Altronic DE-4000 Installation Instructions Manual
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Altronic DE-4000 Installation Instructions Manual

Configurable safety shutdown and control system
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Installation Instructions
DE-4000 Configurable Safety Shutdown and Control System
Form DE-4000 II 1-19
This manual contains information on installing, wiring, and connecting to a DE-4000
Safety Shutdown and Control System in a hazardous or non-hazardous area. This manual
supplements the DE-4000 Safety Shutdown and Control System Operation and Configu-
ration manual form DE-4000 OCM.

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Summary of Contents for Altronic DE-4000

  • Page 1 DE-4000 Configurable Safety Shutdown and Control System Form DE-4000 II 1-19 This manual contains information on installing, wiring, and connecting to a DE-4000 Safety Shutdown and Control System in a hazardous or non-hazardous area. This manual supplements the DE-4000 Safety Shutdown and Control System Operation and Configu-...
  • Page 2 THIS PAGE INTENTIONALLY BLANK DE-4000 II All rights reserved © ALTRONIC, LLC 2019...

  • Page 3: Table Of Contents

    CONTROLLER MODULE (691759-1) ................7 TERMINAL MODULE (691760-1) ................8 MOUNTING ......................12 WIRING ........................13 HAZARDOUS AREA OPERATION................17 CONNECTING VIA ETHERNET TO CONFIGURE THE DE-4000 ........18 10.0 LIST OF FIGURES ....................19 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...

  • Page 4: General Safety And Wiring Precautions

    Power must be from a Class 2 power source with transient protection or from a 24-volt battery system. b) The power to the DE-4000 System must be installed in accordance with the requirements of the National Electrical Code (US) and the Canadian Electrical Code (Canada) c) Over-current power protection is required for the DE-4000 System.

  • Page 5: Overview

    System Configuration files can be created via a laptop or the HMI Display Module, saved and downloaded, as well as uploaded, to other DE-4000 Systems. This al- lows for configuration portability for users operating several similar systems.

  • Page 6: Hmi Display Module (691766-1)

    Controller Module and Terminal Module: –40°C to +85°C (–40°F to +185°F) HMI Display Module: –30°C to +80°C (–22°F to +176°F). 2.12 The DE-4000 System is CSA- and UL-certified for use in Class I, Division 2, Groups C and D hazardous locations.

  • Page 7: Controller Module (691759-1)

    The Controller Module is the hub of the system. It is the main controller interfacing with up to five Terminal Modules, the HMI Display Module, and other systems. The scalable and expandable nature of the DE-4000 allows it to be used on the simplest safety-shutdown-oriented applications, on mid-range applications with minimal or...

  • Page 8: Terminal Module (691760-1)

    0 to 5VDC or 0 to 25mA TERMINAL MODULE I/O POINT IDENTIFICATION Up to five Terminal Boards can be used in a DE-4000 System. The system uses a simple Terminal Module/Channel number assignment method that identifies the Terminal Module and I/O point.
  • Page 9 K type thermocouples the red insulation color is (-), the other color is the (+). INPUTS – PRESSURE TRANSDUCERS The pressure transducers, Altronic P/N 691201-x and P/N 691204-x, are pack- aged in a rugged sealed case with an NPT pressure port, a corrosion resistant media cavity, and a Packard Electric Metri-Pack connector.
  • Page 10 200 volts max. The RPMx- terminals are common to DC-. Connect the speed input to the ter- minals marked RPMx+ and RPMx-. Altronic magnetic pickups or Hall effect pickups are typical sources for RPM measurement.
  • Page 11 The Hardware Safety Connection on the Terminal Module, when connected to the Controller Module, acts as an independent shutdown signal from any terminal module to the Controller Module. The DE-4000 System relies heavily on Commu- nications over Ethernet for proper operation. If communications are interrupted, the Hardware Safety Connection provides the system a parallel path for shutdown.

  • Page 12: Mounting

    MOUNTING When the DE-4000 System is installed in a Class I, Division 2 hazardous area, NOTE: Avoid mounting the HMI it must be mounted in a suitable enclosure. Display Module with the LCD display facing direct sunlight. The display HMI DISPLAY MODULE...

  • Page 13: Wiring

    POWER WIRING of 1mm (.04") diameter or 1.2 mm The DE-4000 System uses distributed wiring. Each module has its own power (.047") diameter for troubleshooting input terminals. Using a fuse block in series with the source power, connect purposes.
  • Page 14 E. If it becomes necessary to check sensor switch to panel wiring with an ohmmeter or other checker, first DISCONNECT the plug-in terminal strips from the Terminal Module. Applying voltage to the DE-4000 System through the sensor leads may damage the device. The area should be tested as non-hazardous before such testing commences.
  • Page 15 200 volts max. The RPMx- terminals are common to DC-. Connect the speed input to the terminals marked RPMx+ and RPMx-. Altronic magnetic pickups or Hall effect pickups are typical sources for RPM measurement.
  • Page 16 RS485 1 port is used for Modbus slave data RS485 2 is used for Modbus master data. The DE-4000 System can communicate to other instruments, PC’s or PLC’s via the two serial RS-485 communication wires. Use a two-conductor shielded cable of fine gauge stranded wire and connect the wires to the terminals marked RS-485A, RS-485B, and shield.

  • Page 17: Hazardous Area Operation

    Sensor wires must be run in separate conduits and junction boxes from high voltage wires such as ignition, fuel valve, and other high voltage wiring. The power for the DE-4000 System must be from a Class 2 power source with transient protection or from a 24-volt battery system.

