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Bacharach GDA-1600 Instructions Manual

Gas alarm 16-channel controller
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GDA-1600
16-Channel Controller
Instruction 5700-9001
Installation / Operation / Maintenance
Rev. 1 – September 2012
Product Leadership • Training • Service • Reliability

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Summary of Contents for Bacharach GDA-1600

  • Page 1 GDA-1600 16-Channel Controller Instruction 5700-9001 Installation / Operation / Maintenance Rev. 1 – September 2012 Product Leadership • Training • Service • Reliability...
  • Page 2 Bacharach Inc.'s reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given by Buyer to Bacharach Inc. within one (1) year after the date of delivery of this Product by Bacharach, Inc.

  • Page 3: Table Of Contents

    Instruction 5700-9001 GDA-1600 16-Channel Controller Table of Contents IMPORTANT SAFETY ISSUES ........................5 GENERAL DESCRIPTION .......................... 6 Data Display Screens........................6 2.1.1 Trend Screen ........................7 2.1.2 Bar Graphs Screen ......................7 2.1.3 Combination Screen ....................... 7 Specifications ..........................8 Accessories ...........................
  • Page 4 GDA-1600 16-Channel Controller Instruction 5700-9001 Wireless Receiver Mode ......................47 8.3.1 Radio Status Alarms - Wireless Receiver Mode............47 8.3.2 Wireless Modbus Slave Mode ..................48 Wireless Modbus Master Mode ....................48 Antenna Selection........................49 8.5.1 Dipole and Collinear Antennas ..................49 8.5.2...

  • Page 5: Important Safety Issues

    Instruction 5700-9001 GDA-1600 16-Channel Controller 1 Important Safety Issues The following symbols are used in this manual to alert the user of important instrument operating issues. This symbol is intended to alert the user to the presence of important operating and maintenance / servicing instructions.

  • Page 6: General Description

    GDA-1600 by optional analog inputs or the standard Modbus A Modbus RTU slave RS-485 port is also standard for sending data to PCs, PLCs, DCSs, or even other GDA-1600 Controllers. Options such as analog I/O and discrete relays for each alarm are easily added to the addressable I C bus.

  • Page 7: Trend Screen

    2.1.3 Combination Screen The GDA-1600 Combination screen shown in Figure 3.0 (on page 10) offers a view of a single channel but displays the data as a 30 minute trend, bar graph and large engineering units.

  • Page 8: Specifications

    Specification Description Input Power Standard GDA-1600 power requirements are 10-30VDC @ 3 watts applied to terminals 9 and 11 of TB2 on the standard I/O PCB (see section 4.0 on page 27). Optional features increase power consumption as described below: •...

  • Page 9: Accessories

    Instruction 5700-9001 GDA-1600 16-Channel Controller Accessories Part Number Description 5700-0002 Main I/O Interface Board 5700-0003 Auxiliary COMMON relay for Alarm 1, 2, and Horn 5700-0004 Optional Analog Input Printed Circuit Board 5700-0005 Optional 8-channel 4-20mA Analog Output Board 5700-0006 Optional 8-channel RTD/4-20mA Analog Input Module 5700-0007 150 Watt AC –...

  • Page 10: Operation

    Instruction 5700-9001 3 Operation The GDA-1600 offers 3 graphic screens for viewing monitored data and a Set-Up menu screen for operator interface to configuration menus. They are shown below in Figure 3.0. The Bar Graphs screen allows viewing of all active channels simultaneously. The Trend screen displays a 24 hour trend, one channel at a time.

  • Page 11: Changing Menu Variables Using The Keypad

    Instruction 5700-9001 GDA-1600 16-Channel Controller 3.1.1 Changing Menu Variables Using the Keypad Upon entering a menu, a pointer controlled by the UP/DOWN keys indicates the selected variable. Some are simple YES/NO or ON/OFF entries toggled by pressing the EDIT key. Others, such as Measurement Name and Eunits fields, may have many ASCII character possibilities.
  • Page 12 GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 3.1 – Channel Configuration Menus...

