 75ms on 24Vdc power up
Transmitter Power Supply 21V to 28V @ 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 Outputs.
The unit can also withstand transients of 2.5kV for 50 µsecs.
Dimensions 114.5 mm x 99mm x 17.5mm (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. 115g
EMC BS EN61326
LVD Standards EN61010-1
Installation Category (IEC 664) II
Pollution Degree (EN61010-1) 2
Equipment Class (IEC 536) II
Page 16 IIG-010902

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DUALCON-6 USERS GUIDE

1.1 Hardware Features

The DUALCON-6 is a universal input Isolating Signal Converter. It can accept

1.1.1 Isolation Details

The instrument comes with the following items as standard:

1 Dualcon-6 Isolating Signal Converter

If re-configuration is required please refer to Section 4 of this manual.

The DUALCON is housed in a compact DIN rail mounting enclosure, with 12

3 24V Tx Supply 4-20mA Sink

4. CONFIGURING THE DUALCON

Press here gently

4.1.1 Voltage Input:

0-30V & 0-40V

All other Ranges

Please note that PC Software is available to provide information on

4.1.2 Current Input

Please note that PC Software is available to provide information on

4.1.3 Millivolt (mV) Input

Please note that PC Software is available to provide information on

4.1.4 Potentiometer Input

Please note that PC Software is available to provide information on

4.1.5 Thermocouple Input

Switch S1 for Thermocouple Input

* n/a for types N and E CJC ON 0

Please note that PC Software is available to provide information on

4.1.6 RTD Input

RTD linearisation ON 0 PT100 0

Please note that PC Software is available to provide information on

4.1.7 Output Configuration

0 Buttons Disabled High Burnout 0

Please note that PC Software is available to provide information on

5. CALIBRATING THE DUALCON

LED CH1 LED CH2 Mode Action

Zero output 2 value. Press and release both

The unit is now calibrated and ready for use.

When the unit is used to convert a thermocouple input it is important when

The use of bootlace ferrules is recommended on wiring terminations.

Do not exceed terminal torque rating of 0.4 Nm – use an appropriate screwdriver.

No of Nature of Fault Corrective Action

7.1 Incorrect Reading

• Check that Unit is configured for the correct Sensor

7.2 Sensor Failure

• Check that sensor wiring is correct.

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