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PC/104 8-Channel Smart Sensor Interface
Technical Manual
Model 518 | Re .2.0.2 | September 2017
Copyright © 2017 by Sensoray
Table of Contents
Chapter 1: Introduction....................................1
1.1 Functional overview............................................1
Chapter 2: Configuration and installation.........2
2.1 Handling instructions..........................................2
2.2 Configuration......................................................2
2.2.1 Address mapping.................................................2
2.2.2 Interrupts..............................................................2
2.2.3 Thermocouple shunts...........................................3
2.3 Installation..........................................................3
Chapter 3: ensor connections.........................4
3.1 Connector P1.......................................................4
3.2 RTDs, thermistors and resistors..........................4
3.3 Thermocouples and voltage................................5
3.4 train and pressure gauges..................................6
3.5 Current loops.......................................................6
Chapter 4: Register-level programming...........7
4.1 Programming model............................................7
4.2 tatus register......................................................7
4.3 Control register...................................................8
4.4 Handshaking.......................................................8
4.4.1 Byte handshake....................................................8
4.4.2 Endianness...........................................................9
Chapter 5: Commands....................................10
5.1 Overview...........................................................10
5.1.1 Conventions.......................................................10
5.2 Basic operation..................................................10
5.2.1 Declare ensorType............................................10
5.2.2 ReadChannel......................................................11
5.2.3 ReadAllChannels...............................................11
5.3 Alarm/fault commands......................................11
5.3.1 etOpenValues...................................................11
5.3.2 etLimits............................................................12
5.3.3 ReadAlarms........................................................12
5.4 Gauge commands..............................................13
5.4.1 etGaugeZero....................................................13
5.4.2 etGauge pan....................................................13
5.4.3 TareGauge..........................................................13
5.4.4 ReadGaugeCalibration.......................................14
5.4.5 etGaugeCalibration..........................................14
5.5 Miscellaneous commands.................................14
5.5.1 ReadFirmwareVersion.......................................14
5.5.2 ReadBoardTemperature.....................................15
5.5.3 ReadModel.........................................................15
5.5.4 Calibrate.............................................................15
Chapter 6: ensor specifics............................17
6.1 Thermocouples..................................................17
6.1.1 Accuracy............................................................17
6.2 Gauges..............................................................17
6.2.1 Resolution..........................................................17
6.2.2 etting zero and span.........................................18
6.2.3 Taring.................................................................18
Chapter 7: Timing..........................................19
7.1 Warm-up...........................................................19
7.2 ampling...........................................................19
7.3 Communication.................................................19
Chapter 8: pecifications................................20
8.1.1 General specifications........................................20
8.1.2 ensor specifications..........................................21
Chapter 9: Limited warranty..........................22
518 Instruction Manual i Table of Contents
518 Instruction Manual ii Table of Contents
Chapter 1: Introduction
1.1 Functional overview
Model 518 is a PC/104 circuit board that interfaces any combination of up to eight sensors to a host computer. Each sensor
channel provides complete signal conditioning for a variety of sensor types, thus allowing any channel to be directly
connected to a thermocouple, RTD, strain gauge, thermistor, resistor, 4-to-20 mA current loop, or DC voltage.
Block diagram
Pulsed excitation is provided for thermistors, resistors, RTDs, and strain gauges, which minimizes sensor self-heating and
reduces power consumption. Excitation signals are routed to dedicated connector pins to allow four-wire sensor circuits that
completely eliminate lead-loss errors.
Cold junction compensation is automatically applied to thermocouples (requires optional, external sensor), and fully
differential inputs are used to provide common-mode voltage rejection.
The onboard controller continuously scans the eight sensor channels. As each channel is scanned, the sensor is excited,
digitized, normalized to precision standards, linearized, and converted to engineering units as appropriate for the sensor
type. The most recent measurement from each channel is immediately accessible to the host.
Alarm limits may be programmed for each channel. A status flag is set when any limit is violated, eliminating the need for
host polling.
