Temperature Controllers - Cal Controls
Contents
1. Access Level P from Level 1 Press and hold Y Function ProG run Fail Stv SPru SEG 16 Press A or W to change Program number Run Program Power failure recovery mode Program start value Ramp rate time units Segment number Settings Factory settings shown in brackets Press A or W to change 1 oFF on hoLd Edit dEL Edit inS Edit CoPy Edit PStE rSEt Cont hoLd PV SP hour 60s 1 Add new programs 1 to 31 Program not running Run program Pause program Delete program te Insert new program 1 Copy another program Paste copied program t Reset to program start Continue from interruption Hold at interruption User re start Process value Setpoint value Ramp rate adjust in hours Ramp rate adjust in minutes Add new segments 1 to 126 Function Sub functions Press A or W to change TyPE Define segment type SPr SPrr t SP hb u SoAK Sint StEP LooP Pcyc CALL Sub P Edit dEL Edit inS 2 on page 17 See examples of EDIT procedures page 18 Deleting a Program automatically re numbers those programs with higher numbers Until memory full See page 11 for further explanation and memory allocation table Settings Factory settings shown in brackets Press A or W to change Ramp to next target setpoint 100 Setpoint ramp rate Units per hour minute 0 9990 as set at Spru above Segment target setpoi2. 95221P 95X11P 95X21P Substitute for X in table above Analogue options B 4 20mA C 0 5V D 0 10V Re transmission These models above offer the option of using the analogue output for Re transmission Select bAnd or bnd 2 value in LEVL 1 to equal the full range setting in LEVL A and if using SP1 output set int t and dErt t in LEVL 1 to off Example Set Up using a Model 95B11P to Re transmit the 4 20 mA input scaled 0 to 100 units SP1 relay is used as the control output and SP2 analogue output is used for re transmission Note Read in conjunction with Linear Input Set up Procedure on page 6 Function Options Factory settings shown in brackets From initial power up Set inPt nonE to inPt Lin unit nonE to unit SEt for example SP1 dnonE to SP1 d rLY To scale the input select LEVL A then Set dECP to 000 0 e g required resolution An hi to 100 0 An Lo to 0 0 hi in to 50 ie 20mA Lo in to 10 ie 4mA To align SP2 analogue re transmission with SP1 control output select LEVL 2 then Set SP2 A to FS hi And in LEVL 1 Set SEt 2 to 50 ie 50 of display range bnd 2 to 100 ie 100 of display range Finally set SP1 setpoint value as required for process to start Using SP1 output for re transmission Set int t to off dErt to off rev d to 1d 2d to invert SP1 output SP1 Setpoint to midscale burn Sensor burn out break protection Caution Settings affect fail safe state SP1 SP2
3. If a Primary Alarm mode has been configured when an alarm condition occurs the alarm annunciator AL will be displayed alternating with the process variable The alarm together with the display will be automatically reset as soon as the alarm condition has been cleared The annunciator may be disabled by selecting no AL on in Level 4 ERROR MESSAGES SENSOR FAULT Display flashes inPt FAiL Indicates sensor open or short circuit or linear input over range Action Check sensor wiring connectors NON VOLATILE MEMORY ERROR Display flashes dAtA FAIL Action De power briefly Replace unit if problem persists MANUAL POWER ERROR Display flashes hAnd FAiL SP1 set to on off in CYC t Action Select proportional mode IMMEDIATE FAIL ON AUTOTUNE START Display flashes tunE FAiL Setpoint display O 1 No setpoint entered Action Enter setpoint 2 SP1 set to ON OFF in CyC t Action Select proportional mode Note To reset and clear error press AW together briefly to cancel message FAIL LATER DURING AUTOTUNE CYCLE The thermal characteristics of the load exceed the Autotune algorithm limits The failure point indicated by any display 0 0 in tech e g Ctb 0 0 Action 1 Change the conditions eg raise setpoint 2 Try tunE At SP 3 If the error message persists call local CAL representative for advice LINEAR INPUT Set up Procedure The 4 20mA input model converts current into voltage using an internal resistor w
4. uP SC Upscale Upscale dn SC Downscale Downscale 1u 2d Upscale Downscale 1d 2u Downscale Upscale Retransmission range is limited to the sensor full scale value Example RTD 400C 759F Will be affected by dECP settings in Level A LEVEL 3 CONTINUED Function Options Factory settings shown in brackets rEu d Select output modes Direct Reverse Caution Settings affect fail safe state SP1 SP2 1r 2d Reverse Direct 1d 2d Direct Direct 1r 2r Reverse Reverse 1d 2r Direct Reverse Select Reverse on SP1 for heating and Direct for cooling applications rEu L Select SP1 2 LED indicator modes SP1 SP2 1n 2n Normal Normal 1i 2n Invert Normal 1n 2i Normal Invert 11 23 Invert Invert SPAn 0 0 Sensor span adjust For recalibrating to align readings with another instrument e g External Meter data logger See Full Operating Manual ADVANCED SETTINGS to 25 sensor maximum 1999 2500 in Linear ZEro 0 0 to 25 sensor f s Zero sensor error see Sensor span adjust above 1999 2500 in Linear ChEK oFF on Select control accuracy monitor rEAD Var hi Lo Read control accuracy monitor tECh Ct A CTb Ct1 Ct2 Ct3 Ct4 oS1 uS oS2 Read Autotune tuning cycle data see Operating Manual UEr Software version number rSET nonE ALL Resets all functions to factory settings Caution This selection will lose all of the current settings Access to level 4 is gained through UEr in level 3 Press and hold