  • Page 13: Alarm 1 / Alarm 2 / Horn Relay Setup Menu

    Instruction 5700-9001 GDA-1600 16-Channel Controller 3.2.2 Alarm 1 / Alarm 2 / Horn Relay Setup Menu Alarms 1 and 2 are identical except A1 may not be acknowledged and front panel LED indicators are yellow while A2s are red. Since their configuration menus are the same only one is shown in Figure 3.2 for clarity.

  • Page 14: Alarm 3/Fault Alarm Menu

    GDA-1600 16-Channel Controller Instruction 5700-9001 3.2.3 Alarm 3/Fault Alarm Menu The discrete channel alarms identified as Alarm 3/Fault may be configured either as a 3 level alarm or as a Fault alarm indicating the input is out of range in the negative direction.
  • Page 15 12-bit analog inputs may be direct from Sensor Input options of Voltage/Current Input options. Analog Input Analog with Local Cal is available when the GDA-1600 will be the point of calibration with Local Cal for the analog input. Analog Input Analog Input should be selected when the channel’s input comes from a transmitter...
  • Page 16 Modbus® device with zero at 200 counts and 100% at 1000 counts, then this menu’s MIN should be set at 200 and MAX at 1000. If communicating with the GDA-1600’s optional 12-bit Analog Input PCB, the MIN should be 800 and the MAX should be 4000.
  • Page 17 5.0mA for five seconds depending on remaining sensor life, where 4.0mA = 0% and 5.0mA = 100% remaining sensor life. The GDA-1600 reads this value and records it as the channel’s Sensor Life. Sensor Life is stored in the GDA-1600 Modbus database and displayed as a bar-graph in the Sensor Info screen (see section 3.3.6...

  • Page 18: Linearization Menu

    GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 3.6 – Sensor Life Detection 3.2.5 Linearization Menu The linearization menu allows each channel to have its own linearization curve stored in the controller’s non-volatile memory. Input versus output points must be entered in percent of full scale values.

  • Page 19: Cal Mode

    Setup screen as indicated by channels 15 & 16 in Figure 3.0 (page 10). If less than 9 channels are to be activated, the GDA-1600 may be set for 8 channel mode, deactivating channels 9-16. This is done in the System Setup menu described in section 3.3 (page 20).

  • Page 20: System Configuration Menus

    GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 3.9 – Calibration Menus Entries Description Set Zero The CALIBRATION MENU allows for entering of the correct Cal ZERO & Cal SPAN set- point values needed to calibrate the sensor. These are entered in the same Set Span engineering units as input range.
  • Page 21 Instruction 5700-9001 GDA-1600 16-Channel Controller Figure 3.10 – Configuration Menus...

  • Page 22: Common Alarm Relay 1 & 2

    GDA-1600 Controller. In these cases, it may be undesirable for a sensor on channel 9 to trip the same relay as a sensor on channel 2. The Group menus may restrict this.

  • Page 23: Discrete Relay "Failsafe" Mode

    Figure 3.12 – Failsafe Mode 3.3.3 Common Horn Relay & Local Piezo The GDA-1600 is equipped with a low decibel audible piezo which chirps when keys are pressed and may be configured to audibly indicate alarm conditions. The common horn relay is similar to the common A1 &...

  • Page 24: Comm Port Menus

    (comm1 master port ID settings are per channel as described in section 3.2.4). Parity This slave port may be used to transfer GDA-1600 data to a host device such as a PC, PLC, DCS or even another GDA-1600. The slave port is addressable, allowing many GDA-1600 controllers to be connected to a single RS-485 cable.

  • Page 25: Eight / Sixteen Channel Modes

    CONTROLLING OTHER CRITICAL EVENTS! 3.3.5 Eight / Sixteen Channel Modes The system menu allows for setting of the GDA-1600 controller to accept either 8 or 16 channels. If 8 channels are selected by this menu they are channels 1-8 and 9-16 become disabled.