518 Instruction Manual 1 Introduction
Chapter 2: Configuration and installation
2.1 Handling instructions
The model 518 board contains electronic circuitry that is sensitive to electrostatic discharge (E D). pecial care should be
taken in handling, transporting, and installation to prevent E D damage to the board. In particular:
•Do not remove the board from its protective packaging until you are ready to configure and install it.
•Handle the board only at grounded, E D protected stations.
2.2 Configuration
Hardware configuration must be completed before the board is installed. This is accomplished by installing shunts to
configure various hardware options. ome shunts are factory installed, which results in the following configuration:
Default configuration:
Base address 0x2B0
PC/104 interrupts Disabled
Channel filters Disabled
2.2.1 Address mapping
The board may be mapped to any four-byte address block within the range 0x000 to 0x3FF. The board occupies a four-byte
address range but uses only the first two address locations in the range.
To avoid address conflicts, you must map the board into an address range that is not used by other devices. Model 518 does
not decode the full PC/104 16-bit I/O address; only the low ten address bits are decoded. Consequently, aliased “images” of
the 518 will appear throughout the 16-bit address range at intervals of 0x400 bytes. You must ensure that these images do
not conflict with other devices.
hunts E1 through E8 are used to select the board's base address. hunts are factory set to locate the board at base address
0x2B0. If you require a different base address, use the following table to determine the shunts needed for your base address.
Address selection shunts:
Address bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
hunt 0 0 0 0 0 0 E8 E7 E6 E5 E4 E3 E2 E1 0 0
You must install a shunt to match address bit = '0', or remove the shunt to match address bit = '1'. For example, to configure
the board's base address to 0x390 (binary 0000 0011 1001 0000), install shunts E5, E4, E2 and E1.
2.2.2 Interrupts
The board may be configured to interrupt the host computer in response to various alarm and communication events. All of
the board's interrupt requests share a common IRQ line on the PC/104 bus.
If you will be using interrupts, you must install a shunt to select the desired IRQ line. Any interrupt line from IRQ2 to IRQ7
may be selected (be sure to choose an IRQ line that will not conflict with other devices in your system). Do not install any
IRQ shunts if you will not be using interrupts.
518 Instruction Manual 2 Configuration and installation
2.2.3 Thermocouple shunts
Each sensor channel is associated with two shunts which provide a ground-reference and facilitate open-sensor detection for
thermocouples. If a channel is connected to a thermocouple or other floating voltage source then you must install both of its
shunts, otherwise both shunts should be removed.
Thermocouple shunts:
Channel 01234567
hunts E9, E17 E10, E18 E11, E19 E12, E20 E13, E21 E14, E22 E15, E23 E16, E24
2.3 Installation
Before installing or removing the circuit board from the system:
•Remove power from the system.
•Disconnect the board's P1 connector.
To install the board:
•Plug the board into the PC/104 stack and secure it with the included hardware.
•Connect an external field-wiring termination board to connector P1 with a 40-conductor flat ribbon cable.
ensoray recommends the model 7409TB termination board and 7409C cable for this purpose.
•Connect your sensors to the termination board as required. ee ensor connections for details.
518 Instruction Manual 3 Configuration and installation
Chapter 3: Sensor connections
3.1 Connector 1
All sensors connect to the board via connector P1. Optionally,
sensors may be connected to a ensoray model 7409TB screw
termination board, which in turn connects to P1 via ribbon cable.
A 7409TB (or equivalent) is required if you are measuring
thermocouples as it provides an essential temperature transducer
for cold junction compensation.
Each sensor may have as many as five connections to a sensor
channel. H and L are are used for all sensor types; these are
the positive and negative differential sense inputs. Passive
sensors also require connections to the PH/PL excitation
terminals. The GND and HLD pins may be connected to cable
shields.
The following sections explain how to connect sensors when
using a 7409TB termination board.