5. 44 8 116 2 106 7 Dimensions in mm includes gasket ELECTRICAL INSTALLATION See important Safety Information page 20 OUTPUT DEVICES WARNING Three types of output device may be factory fitted to the controllers and users must choose how to allocate these to outputs SP1 and SP2 SP3 is always RLY Check the model number and output configuration against the Output Options Table on page 8 before wiring the instrument and applying power 1 Solid state relay drive SSd1 SSd2 6Vdc nominal 20mA max To switch remote SSR or logic 2 Miniature power relay rLY rLY1 rLY3 QA 250V AC resistive Form A SPST contacts 3 Analogue Output AnLG isolated Specify 4 20mA 500Q max 0 1 fs typical 0 5Vdc 10mA 500Q min 0 1 fs typical 0 10Vdc 10mA 1KQ min 0 1 fs typical SUPPLY VOLTAGE 100 240V 50 60HZ 6 0VA nominal 10 maximum permitted fluctuation WIRING THE CONNECTOR Prepare the cable carefully remove a maximum of 8mm insulation and ideally tin to avoid bridging Prevent excessive cable strain Maximum recommended wire size 32 0 2mm 1 0mm 18AWG INDUCTIVE LOADS To prolong relay contact life and suppress interference it is recommended engineering practice to fit a snubber 0 1uf 100 ohms between relay output terminals CAUTION Snubber leakage current can cause some electro mechanical devices to be held ON Check with the manufacturers specifications 19 EN6
6. 60Hz 50ppm C SM typical 22 C 9 C rated voltage after 15 minutes settling time solid state relay driver To switch a remote SSR 6Vdc nominal 20mA non isolated form A SPST contacts AgCdO 2A 250ac resistive load 4 20mA 500Q max 0 1 fs typical 0 5Vdc 10mA 5009 min 0 1 fs typical 0 10Vdce 10mA 1KQ min 0 1 fs typical Upper 4 Digits high brightness green LED 10mm 0 4 high Lower 4 Digits high brightness Orange LED 9mm 0 35 high Digital range 199 to 9999 Hi res mode 199 9 to 999 9 LED output indicators flashing SP1 square green SP2 SP3 round red 3 elastomeric buttons Max 95 non condensing up to 2000M Categories Il and Ill Degree Il NEMA 4X IP66 Front panel only EN50081 1 FCC Rules 15 subpart J Class A EN50082 2 0 50 C 32 130 F flame retardant polycarbonate 180g 6 4 oz SAFETY AND WARRANTY INFORMATION INSTALLATION AN AN Designed for use UL873 only in products where the acceptability is determined by Underwriters Laboratories Inc EN61010 1 CSA 22 2 No 1010 1 92 To offer a minimum of Basic Insulation only Suitable for installation within Catagory II and III and Pollution Degree 2 SEE ELECTRICAL INSTALLATION Page 19 It is the responsibility of the installation engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations CONFIGURATION All functions are front se
7. A and W for 10 seconds Enter level 4 at Lock release A and W together Display reads LoCK nonE Program security using Lock nonE Select from three Lock options Press and hold press A to index LEV 3 locks level 3 4 A and C when fitted LEV 2 locks level 2 3 4 A and C when fitted ALL locks all functions including C when fitted Note Any locked functions and options can still be read Press W to access following functions Function Options Factory settings shown in brackets ProG Auto StAY Program mode auto exit switch Auto exit returns display to normal if 60 seconds of key inactivity select StAY to disable no AL oFF on Disable SP2 alarm annunciator AL Select on to disable AL di SS dir 1 to 32 6 Display sensitivity dir direct display of input 7 maximum 32 minimum sensitivity dEr S 0 1 to 1 0 0 5 Derivative sensitivity SEt L oFF on Remember next menu exit point and use as new menu entry point except when exit is in Level 1 LEVEL P O EUL P See PROGRAMMER Section page 11 LEVEL Cc LEUL C COMMS SETTINGS visible only when Comms option fitted Additional in depth information on controller operation is available in the APPGUIDE PDF available for down load from www cal controls com Will be affected by dECP settings in Level A 10 LEVEL A PST Function Options Factory settings shown in brackets Linear Input Scaling Please read in conjunction with Linear Input
8. Set up Procedure page 6 2 Select operating unit Press and hold and use the A or V buttons to scroll through the unit selection list until the correct unit is displayed Release the buttons The display will read selected unit e g unit C Press A once The display will now read SP1 d nonE 3 Select SP1 Main setpoint output device Analogue output The allocation of the analogue output to SP1 automatically overrides the default proportional cycle time setting of 20 seconds Where the analogue output is allocated to SP2 the default CyC 2 setting on off must be manually changed in Level 1 to a time proportioning setting to enable the analogue output to operate in proportional control mode Press and hold and use the A or W buttons to select from the choices Rly SSd or AnLG depending on the model supplied SP2 and SP3 outputs will be automatically allocated See output options table on page 8 4 To enter initial configuration into controller memory Press and hold both A and V buttons for 3 seconds The display will now read PArK and measured variable e g ambient temperature 23 PArK is displayed because a setpoint has not yet been entered To display setpoint units Press and hold The displays will now read unit eg C and 0 To enter setpoint Press and hold and use A button to increase or W button to decrease the reading and scroll to required setpoint value The digit roll over rate increases wit