  • Page 26: Authorization Mode

    GDA-1600 16-Channel Controller Instruction 5700-9001 Authorization Mode A password entered in the AUTHORIZATION menu allows for the ability for all of the menus to be locked. Viewing menus is not denied but attempts to edit variables flashes the Locked message on the LCD.

  • Page 27: Display To Device Connections

    4 Display to Device Connections Main I/O Interface PCB # 5700-0002 The most basic GDA-1600 Controller requires only the I/O PCB shown in Figure 3.1 for interfacing to field wiring. The GDA-1600 primary power supply is applied to terminals 9 & 11 of TB2. This may be from 10–30 VDC.
  • Page 28 GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 4.2 – Main PCB...

  • Page 29: Optional Analog Input Pcb # 5700-0004

    Instruction 5700-9001 GDA-1600 16-Channel Controller 4.2.1 Optional Analog Input PCB # 5700-0004 Many transmitters or sensors have analog output signals and the 12 bit Analog Input PCB, shown in Figure 4.3 is available to accept these. TB1, with 24 positions, offers 3 terminals per channel for distributing power and receiving analog inputs.

  • Page 30: Optional Discrete Relay Pcb # 5700-0012

    ALL zone relays. Failsafe operation of these discrete relays (P/N 5700-0012) may be programmed in the system menu as described in section 3.3.2. Many GDA-1600 applications utilize the common alarm relays (see section 4.1)

  • Page 31: Optional *Bridge Sensor Input Board #5700-0011

    48 alarm events (16 A1s, 16 A2s & 16 A3s). If discrete relays are needed for all 48 alarms, then six PCBs are required. 5 VDC power to the discrete relay option PCBs is normally supplied from the GDA-1600 Controller via the slender I C cables connected to J2 and J3.

  • Page 32: Catalytic Bead Sensor Initial Setup

    GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 4.4 – Discrete Relay PCB 4.2.4 Catalytic Bead Sensor Initial Setup Catalytic bead sensors vary widely in power requirements and sensitivity. It is therefore important to configure each channel to match the sensor with which it will operate.
  • Page 33 28. Initial setup is now complete and normally only requires repeating if a sensor is replaced. Final calibration of this channel may now be performed using the GDA-1600’s electronic Cal Mode feature described in section 3.2.1. Figure 4.5 – Catalytic Bead Sensor Layout...

  • Page 34: Optional Rtd / 4-20Ma Analog Input Board # 5700-0006

    An optional 12 bit RTD Sensor Input board, shown in Figure 4.6, allows these popular temperature sensors to be connected directly to the GDA-1600 without additional signal conditioning or transmitters. A 3-position range jumper allows setting the gain of the input bridge amplifier for the three popular ranges of 0-100°C, 0-200°C or 0-400°C.

  • Page 35: Optional 4-20Ma Analog Output Board #5700-0005

    NOTE: This PCB requires nominal 24VDC power be connected to TB2 terminals 1 & 2 as shown in Figure 4.7. Suitable power is available from the GDA-1600 Main I/O board’s TB2 terminal 10 & 12 (see Figure 4.2).
  • Page 36 GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 4.7 – Analog Output Board...

  • Page 37: System Diagnostics

    Instruction 5700-9001 GDA-1600 16-Channel Controller 5 System Diagnostics A System Diagnostic Mode shown in Figures 5.1 and 5.2 may be entered during normal operation from the Setup menu. The entry menu indicates firmware revision and offers useful routines for testing front panel LED’s, relays, serial ports and analog I/O. It is exited manually by pressing NEXT and automatically if no keys are pressed for 5 minutes.
  • Page 38 GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 5.2 – System Diagnostic Options...