  • Page 18: Connecting Via Ethernet To Configure The De-4000

    For further information, please refer to the document How to Establish an Ether- net Connection to a PLC+ Module on the Altronic website www.altronic-llc.com. A web browser on the laptop PC is used to communicate to the DE-4000 System. Preferred browsers are Google Chrome and Firefox.

  • Page 19: List Of Figures

    WIRING DIAGRAM – TERMINAL, SENSOR AND TRANSDUCERS INPUTS FIG 10 WIRING DIAGRAM – TERMINAL, DIGITAL OUTPUTS FIG 11 WIRING DIAGRAM – TERMINAL, CURRENT LOOP OUTPUTS FIG 12 WIRING DIAGRAM – TERMINAL, RPM INPUT DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 20 SMART PHONE INTERNET CONTROLLER MODULE NOTES: SYSTEM MODULES ARE INTERCONNECTED WITH CAT5e ETHERNET CABLE ASSEMBLIES. PLC+ MODULE TERMINAL I/O TERMINAL I/O TERMINAL I/O SK2205 MODULE MODULE MODULE (LOCAL) 11-14-17 (LOCAL) (REMOTE) DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 21 CLASS 2 POWER SUPPLY DISPLAY WITH TRANSIENT PROTECTION MODULE POWER PANEL GROUND FUSE POWER (+) TERMINAL BLOCK CONTROLLER MODULE POWER (-) TERMINAL BLOCK TERMINAL I/O TERMINAL I/O MODULE MODULE (T:1) (T:2) SK2236 12-18-18 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 22 FIG. 3 DE-4000 SYSTEM CONFIGURATION CONNECTION CONTROLLER MODULE FIG 3 SYSTEM CONFIGURATION CONNECTION, CONTROLLER MODULE HMI MODULE ETHERNET CABLE SK2202 11-10-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 23 1 each CAN port o 1 each RS485 port o 2 each USB Ports o 1 each USB OTG Port • Keypad: 5 keys o Stop o Reset o Test o F1 o F2 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 24 32 OR 35mm DIN MOUNTING RAILS (SEE PROFILES). 5 AMP REPLACEABLE AUTOMOTIVE STYLE BLADE FUSE 10.09 POWER INDICATOR 4.94 SOM MODULE MOUNTED UNDER LABEL RJ45 CONNECTORS, TO DE-4000 TERMNAL MODULES ONLY 1.79 SK2201 CONTROLLER MODULE 11-13-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 25 Run – Green o Timers Active – Yellow o Alarm – Orange o Stop – Red • On-Board uSD card socket, used for data logging memory and device backup and recovery DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 26 32 OR 35mm DIN MOUNTING RAILS (SEE PROFILES). 10.09 5 AMP REPLACEABLE AUTOMOTIVE STYLE BLADE FUSE POWER INDICATOR 4.94 HARDWARE SAFETY CONNECTION LED BOARD ID# 2.19 1.98 SK2196 TERMINAL MODULE 11-13-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 27 Switch position 1 = board 1 o Switch position 2 = board 2 o Switch position 2 = board 3 o Switch position 2 = board 4 o Switch position 2 = board 5 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 28 OUTPUT 1 TYPICAL USE: 24 VDC POWERED FUEL VALVE. SK2203 OUTPUT 2 TYPICAL USE: LOW VOLTAGE IGNITION SHUTDOWN. 11-14-17 OUTPUT 3 TYPICAL USE: CRANK DISCONNECT. OUTPUT 4 TYPICAL USE: PRELUBE / POSTLUBE. DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 29 1. DRY MOMENTARY PUSH BUTTON SWITCHES ARE REQUIRED FOR STOP, RESET, AND TEST. THEY ARE PULLED HIGH INTERNALLY TO 3.3 V AND GET GROUNDED TO (-) TO ACTIVATE THE CONDITION. SK2204 11-14-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 30 MUST BE FUSED WITH A 0.5 AMPERE FUSE. ALL +5VDC TERMINALS ARE ELECTRICALLY CONNECTED TOGETHER. EIGHT TERMINALS ARE PROVIDED FOR WIRING CONVENIENCE ONLY. 5. 24 VOLT POWER TO 4-20mA TRANSMITTERS MUST HAVE A COMMON GROUND TO POWER SUPPLY. SK2197 11-13-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 31 5. USE PILOT DUTY RELAYS CONNECTED TO DIGITAL OUTPUTS TO CONTROL. - OIL OR WATER COOLERS - OIL TEMPERATURE CONTROL VALVE - OIL HEATERS - PRELUBE PUMPS AND OTHER MEDIUM TO HIGH CURRENT AUXILIARY EQUIPMENT SK2200 11-13-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 32 2. FOLLOW MANUFACTURERS RECOMMENDATIONS FOR MOUNTING AND MECHANICAL HOOK-UP OF CURRENT LOOP CONVERTERS. 3. CONNECT HARDWARE SAFETY CONNECTION (HSC) FROM EACH OF THE TERMINAL MODULES TO THE HSC CONNECTION ON CONTROLLER MODULE. SK2199 11-10-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...
  • Page 33 10K, 1/2W SERIES RESISTOR NORTH POLE TYPICALLY OF MAGNET 8 TO 20 PITCH GEAR MUST FACE PICK-UP NOTE: EITHER RPM INPUT CAN ACCEPT A MAGNETIC OR HALL EFFECT PICKUP. SK2198 11-14-17 DE-4000 II All rights reserved © ALTRONIC, LLC 2019...

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