9. The following additional Subsidiary alarm functions can be added to any Primary alarm configurations using the settings found at SP2 b in Level 2 and SP3 b in Level A LtCh Once activated the alarms will latch and can be manually reset when the alarm condition has been removed Hold This feature inhibits alarm operations on power up and is automatically disabled once the process reaches the alarm setting Lt ho Combines the effects of both LtCh and hold and can be applied to any Primary alarm configuration SECOND SETPOINT SP2 Proportional control output Configure in Level 1 using CyC 2 to select proportional cycle time and bnd 2 to adjust proportioning band For Heat Cool operation see Operating Manual Additional in depth information on controller operation is available in the CAL 9400 PDF available for down load from www cal controls com In on off mode bnd 2 adjusts SP2 hysterisis On Off operating mode SP2 and SP3 Proportional operating mode SP2 only Output state LED state Output state LED state te Pw e a_ 2 Output ON ore Relay or SSd i on off mode only energised Full scale SA Output OFF Relay or SSd de energised AKA Output Device Factory Setting Recommended Minimum Internal relays 20 seconds 10 seconds Solid state drives 20 seconds 0 1 seconds Temperature above setpoint SP2 SP3 OUTPUT AND LED STATUS IN ALARM CONDITION SP2 SP3 ALARM ANNUNCIATOR
10. input minimum 8 Enter display resolution Enter Linear Input configuration into controller memory and enter setpoint Now configure Levels 1 2 and 3 and if required proceed with AUTOTUNE Note Any apparent calibration errors can be removed using the ZEro and SPAn adjustments in Level 3 Will be affected by dECP settings in Level A FUNCTION LIST LEVELS 1 to 4 and A Note A Functions Menu is shown on page 3 LEVEL 1 Function Options Factory settings shown in brackets SELECT AUTOTUNE see pages 4 5 tunE oFF on PArK At SP Used to switch the Autotune feature on and off to select PArK or Autotune at setpoint PArK temporarily turns the output s off To use select PArK and exit program mode To disable re enter program at tunE and select oFF SP1 OPERATING PARAMETERS bAnd 0 1to C F SP1 proportional band Gain or Hysteresis 100 Hi Sc sensor maximum Proportional control eliminates the cycling of on off control Output power is reduced by time proportioning action across the proportional band 10 C 18 F 100 units int t OFF SP1 integral time reset Auto corrects proportional control offset error 0 1 to 60 minutes 5 0 dEr t oFF SP1 derivate time rate Suppresses overshoot and speeds response to disturbances 1 200 seconds 25 dAC 0 5 5 0xbAnd 1 5 SP1 derivative approach control dAC Tunes warm up characteristics independent of normal operating conditions by adjusting when derivative a
11. program see page 5 AUTOTUNE continued Hereafter in the Manual the symbol AY signifies both buttons are held pressed for 3 seconds to ENTER or EXIT Program mode TUNE OR TUNE AT SETPOINT PROGRAM Enter program AV and from the display tunE OFF press and hold and press A to display tunE on or tunE At SP Exit program mode AV The TUNE program will now start The display will show tunE as the process variable climbs to setpoint Note Avoid tuning while running a program as SP1 may be different from the target setpoint When the TUNE or TUNE AT SETPOINT program is complete the PID values are entered automatically The process will rise to setpoint and control should be stable If not this may be because optimum cycle time is not automatically implemented To set the cycle time see PROPORTIONAL CYCLE TIME PROPORTIONAL CYCLE TIME The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Factory set To use the 20 sec factory set cycle time no action is needed whether autotune is used or not To Manually Select AUTOTUNE Calculated CYCLE TIME When AUTOTUNE is completed enter program AW and select CYC t in Level 1 The display will read CYC t 20 the factory setting To view the new calculat
12. 1010 CSA 22 2 No 1010 1 92 Compliance shall not be impaired when fitted to the final installation Designed to offer a minimum of Basic Insulation only The body responsible for the installation is to ensure that supplementary insulation suitable for Installation Category Il or Ill is achieved when fully installed To avoid possible hazards accessible conductive parts of the final installation should be protectively earthed in accordance with EN61010 for Class 1 Equipment Output wiring should be within a Protectively Earthed cabinet Sensor sheaths should be bonded to protective earth or not be accessible Live parts should not be accessible without the use of a tool When fitted to the final installation an IEC CSA APPROVED disconnecting device should be used to disconnect both LINE and NEUTRAL conductors simultaneously A clear instruction shall be provided not to position the equipment so that it is difficult to operate the disconnecting device EMC Immunity EMC immunity may be improved by fitting large Ferrite cores around the sensor cables at the point where they enter the cabinet and an earth bond is recommended TYPICAL APPLICATION In this example the load temperature is monitored by a temperature transducer transmitter which provides a 4 20mA input signal to the controller The 4 20mA output has been allocated to SP1 to drive an SCR power controller providing a phase angle controlled output to the heater F1 Fuse 1A t