  • Page 39: Modbus Descriptions

    6 MODBUS Descriptions MODBUS RS-485 Ports The GDA-1600 is equipped with Master (COMM 1), and Slave (COMM 2), Modbus RTU ports. Port configurations are described in sections 3.2 and 3.3 of this manual. Section 6.2 defines register locations of data available via the GDA-1600 slave port.
  • Page 40 GDA-1600 16-Channel Controller Instruction 5700-9001 Six character Value ASCII string: Type Channel First Last Read FC Write FC Notes ASCII Value 40577 40579 2 characters per register; 3 registers per channel ASCII Value 40580 40582 2 characters per register; 3 registers per channel...
  • Page 41 Instruction 5700-9001 GDA-1600 16-Channel Controller Alarm status words are bits packed into 16 bit integer where lsb = channel 1 alarm status and msb = channel 16 alarm status. Alarm status (bit = 1 indicates alarm is active): Type Channel...
  • Page 42 GDA-1600 16-Channel Controller Instruction 5700-9001 Memory Discretes Notes: May be read as single discrete or packed with multiple register read. Type Channel First Last Read FC Write FC Notes Chnl Alarm 1 1-16 12001-16 discrete, may be packed Type Channel...

  • Page 43: Enclosure Installation

    7 Enclosure Installation Panel / Rack Mount Enclosure The GDA-1600 shown in Figure 7.1 is a half width 19” rack enclosure. It is supplied with hardware that allows mounting in either a full width 19” rack style cabinet or it may be panel mounted in a rectangular cutout.
  • Page 44 GDA-1600 16-Channel Controller Instruction 5700-9001 Figure 7.2 – Wall Mount Enclosure Figure 7.3 – Grounding Illustrations...

  • Page 45: Adding The Wireless Radio Kit Option

    GDA-1600 16-Channel Controller 8 Adding the Wireless Radio Kit Option Introduction The GDA-1600 slave serial port may be connected to a FHSS (Frequency Hopping Spread Spectrum) wireless radio modem shown in Figure 8.1. There are two different frequency options offered: •...

  • Page 46: Radio Setup Menu

    350s sleep most of the time and therefore may not be Servers. If an application calls for multiple GDA-1600 locations, only one may be set for Server and all others must be Clients. This single Server transmits a beacon which all of the network’s Clients synchronize to.

  • Page 47: Wireless Receiver Mode

    Remote Id address setting in the GDX-350 RF providing data to this GDA-1600 channel. Input Req is typically set to VALUE but also allows a BATT entry into this field. Entering BATT causes the channel to display (and alarm) from battery voltage levels at this GDX-350 RF.

  • Page 48: Wireless Modbus Slave Mode

    GDA-1600’s sixteen channels so it is also possible to accept wired signals from analog input option PCBs described in section 4.2. This is a popular application when the Modbus slave is another remote GDA-1600 or our GDA-400 controller available with built in radio modem compatible with the GDA-1600...

  • Page 49: Antenna Selection

    6mm diameter (1/4 inch), do not connect the cable directly to the radio connection on the GDA-1600 enclosure. Thick cables have large bending radii and sideways force on the connector can cause a poor connection. Use a short flexible pigtail between the thick cable and the radio.

  • Page 50: Mounting Near Other Antennas

    Solid connection means a large capacity conductor (not a small wire) with no coils or sharp bends. All other devices connected to the GDA-1600 need to be grounded to the same ground point. There can be significant resistance between different ground points leading to very large voltage differences during lightning activity.

  • Page 51: Antenna Grounding

    Electromagnetic energy in the air will be drained to ground via any and every earth path. An earth path exists between the antenna and the GDA-1600 and to protect against damage this earth path current must be kept as small as possible. This is achieved by providing better alternate earth paths.

  • Page 52: Service Center

    GDA-1600 16-Channel Controller Instruction 5700-9001 9 Service Center United States 8621 Highway 6 Hitchcock, TX 77563 Ph: 724-334-5051 Fax: 724-334-5723 Email: help@MyBacharach.com...
  • Page 53 Instruction 5700-9001 GDA-1600 16-Channel Controller...
  • Page 54 GDA-1600 16-Channel Controller Instruction 5700-9001 Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068-7074 Toll Free: 800-736-4666 • Tel: +1-724-334-5000 • FAX: +1-724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com Printed in U.S.A. ® Registered Trademark of Bacharach Inc.

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