Pin functions
P1
Signal Na e
7409TB
Legend
Function
Hx V+ Positive analog input for sensor channel x (half of differential pair H/ L).
Lx V- Negative analog input for sensor channel x (half of differential pair H/ L).
PHx I+ Positive excitation output for sensor channel x (half of excitation pair PH/PL).
PLx I- Negative excitation output for sensor channel x (half of excitation pair PH/PL).
GND / HLD Cable shields; power return for cold junction temperature sensor.
+12V +12 VDC power for cold junction temperature sensor (5 mA maximum).
TREF Cold junction temperature sensor output (10 mV/°K).
NC No connect.
3.2 RTDs, thermistors and resistors
RTDs, thermistors and other resistors can be connected using a two-, three- or four-wire circuit. The simplest of these is the
two-wire circuit which, as the name implies, requires only two wires. The V+ and I+ terminals are shorted together, and V-
and I- are shorted together at the 7409TB. This conserves wire but introduces error as a result of the voltage difference (a
“voltage loss”) between the V/I junctions and sensor.
518 Instruction Manual 4 ensor connections
P1 connector pinout
By using three wires, it is possible to reduce voltage loss errors by 50 percent. Instead of shorting V- and I- together at the
7409TB, separate wires can be run from each of these terminals out to the sensor. The wires are then shorted together at the
sensor so that the high impedance V- terminal detects the voltage at the sensor, before losses can occur.
A four-wire circuit will entirely eliminate voltage losses. Like the three-wire circuit, separate wires are run from the V- and
I- terminals to the sensor. In addition, separate wires are run from V+ and I+ to the sensor, where they are shorted together.
Thermistors have much higher resistance than RTDs over most of their operating range. As a result, a two-wire circuit may
be used if your sensor will be operating only at higher resistance values. If it will be operating at lower resistance values, it
is recommended to use a three- or four-wire circuit to prevent significant voltage losses.
It is recommended to use shielded cable for all passive resistive devices. The cable shield must be connected only to the
terminal on the 7409TB; leave it unconnected at the sensor end of the cable.
3.3 Thermocouples and voltage
Thermocouples and DC voltages are connected directly to the V+ and V- terminals. Thermocouples and DC voltage sources
should never be connected to the I+ or I- terminals.
Thermocouple wires are color coded to indicate polarity. The positive thermocouple wire should be connected to the V+
terminal and the negative thermocouple wire should be connected to the V- terminal (the red thermocouple wire is negative
by convention).
518 Instruction Manual 5 ensor connections
Electrical noise may be present on thermocouple and voltage signals. It is not within the scope of this manual to discuss all
treatments of such noise, however, a few simple techniques are available which will solve many noise problems:
1. Inspect the sensor signal with an oscilloscope to confirm that it matches your expectations. “Noise” can often be
the result of an incorrect sensor wiring or other external influences.
2. Install the hardware filter jumper on the offending channel.
3. In the case of thermocouples, try grounding the hot junction. ometimes the thermocouple is not referenced to the
PC/104 return. Noise induced into the thermocouple wire from the environment can elevate common mode voltage
beyond the board input range. Make sure that the ground is referenced to the PC/104 bus ground. In the case of a
DC voltage source, try grounding either the V+ or V- signal (but not both) to limit the common-mode voltage.
3.4 Strain and pressure gauges
Four wires are used to connect a gauge to the measurement system. Two wires supply excitation and the other two wires
convey the gauge output signal. If you have a six-wire gauge, connect its excitation source and sense leads together at the
7409TB I+ and I- terminals. train and pressure gauges should use shielded cable. The shield should be connected only to
the channel terminal on the 7409TB.
3.5 Current loops
The board supports 4-20 mA current loop inputs on any channel when an optional 250-ohm 0.01% resistor is installed as
shown below. These resistors are available as an option for model 518: order ensoray part number 7408R. Note: The
sensor channel must be located at the ground end of the current loop so that common mode voltage will not exceed 5 V.
518 Instruction Manual 6 ensor connections
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