13. It is CAL Controls aim to provide the best possible service to our customers Feedback from our customers is therefore very important to ensure that we can make continual improvements to our products and services Should you wish to register any issues with CAL please e mail us at support cal controls co uk or via the contact us section of our web site at www cal controls co uk Title your e mail comments as Registered customer feedback or Registered customer complaint Alternatively you can contact us on tel 44 0 1462 436161 or fax 44 0 1462 451801 23 CAL Controls CAL Controls Ltd Bury Mead Road Hitchin Herts SG5 1RT UK Tel 44 0 1462 436161 Fax 44 0 1462 451801 email support cal controls co uk http www cal controls com CAL Controls Inc 1117 S Milwaukee Avenue Libertyville IL 60048 USA Tel 847 680 7080 Fax 847 816 6852 email sales cal controls com http www cal controls com 33022 02 0901 000M18 1
14. Set up Procedure on page 6 An hi 1999 to 9999 1000 Adjusts required scale maximum An Lo 1999 to 9999 0 Adjusts required scale minimum hi in 0 1 to 50 0 50 0 Configure input maximum Lo in 0 0 to 49 9 10 0 Configure Input minimum This setting must be at least 0 1 less than the setting for hi in above Note Refer to Linear Input conversion factors detailed in the Set up Procedure on page 6 dECP 000 0 to 00 00 0000 Scale resolution NB Once the Linear Input option has been selected the setting here over rides the scale resolution setting di SP in Level 2 and will affect the following display readings Level A An hi An Lo Set 3 hYS 3 Level 1 bAnd ofSt SPrr SEt2 bnd 2 Level 2 hiSC LoSC Level 3 SPAn ZEro rEAd tECh SP3 SETTINGS SP3 A nonE dV hi dV lo bAnd FS hi FS Lo EoP Main SP3 operating mode SP3 b nonE LtCh hold Lt ho Subsidiary SP3 operating mode SEt 3 0 to 2500 0 SP3 setpoint adjustment hyS 3 0 1 to 100 of hiSC 20 Set SP3 hysteresis Function Options brn 3 uPSC uPSC or dnSC Sensor burn out break protection Select upscale or downscale rEV 3 3d 3d or 3r Reverse SP3 output mode Select direct or reverse operation Will be affected by dECP settings in Level A Factory settings shown in brackets PROGRAMMER INDEX Function overview 11 Getting started 12 Program run mode 12 Display functions 12 Example program 13 Function map 14 Function list 16 Me
15. appears in the instrument display as the character KEY V OR A TOGETHER TO CHANGE LEVELS OR OPTIONS LINEAR SCALING AND INPUT SETTINGS sP3mooes SP3 ADJUSTMENTS SP3 SAFETY SETTINGS i gt KEY V OR A TO VIEW FUNCTIONS GETTING STARTED After power up the controller requires programming with the following information Type of Sensor See list of sensors p 22 Operating unit C F bAr PSi Ph rh SEt Allocation of Output Device to SP1 SP2 Relay SSd or analogue SP3 is always relay Setpoint When the above information has been programmed into the controller it will be operational with factory PID settings INITIAL SET UP On power up the controller will display the self test sequence followed by the initial display inPt nonE 1 Select input sensor Press and hold and use the A or V buttons to scroll through the sensor selection list until the correct sensor is displayed Release the buttons The display will now read selected sensor type e g inPt tCS type S thermocouple Press A once The display will now read unit nonE LINEAR INPUT When Linear Input is selected the display resolution of the setpoint and many other functions will be changed from the setting previously made at di SP in Level 2 to that set at dECP in Level A It is therefore recommended that on completion of the Initial Set up the Linear Input settings in Level A be completed before moving on to configure Levels 1 2 and 3 see
16. ction starts during start up smaller dAC value nearer setpoint CyC t A on oF 0 1 81 sec 20 SP1 proportional cycle time see pages 9 10 Determines the cycle rate of the output device for proportional control Select on oF for ON OFF mode oFSt 0 to C F units 0 SP1 offset manual reset 50 bAnd Applicable in proportional and ON OFF mode with integral disable Int t OFF SP LK oFF on Lock main setpoint Locks the setpoint preventing unauthorised adjustment bnd 2 0 1 C F units SP2 OPERATING PARAMETERS see page 6 Function Options Factory settings shown in brackets SEt2 0 to C F units Adjust SP2 setpoint Deviation Alarms DV hi DV Lo bAnd 25 sensor maximum gt Full scale alarms FS hi FS Lo sensor range f s 2 0 C 3 6 F 2 units Adjust SP2 hysteresis or proportional band gain see CyC 2 setting 100 sensor f s Hi Sc CyC 2 on oFF 0 1 81 seconds Select SP2 ON OFF or proportional cycle time Select on oFF for ON OFF mode or the cycle rate of SP2 output device for proportional mode LEVEL 2 ENE MANUAL CONTROL MODES Function Options Factory settings shown in brackets SPI P 0 to 100 read only Read SP1 output percentage power hAnd oFF 1 to 100 not in ON OFF SP1 manual percentage power control For manual control should a sensor fail Record typical P1 P values beforehand PL 1 100 to 0 duty cycle 100 Set SP1 power limit percentage Limits ma
17. e front panel The Programmer Functions List describes the full range of available Settings for each Programmer Function together with their display mnemonic The Model 9500P is supplied with a suite of Factory Settings for each Function These are shown in bold type The Functions Map illustrates the relationship between the Functions and their Settings and provides a guide to the Keying Operations required to navigate around the menu when configuring or running a Program 11 12 GETTING STARTED PROGRAMMER For users with previous experience of configuring programmers the EXAMPLE PROGRAM Soak Function i Interval 45 mins Ramp Function Rate 105 deg hour Target setpoint 137 deg i Step Function Pad Target setpoint 85 deg 3 Ramp Function Rate 55 deg hour i Target setpoint 30 deg i Loop Function Number of repeat program cycles 1 See segment configuration of this program detailed on page 18 13 Time PROGRAMMER FUNCTION MAP START HERE Press and hold VA for 3 seconds ENTER PROGRAM Paste only appears after a program is copied Program 1 has Copies the been copied to selected A copy of program 1 can be program 3 To add new Program pasted into another program program press A once Program editing functions Insert Another program has been Program 3 has been inserted into Pr oL 2 deleted Display re nu
18. ed optimum value press and hold both and W buttons until indexing stops The calculated value will be displayed eg A16 If acceptable exit program AV to implement this setting To Pre select Automatic Acceptance of AUTOTUNE Calculated CYCLE TIME Before AUTOTUNE is initiated select CYC t in Level1 press and hold both and W buttons until indexing stops at A Exit program AW to accept calculated value automatically To Manually Pre select Preferred CYCLE TIME Before AUTOTUNE is initiated select CYC t in Level 1 press and hold both and Aor V buttons until indexing stops at preferred value then exit program AW to accept CYCLE TIME RECOMMENDATIONS SECOND AND THIRD SETPOINTS SP2 and SP3 PRIMARY ALARM MODES Configure SP2 output to operate as an alarm from SP2 A in Level 2 and set the alarm setting in SEt 2 Level 1 Configure SP3 alarm mode SP3 A and setting SEt 3 in Level A The alarms will be individually triggered when the process value changes according to the options listed below dV hi Rises above the main setpoint by the value inserted at SEt 2 3 dV Lo Falls below the main setpoint by the value inserted at SEt 2 3 BAnd Rises above or falls below the main setpoint by the value inserted at SEt 2 3 FS hi Rises above the full scale setting of SEt 2 or SEt 3 FS Lo Falls below the full scale setting of SEt 2 or SEt 3 EoP Event Output See Programmer section pages 11 to 18 SUBSIDIARY SP2 SP3 MODES
19. eve mounted in a 1 16 DIN panel cutout with only the front panel rated to NEMA4 IP66 provided that the panel is smooth and the panel cutout is accurate the mounting instructions are carefully followed DIN PANEL CUTOUT 1 16 DIN 45 0mm 0 6 0 0 wide 45 0mm 0 6 0 0 high Maximum panel thickness 9 5mm Minimum spacing 20mm vertical 10mm horizontal MOUNTING To mount a Controller proceed as follows 1 Check that the controller is correctly orientated and then slide the unit into the cutout 2 Slide the panel clamp over the controller sleeve pressing it firmly against the panel until the controller is held firmly 3 The controller front bezel and circuit board assembly can be unplugged from the sleeve Grasp the bezel firmly by the recesses on each side and pull A screwdriver can be used as a lever if required 4 When refitting the bezel assembly it is important to press it firmly into the sleeve until the latch clicks in order to compress the gasket and seal to NEMA4X IP66 CLEANING Wipe down with damp cloth water only CAUTION The controller should be isolated before removing or refitting it in it s sleeve Live circuits can hold a charge for short periods after isolation from voltage supply Electrostatic precautions should be observed when handling the controller outside it s sleeve DIMENSIONS Bezel Behind Panel Overall Behind panel Width Height Width Height Length Length 51 0 51 0 44 8
20. h time THE CONTROLLER IS NOW OPERATIONAL WITH THE FOLLOWING FACTORY SETTINGS Proportional band Gain 10 C 18 F 100 units Integral time Reset 5 mins Derivative time Rate 25 secs Proportional cycle time 20 secs Typical setting for relay output DAC Derivative approach control 1 5 Average setting for minimum overshoot Note For more precise control or for non temperature applications where a Linear input transducer is being used the controller may need to be tuned to the process Please refer to the following section on AUTOTUNE AUTOTUNE This is a single shot procedure to match the controller to the process Select either Tune or Tune at Setpoint from the criteria given below The Tune program should be used for applications other than those listed under Tune at Setpoint below The procedure will apply disturbances when the temperature or process reaches 75 of the setpoint value causing overshoot which is monitored in order to adjust the DAC overshoot inhibit feature Care should be taken to ensure that any overshoot is safe for the process The Tune at Setpoint program is recommended when e The process is already at setpoint and control is poor e The setpoint is less than 100 C in a temperature application e Re tuning after a large setpoint change e Tuning multi zone and or heat cool applications Notes DAC is not re adjusted by Tune at setpoint Proportional Cycle Time can be pre selected before running the Autotune
21. hich spreads the signal across the input range 10 to 50 mV using multiplier of 2 5 When using a transducer with an output less than 4 20mA the input maximum and minimum mV values can be calculated using the same multiplier Models with 0 to 5V input use an internal resistor to spread the signal across the input range 0 to 50 mV using a divider of 100 Where a transducer provides a smaller output the input maximum and minimum values can be similarly calculated Decide what scale minimum and maximum will be required and whether the scale needs inverting See Level A Linear Input Scaling for list of settings and limits page 10 The example below shows how a 4 20mA linear Input should be configured e g 4 20mA 60 to 260 units where 4mA 60 units Follow INITIAL SET UP procedure also see page 4 1 Select input sensor Select inPt Lin 2 Select unit Select required unit if not available Select unit SEt 3 Select SP1 output Select from Rly SSd or AnLG Enter initial configuration into controller memory DO NOT ENTER SETPOINT until Linear Input has been configured in Level A See functions menu page 3 and functions list page 10 Configure Linear Input Enter level A Then using example given above Select An hi 260 Select An Lo 60 Select hi in 50 0 Select Lo in 10 0 Select dECP 0000 WARNING otherwise settings marked may be altered 4 Enter scale maximum 5 Enter scale minimum 6 Enter input maximum 7 Enter
22. ime lag type to IEC127 CSA UL rating 250Vac F2 Fuse High Rupture Capacity HRC Suitable for maximum rated load current S1 Switch IEC CSA UL Approved disconnecting device 20 TYPICAL APPLICATION Analogue power User configurable controller alarms 4 20mA 9 Transducer INPUT OPTIONS Wire link RTD PT100 2 wire Input Spare Supply E L N RTD PT100 3 wire Spare Supply LESON Linear transducer input Standard Input Code 95 PA Linear Input Codes 95___PB 4 20mA 95___PC o0 5v 95___PD 0 10v OUTPUT HARDWARE OPTIONS amp TERMINATIONS Model Output Codes 95111P 95001P SSd SSd 95221P 95B11P 4 20mA 95C11P 0 5v 95D11P 0 10v AnLG SSd 95B21P 4 20mA 95C21P 0 5v 95D21P 0 10v Relay 1 SSd 2 Analogue B C D The analogue output always replaces the output on terminals 19 amp 20 21 INPUT SENSOR SELECTION Temperature sensors Thermocouples Description Sensor range Linearity tCb Pt 30 Rh Pt 6 Rh 0 to 1800 C 2 0 tCE Chromel Con 0 to 600 C 0 5 tcJ lron Constantan 0 to 800 C 0 5 tC K Chromel Alumel 50 to 1200 C 0 25 tCL Fe Konst 0 to 800 C 0 5 tCn NiCrosil NiSil 50 to 1200 C 0 25 tCr Pt 13 Rh Pt 0 to 1600 C 2 0 tCs Pt 10 Rh Pt 0 to 1600 C 2 0 tct Copper Con 200 250 C 0 25 Resista
23. lectable it is the responsibility of the installing engineer to ensure that the configuration is safe Use the program lock to protect critical functions from tampering ULTIMATE SAFETY ALARMS Do not use SP2 SP3 as the sole alarm where personal injury or damage may be caused by equipment failure WARRANTY CAL Controls warrant this product free from defect in workmanship and materials for three 3 years from date of purchase 1 Should the unit malfunction return it to the factory If defective it will be repaired or replaced at no charge 2 There are no user servisable parts in this unit This warranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse 3 Components which wear or damage with misuse are excluded e g relays 4 CAL Controls shall not be responsible for any damage or losses however caused which may be experienced as a result of the installation or use of this product CAL Controls liability for any breach of this agreement shall not exceed the purchase price paid E amp O E Copyright CAL Controls Ltd 2000 Not to be reproduced without prior written permission from CAL Controls Ltd Whilst every effort has been made to ensure the accuracy of the specifications contained in this manual due to our policy of continuous development CAL Controls Ltd reserves the right to make changes without prior notice CUSTOMER FEEDBACK
24. lete a Segment 3 E pm P t deleted segmeni 2 3 d gt gt To add new i oe i Define the program Returns to number called SEG H Default none Call up Sub V another gt gt program pot mene T Z Set Numbers of H H re cycles 1 to 999 unless Y full Or continuous Program Default 1 oo pami re cycles gt gt Hold back band 3 size adjustable 0 1 to 150 units Add new Segment 3 y segments at now appears E c top of existing imenu 7 E S7 CO 1 Soak time in minutes y 2 E or continue Default 10 Soak 9 gt ict gt To view existing Important note tu segnente to 126 Up A button must be or full Ramp used after selecting the segment type to confirm it s selection GS Set the segment to be To select operational Adjusts ramp Target set point adjustable Hold back this function only Event output options only adjusted mode of each segment rate over the unit s range appears for ramp operational appear when SP2A or SP3A Default 1 Default Ramp Default 100 Default Current main SP once a value is set modes set to E OP Default off Default de energise lt x 15 FUNCTION LIST LEVEL P PROGRAMMER
25. mbering existing shows next program Prot dtod down from top of list Program editing functions Delete Program 3 Hold the program at the point it stopped Cx Add new Programs at now appears top of existing Heh PP Hold the menu i program at i current position Continue thej program from where it stopped Start program when on selected This locks other options out Options start program at main Options SP or process hours variable minutes Reset the Program program at off state beginning If COMMS option or full fitted LEVEL C appears between LEVEL P and LEVEL A To view existing programs 1 to 31 Select the required program number Default 1 Select program mode Power failure recovery Select the starting point of Ramp rate time units of operation position program after power up adjustment Default off Default reset Default PV Default hour Memory used 14 Event output options energise and de energise for all combinations of SP2 amp SP3 Insert my New segment now E pm P segment in inserted into 2 Old the menu segment 2 becomes 3 ec E 2 E De
26. mory allocation table 17 Memory full indicator Ad Programming example 18 Program edit example 18 FUNCTION OVERVIEW The Programmer function in Level P enables the Model 9500P to control applications needing Setpoint changes over time Examples of this are Ramp changes where a gradual Rate of change can be set or Step changes which are instantaneous These can be separated by Soak periods during which the process is held at a constant value Each individual time interval of the program or Segment together with it s associated moving setpoint value can be stored as a unique Program and for example be represented by the diagram below Setpoint Time Segments In addition to those settings that determine the segment profile it is also necessary to set program start values together with the preferred ramp rate time units for each individual program At the end of a sequence a Program can be arranged to repeat Loop either a specified number of Cycles or continuously Only one Loop can be included in a Program When the program is running the Display indicates progress through the sequence of segments and can additionally be interrogated for further segment information It is also possible to CALL an already existing program as a sub program that can be inserted as a segment of another program To speed up Program configuration several Edit functions have been provided so that individual Segments and Programs may be Deleted o
27. nce thermometer rtd 2 3 wire Pt100 RTD 2 3 200 400 C 0 25 Notes 1 Linearity 5 95 sensor range 2 Linearity B 5 70 500 C K N 1 gt 350 C exceptions R S 5 lt 300 C T 1 lt 25 gt 150 C RTD Pt100 0 5 lt 100 C Linear input specification Maximum recommended display resolution 1mV 500 Linear Input Typical accuracy Range 0 50mV 0 1 199 to 9999 4 20mA 0 1 199 to 9999 0 5 0 1 199 to 9999 0 10V 0 1 199 to 9999 SPECIFICATION Thermocouple 9 types Standards CJC rejection External resistance 22 IEC 584 1 1 EN60584 1 20 1 0 05 C typical 100Q maximum Resistance thermometer RTD 2 Pt100 2 wire Standards Bulb current IEC 751 EN60751 1009 0 C 138 5Q 100 C Pt 0 2mA maximum Linear process inputs see Linear input specification mV range 0 to 50mV Applicable to all inputs SM sensor maximum Calibration accuracy Sampling frequency Common mode rejection Series mode rejection Temperature coefficient Reference conditions Output devices check configuration SSd1 and SSd2 Miniature power relay rLy rLY1 and rLy3 Analogue output General Displays Keypad Environmental Humidity Altitude Installation Pollution Protection EMC emission EMC immunity Ambient Mouldings Weight 0 25 SM 1 C input 10Hz CJC 2 sec Negligible effect up to 140dB 240V 50 60Hz 60dB 50
28. nt adjustable over instrument s configured range Hold back oFF sets the permitted band size for the measured value to deviate from the ramp setpoint before the program is held back waiting for the measured value to catch up 0 1 to 150 units Hold setpoint for pre set time 10 Soak time adjust in minutes cont 1440 x 0 1 Step to new target setpoint Set tSP as above Re cycle program 1 Set number of program loops up to 999 or continuous loop Call up another program by number to import into this program nonE Number of Program called at Call above Delete segment Insert new segment Function Settings Factory settings shown in brackets Press A or W to change Press A or W to change E oP Event output nonE Function can be applied to each segment independently to trigger an output at the start of that segment for the duration of that segment Setting blocked unless either or both outputs SP2A or SP3A have been configured as an Event Output in Level 2 or Level A respectively 2d SP2A de energised to mark event 2E SP2A energised to mark event 3d SP3A de energised to mark event 3E SP3A energised to mark event 2d 3d SP2A and SP3A de energised to mark event 2E 3d SP2A energised SP3A de energised to mark event 2E 3E SP2A and SP3A energised to mark event 2d 3E SP2A de energised SP3A energised to mark event To Return to LEVL P Press and hold To Read Programmer memory
29. ogram INSTRUMENT PANEL FEATURES This page can be photocopied and used as a visual aid and bookmark when working in other parts of the manual Right Red LED Program Holdback indicator Orange Display Setpoint value or program selection Press A W together for 3 seconds Press A or V Press A together or W together Press Press A together Press W together Press A W together briefly Press W together for 3 seconds Notes If in difficulty by becoming lost in program mode press A and W together for 3 seconds to return to display mode check the INSTRUMENT ADJUSTMENTS above and try again When in program mode after 60 seconds of key inactivity the display will revert to either inPt nonE or if the initial configuration has been completed the measured value Any settings already completed will be retained During Program Configuration it is recommended that this feature is inhibited Select ProG StAY in Level 4 FUNCTIONS nA R j This page can be photocopied and used as a visual aid and bookmark when working in other parts of the manual s s a INITIAL D EEE GD ei ER E LD E e i SP2 MODES E configure input Range of Adjustment shown under description If applicable factory settings shown in bold For a full description of menu functions refer to pages 7 to 10 and 16 17 in Programmer Level only visible section when COMMS Option fitted Note The letter K
30. r Inserted and an entire Program may be Copied and then Pasted into another that it will replace For safety reasons three modes of recovery from a power failure are available These either automatically Re start the Program from the beginning Continue it from where it stopped or Hold it waiting for a user re start Either one or both of the two auxiliary outputs can be configured as Event outputs Engaging the Holdback feature will temporarily halt Setpoint ramping to allow the process temperature to catch up should it deviate by more than a pre set amount during a Ramp segment To afford maximum programming flexibility memory is allocated dynamically and not pre allocated This allows the user the freedom to configure a small number of long programs or a larger number of shorter ones up to the permitted maximum of 126 Segments per program and a limit of 31 Programs Should these limits be exceeded or the Programmer memory become fully used the display will read ProG FULL Programs can be planned using the Memory Allocation Table which details the memory requirements of individual segment types During configuration a check can be kept on memory usage by interrogating the USEd feature of the display to give an instant reading of percentage memory used Finally once a program has been configured it can be run from the run off on hold controls in Level P and in addition a quick access run hold toggle is directly available from th
31. used USEd Press and W together in LEVL P ProG 1 1 100 Memory Allocation Table Segment type Memory required Ramp Ramp with Holdback Soak Step Loops 1 3 Loops 4 Call Event Output Program Header Maximum capacity 351 Bytes 31 Programs 126 Segments Examples 1 1 program of 58 Ramps and 58 Soaks 349 Bytes 2 4 programs of 14 Ramps and 14 Soaks 340 Bytes 3 31 programs of 2 Ramps and 1 Soak 341 Bytes 4 2 programs of 10 Ramps 10 Soaks 2 Steps and 1 loop 136 Bytes Memory Full Indication Should the programmer memory capacity be reached during program configuration the display will show FULL 17 PROGRAMMING EXAMPLES wn CJ Z a wl I v 4 0 gt Oo Fr 5 I i o e F lt 3 Oo gt fal x 18 Program 1 j now pasted KEY as Program 2 A Arrows drawn thus signify several key operations Program Edit Function Make copy of Program 1 and paste as new Program 2 Programmer functions shown as white characters on black background have Default settings KEY V OR A TO VIEW FUNCTIONS gt Program Segment Configuration See Program 3 illustrated on page 13 un m El ui c uy m C Program settings for functions run FAIL St U and SPru not shown are all set to Default MECHANICAL INSTALLATION The Controller is designed to be sle
32. ust Suq CAL 9500P Programmable Process Controller CAL Controls 2 5 A 2 N o A c o N a e ee 2 2 5 0 m w o 2 0 INDEX INSTRUMENT PANEL FEATURES FUNCTIONS MENU GETTING STARTED Initial Set up AUTOTUNE Tune or tune at setpoint program PROPORTIONAL CYCLE TIME Cycle time recommendations SECOND AND THIRD SETPOINTS SP2 and SP3 Error messages LINEAR INPUT Set up procedure FUNCTION LIST Level 1 Level 2 Level 3 Output Options Table Re transmission Level 4 Level A PROGRAMMER Function overview Getting started Programmer Program run mode Display functions Example program Function map Function list Memory allocation table Memory full indicator Programming example Program edit example MECHANICAL INSTALLATION DIN panel cut out Mounting Cleaning ELECTRICAL INSTALLATION Typical application Input options diagrams Output options diagrams INPUT SENSOR SELECTION Temperature sensors Linear input SPECIFICATION SAFETY AND WARRANTY OMDWMANYAYNYNAOCOUUUUNAARWNYD Green LED Setpoint 1 output indicator Green Display Process variable or Function Option Upper Red LED Setpoint 2 output indicator Lower Red LED Setpoint 3 output indicator ADJUSTMENTS To enter or exit program mode To scroll through functions To change levels or options To view setpoint units To increase setpoint To decrease setpoint To reset latched alarm or tune fail To run or Hold a pr
33. ximum SP1 heating power during start up and in proportional band PL 2 100 to 0 duty cycle 100 Set SP2 percentage power limit cooling SP2 OPERATING MODES see page 5 SP2 A nonE Main SP2 operating mode dV hi dV Lo bAnd FS hi FS Lo Cool EoP SP2 b nonE LtCh hold nLin Subsidiary SP2 mode latch sequence Non linear cool proportional band Will be affected by dECP settings in Level A 8 LEVEL 2 CONTINUED INPUT SELECTION AND RANGING dl SP 1 0 1 Select display resolution for display of process value setpoint OFSt Set 2 hi SC LoSC hi SC sensor maximum Set full scale sensor maximum C F units Lo SC sensor minimum sensor minimum C 2F units Set scale minimum default 0 C 32 F or O units inPt Select input sensor nonE See SENSOR SELECTION table page 22 NB If Linear Input selected start configuration from Level A unit nonE C F bAr Psi Ph rh SEt Select required operating unit from above options OUTPUT CONFIGURATION Note 1 Read only after initial configuration rSET ALL full reset to factory settings required to change SP1 d subsequently Note 2 Depending on the Model SP1 and SP2 may be fitted with any of three output types RLY SSd or Analogue Specification on page 11 12 where appropriate these must be allocated during initial configuration SP3 is always fitted with RLY Output Options Table SP1 Output SP2 Output SP3 Output 95111P 95001P
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